CASE STUDIES

CASE STUDIES (SUCCESS STORIES)

CASE I  :: Cement Mill Optimisation

EQUIPMENT/SITE :: 3.5 mtr X 9.6 mtr, Two chamber, Open circuit, PPC grinding mill – 5000 TPD plant in Tamil Nadu (India).

ISSUE :: Highly Fluctuating Mill Feed (feed TPH limitations, inconsistent quality) 

 OPTIMakx DIAGNOSIS :: Fly Ash feeding (SFM) control system settings sub-optimal 

ACTION :: SFM panel settings tuned (two stages) 

RESULT :: Fly Ash (hence total feed) variability reduced by 48%.  

BENEFIT ::  8% increase in TPH,  6% Reduction in Specific Power Consumption.

CaseStudy1_CMsppower

 

 

 

 

 

 

 


CASE II ::  Cement Mill 

Optimisation of  Fluctuations in Mill Feeding (SFM fluctuation) 

CEMENTMILL

CEMENTMILLDATA

CASE  :: Power Plant Optimisation

Observation : Low controller performance,5.8% error.

Diagnosis     : Oscillations due to Agressive tuning.

Correction   : ‘I’ action reduced by 20%.

Result : Zero Oscillations, Average error < 1%.

Effect : Stable Steam Pressure / Quality (better Steam Economy)

Drum Level Control

pow

CASE  : Pulp &  Paper Plant

>> Assessment/Diagnosis of Fluctuations in Reagent Quality <<

PULP&PAPER

BENEFITS / SAVINGS

REDUCED VARIABILITY IN OPERATION

  • Higher % in OPTIMUM range (Stable operation, consistent quality) 

  • Lower % of > 1% OWL (higher utility BCTMP, Lower Reagent Requirement) 

  • Lower % of < 0.5% (Lower O2 consumption). 

  • Lower wear and tear of valves/actuators (low replacement cost)

CASE  :: GRINDING MILL 

Progressive Assessment/ Optimisation of Raw Mill (Roller Press + Ball Mill) Operation

gRINDINGMILL1gRINDINGMILL2

GRINDINGCHART

CASE  :: CHEMICAL PROCESSING PLANT

Assessment/Diagnosis of  Fluctuations in Reagent Feeder at Floatation Section

 CHEMICAL PROCESSING PLANT

 

Observation : FIC7013 :: Low controller performance, 11.5% error.

Diagnosis : Oscillations due to High Gain (P setting).

Correction : ‘P’ action reduced by 25%.

Result : Zero Oscillations, Average error < 2%.

Effect : Lower Quality Fluctuation, Lower Re-agent Consumption.

CASE  :: MINERAL PROCESSING PLANT

 Assessment/Diagnosis of  Fluctuations in Mill Section (Flow and Level Variation)

 MINERAL PROCESSING PLANT

Diagnosis :  Oscillations due to High Gain (P setting).

Correction : ‘P’ action reduced as suggested by OPTIMakx (no trial and error).

Result :   >75% lower Oscillations: Average Error reduced by >35%.

Benefits : Lower Quality Fluctuation, Stable Recovery, Lower Re-agent                                          Consumption.

CASE  :: HOOD DRAFT PID OPTIMISATION

 

                          hdpid  

HDPIDO

 

HDPIDDATA

CASE  :: COOLER VENT FAN VFD OPTIMISATION

Kiln Hood Draft regulation using Cooler ESP fan operation (VFD tuning in panel)

COOLERVENTFANVFD

COOLERVENTFANVFDDATA

CASE  :: KILN FEED SFN FLUCTUATION OPTIMISATION

Problem: Feed TPH Fluctuating randomly +/- 6 to 7 TPH.

Diagnosis: Issue is with Solid Flow Meter Operational settings (in Feeder Panel).

Action: Optimisation of feeder response. Adjusted Cycle Time (Ti) in Panel.

KILN

 

KILND

CASE  :: KC FIRING FLUCTUATION OPTIMISATION

KC

 

KCD

CASE  :: FERTILIZER PLANT

Assessment/Diagnosis of  Fluctuations in Nutrient Quality

FERTILIZER

 

Variance Diagnosis: Spot Sampling Effect, Unmeasured Disturbance, Oscillating Inputs,Slow Controller Response, Valve Related Issues.

Actions suggested : AUTOsampler (composite sampling), PID tuning, New Measurements  for external disturbances, Valve servicing.

Result:

FERTILIZERRESULT