pricast millscan dsp - digital control lab

29 de Julio de 2008 www.pricast.es/millscan

MillScan Using vibration to measure the fill level of Ball Mills

MARCIO STASCHOWER


Presentation sequence

1.  MillScan – Introduction and advantages

2.  Installation and calibration 3.  Operational examples 4.  Case studies 5.  Conclusion


• MillScan is a field instrument that measure the mill fill level using the vibra.on signal of the Mill bearing housing or table.

• MillScan can be used in Ball and Ver.cal Mills.

MillScan -‐ Introduc.on

• Due its technology, MillScan yields a highly accurate and instantaneous mill fill level signal that can be used to run the mill under automated loop control or greatly assist control room operators under manual control.


MillScan Advantages

ü Higher resolu=on (more than two =mes) compared with tradi=onal sound bases instruments; ü Is not affected by other equipments or services in the area (system 100% digital);

ü Easy installa=on, setup and calibra=on (DON’T need to stop the mill for installa=on and calibra=on);

ü Op=on for customize the equipment for different products;

ü No addi=onal equipment in the existent plant control system is needed (communica=on via a 4-‐20mA output).


System Components

Main Unit

Sensor

USB Adapter


System Configura.on in a ball mill


Installa.on in a ball mill

Sliding shoe bearing mill

Standard bearing housing


Easy calibra=on (only 3 steps)

System calibra.on


System calibra.on

Elimina=ng interferences from other equipments and mechanical problems.


Signal Examples Looking into the “future”


20:30 21:00 21:30 22:00 22:30

63.833

68.833

73.833

78.833

83.833

88.833

93.833

58.833

99.779

8.0227

13.606

8.0227

13.606

80.227

136.06

80.227

136.06

1560.5

1672.1

29.4164

49.8895

Looking into the “future”

Total Feed

Mill kW

MILLSCAN

MillScan – Signal example


Motor power

MILLSCAN

Elevator

Returns

Looking into the “future”

Aprox. 15min

MillScan – Signal example


MillScan DSP Case Studies

The real benefits of using MillScan


Mill characteristics

ü Cement Mill ü 2 single compartment finish mills

ü Dimensions: 4,0m diameter; 6,4m long; 2.000HP

ü  First generation separators;

ü  Blaine: 5500-4000;

ü  4 Different cements produced.

MillScan – Case Study I


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Bucket El 2 kW

Bucket El 1 kW

Total Feed

Mill kW

Separator 2 kW

Separator 1 kW

Step 1: Mill under Manual control



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Total Feed

Mill kW

Separator 2 kW

Separator 1 kW

Step 2: Mill under kW control



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Total Feed

Mill kW

Separator 2 kW

MILLSCAN

Step 3: Mill under MillScan control



ü  Reduction In kWh/ton (Overall Cements) : 6%

Some Results (after MillScan installation)


Cement Type A

Reduced Ave Blaine 4,6%

Increased Ave 325 Mesh Passing 0,25%

Reduced St Dev at 28 day strength 37%

Cement Type B

Reduced Ave Blaine 5,4%

Increased Ave 325 Mesh Passing 0,7%

Reduced St Dev at 28 day strength 28%


MillScan – Case Study II

Mill Characteristics

ü Cement Mill (nominal 80 ton/h) ü 2 single compartment finish mills



Ajuste em tempo real dos parâmetros do PID, ganhos e BM

Indicação de enchimento – Mill Scan

Alimentação total, controlada somente pelo nível de enchimento



MillScan Signal (fill level in %)



Fresh feed to the mill (in ton/h) – Mill in auto control


Manual Control

Production average 73,88 ton/h

Finesses (0,044mm) 12,3

Auto Control with MillScan

Production average 77,80 ton/h

Finesses (0,044mm) 12,2

Results

Production increase 5,01 %

Production costs decrease 4,77 %

Cement finesses decrease 1,00 %


Comparing before and after MillScan


Mill Characteristics

ü Cement Mill (nominal 20 ton/h) ü 2 single compartment finish mills

MillScan – Case Study III



Comparing before and after MillScan

Motor Power control MillScan Control



Production average

Normal control 20,60 ton/h

MillScan control 21,75 ton/h

Results

Increase production in 5,5%

Decrease specific consumption in 5,3%

Pay-back in 2 months !!!

Specific Consumption

Normal control 38,03 kWh/ton

MillScan control 36,02 kWh/ton


MillScan References

TOTAL OF 210 UNITS AROUND THE WORLD

Buzzi Unicem Cal Portland Cemen.r

Cementos Portland Cemex Cimpor Colacem GCC

Hanson

Heidelberg Holcim

Italcimen. Lafarge Lehigh

Mitsubishi Nuh Beton

Secil Votoran.m and others ...


MillScan Conclusions

MillScan

Op.mum opera.on point

Limits

P1

P2

Operator Be[er informa=on

Repe==bility

Stable process Be[er control

…


ü MillScan high sensibility detects variations in the Mill Fill Level almost instantaneously when other typical signals used for Mill control are not affected or delay to accuse variations.

ü Acting with more precision and earlier gives the operator the possibility to improve operation.

MillScan – Conclusions

Pricast Equipamientos Industriales S.L. Calle Paris, 71, 1/4 -‐ 08029 – Barcelona, Spain Tel: (+34)93.444.31.23 Fax:(+34)93.419.87.71

[email protected] www.pricast.es/millscan

Visit us at: www.pricast.es/millscan

pricast millscan dsp - digital control lab

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