Grinding intelligent optimization control system
Category:
Intelligent control system
Introduction to cement grinding intelligent control system
Sinoma Cement Grinding Intelligent Control System [1] includes APS one-button start-stop technology (incorporating analog automatic control, sequence control, override control, etc.), APC optimization technology based on predictive model control, online laser particle size analyzer, The three are seamlessly connected. When the cement mill is produced, the whole start-stop process only needs to press the one-button start button or the one-button stop button, and realize the automatic control of the key analog quantity during the start-stop process. The cement vertical mill automatically feeds the falling roller, and the online particle size analyzer automatically After the system is in normal operation, the APC control system is automatically put into operation to realize automatic control of parameters such as air volume/feed volume/pressure, and truly realize automatic control of the whole process of cement grinding.
Cement vertical mill intelligent control system function:
All equipment starts and stops with one button, and the vertical mill grinder automatically feeds the falling roller;
The APC control system is automatically put into operation;
Self-learning the characteristics of cement varieties and automatically switching control strategies;
Self-learning characteristics of production conditions, establishing an expert database; automatically identifying current working conditions and automatically switching control strategies;
The automatic control of the whole process of the whole process of the cement mill system realizes the unattended first step of the cement mill system;
Overall structure of cement grinding intelligent control system
The cement grinding intelligent optimization control platform introduces the big data algorithm model theory based on traditional control algorithms, such as predictive prediction model control MPC, neural network, adaptive control, fuzzy logic, expert algorithm, optimal control, etc. . Maximizing production, optimizing quality, minimizing power consumption, and safe operation of equipment are the optimal constraints; through the historical database and current real-time process data, the memory matrix is formed. The row vector of the matrix represents the operational data of all the measuring points at a certain moment. The column vector represents the running data of the measuring point at different times. The big data algorithm of the platform is used to calculate the relationship between the grinding machine body and each subsystem, and the mapping model of the relationship between input quantity and output quantity is constructed. Optimize the platform output optimal value and control constraints for real-time control of the quality controller, output controller, and temperature controller.
Intelligent control system application effect
(1) Full working condition system investment rate
Intelligent control system special condition diagnosis and automatic processing function, can monitor the status of the mill and each warehouse position in real time, automatically identify abnormal working conditions and automatically take measures to ensure the reliable and stable operation of the intelligent control system. The cement mill intelligent control system entered the continuous trial operation stage in September 2018, maintaining a high commission rate under all working conditions. Take the latest data of September operation as an example to carry out KPI data statistics. Under the full working condition, the operating rate of intelligent control system is above 95%, as shown in the following table:
September ICE platform software KPI statistics
(2) Improve stability
After the first control system is put into operation, the standard deviation of the steady flow fluctuation is reduced by more than 70%. After the steady flow bin is stabilized, the operator can set the position at the optimal point, which can ensure the maximum output and avoid the conventional control. The fluctuation of the position is too large, resulting in the stoppage caused by the blockage of the discharge port; the curve before and after the operation is as follows:
Figure 8: Dynamic optimization control system before and after the application of stable flow bin fluctuations
(3) Improve the quality of cement quality
The cement mill intelligent control system significantly improved the quality of cement and effectively reduced the standard deviation of cement 45um sieve residue, from 0.97 to 0.75, and the specific pass rate was 100%. The online fineness analyzer provides real-time stable and reliable fineness distribution data, and provides a basis for real-time optimal control of the classifier, providing real-time reference for cement quality. When the measurement of the online fineness analyzer reaches 45um sieve deviation from the set range, APC adjusts the classifier in time to control the 45um sieve balance within the set range to stabilize the product quality. The figure below shows the measured overall fineness distribution of the online fineness meter.
Online fineness analyzer 45um sieve residue and comparison of table data and laboratory data
(4) Energy saving:
The cement mill intelligent control system obviously improves the working condition of the cement mill system, so that the air volume, the material amount and the vertical grinding work reach an optimal balance state, and the working state of the mill is judged in real time. In the case of normal grinding conditions, the feed will be fed. The quantity is maximally controlled, and when the abnormal working condition is judged, the production reduction operation is performed, so that the production can be increased as much as possible while the working state of the mill is good, and the output can be effectively increased and the power consumption can be reduced. After the application of the intelligent control system, the cement mill production is relatively stable, and the power consumption index per shift is relatively small compared to the manual operation. Under the same ratio, the average power consumption per ton of the three mainframe equipment can reduce the power consumption by 1.1kwh/t. about.
Before and after the control system is used, the power consumption statistics table (data source: cement plant production report data)
(5) Summary of application effects
When the cement mill is produced, the whole start-stop process only needs to press the one-button start button, and realize the automatic control of the key analog quantity during the start-stop process. The cement vertical mill automatically feeds the falling roller, and the online fineness analyzer automatically runs until the system is normal. After the operation, the APC control system is automatically put into operation, realizing the automatic control of parameters such as air volume/feed volume/pressure, realizing the automatic control of the whole process of cement grinding, and adapting well to the production conditions, under normal working conditions The utilization rate is above 95%, and the standard deviation of main parameters is reduced by more than 30%.
1. The cement mill intelligent control system realizes one-button start-stop function; reduces the labor intensity of operators. The startup time is shortened from 8-20 minutes to 8-10 minutes by manual operation, which effectively reduces the idle operation rate of the host equipment and reduces power consumption.
2. Vertical grinding automatic feeding roller: According to the cement type, the pressure is automatically gradually pressurized, fed and aired, and the key parameters such as vibration, material layer and temperature are monitored at all times, and the working condition is identified by expert algorithm. According to the identification result, it is automatically processed, and finally the automatic feeding roller is realized.
3. The cement mill intelligent control system significantly improves the working condition of the cement mill system, so that the air volume, the material volume and the mill work reach an optimal balance state, effectively increasing the output and reducing the power consumption, while the standard deviation of the key control parameters is reduced by more than 30%. . The average electricity consumption per ton of cement is reduced by 1.0 kwh/t or more.
4. The cement mill intelligent control system significantly improves the quality of cement, and effectively reduces the standard deviation of cement 45um sieve residue from 0.97 to 0.75, and the pass rate is 100%.
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