Use of advanced process control for the optimisation of the modern cement plant: Juliano Arantes, ABB (Switzerland)

Filmed at Cemtech MEA 2015, 8-11 February, Grand Hyatt Dubai, UAE

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Good morning everybody? Today, I will be talking about the case study from the for the last project in Turkey. And this is related to advanced process control. So our agenda is, we will be talking about the basics of advances process control, we'll be talking about expert optimizer version 8, the case study for [xx] plant, some testimonials, conclusions and I open for questions.

So that is advanced process control? For those that don't know the basic concept is to eliminate, to minimize the influence of the operators, so we go from the manual operation where we all know that we have normal fluctuation of the process and our main goal is to eliminate to minimize the manual fluctuation in the process.

So first of all before we stabilize the process because you cannot optimize something that is not stable. first off you have to make the process as stable as possible. Afterwards we can optimize. So as soon as we have the process stable we can push the system, we can push the to work towards the limit, towards the bottom neck.

We also all know that normally the operators works in this area here with this fluctuation because he does not want to work with the close to the instability, it's more difficult to operate this [xx] if it's more like say the colder side then on the hot side, so this is why the operators, they tend to work on, say in a hot camp, then towards the optimum, and this optimization here, one of the parameters we use to do this kind of optimization is the quality information, so we need quality feedback to optimize the process, does not make any sense to increase production if quality is not good.

So, what are the benefits from stabilizing the process? So, we will have these small but frequent changes, so we will doing small changes all the time instead of Adobe reader thus big changes not very often. We will reduce these deviation from the target, so we will have the process target and we will be working close to those targets, keeping the process stable.

We will have the same operation, the same way to operate the count for the meals 24/7 so there's no variation because we also all know that each operator has their own style, one is more say aggressive or the other one is a bit slower, this is human being. We will have this, let's say we will a spender operation.

If we have more stable operations, that also, we will increase our reliability. So, the maintenance should be decreased. Less blockages, increasing the line there's life time, bricks lifetime, so that leads to better, so all of these. We will also be respecting the process constraints. So we will program this, we will define the limits, these DOS limits are configurable.

The operators or process engineers could easily change those constraints and that will be respected by the program and that cannot be violated. There's no discussion, a limit is a limit, it would follow

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