CASE STUDIES

CASE STUDIES (SUCCESS STORIES)

CASE I  :: Kiln Feed Bin Level Fluctuation Optimisation..

 ISSUE :: Bin Level Fluctuating with repeated cycle 81.2 to 86.5 Tons

ACTION :: Gate Opening for 1 & 2 readjusted. Other Gate Operation Optimized.

Diagnosis::Fluctuations coming due to malfunctioning of the discharge gates

(Mechanical issue,No where related to Controller tuning / PID).

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RESULT :: 70% reduction in fluctuations. Bin level maintained between 85 to 86 Tons.

BENEFIT ::  Reduces effect on Kiln Feed Rate fluctuation.


CASE II ::Kiln Feed Flow Meter Fluctuation…

 ISSUE ::Sudden Peaks in Kiln Feed.

DIAGNOSIS::Abnormal (non-linearity) Sensor response at higher feed flow rates.

  >> Sensor Anomaly detected as source of Major fluctuations >>

Action: PV Filter for kiln feed PID.

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RESULT:: The Instrument Related spikes were detected & eliminated which reduced the side effect of False Alarm.


CASE III ::PC Temperature Fluctuation Assessment

Optimisation of Fluctuations in PC temperature (Master Loop Optimisation)

ISSUE::Manual mode operation & Suboptimal PID Settings.

ACTION:: Manual mode Operation was shifted to AUTO mode Operation and the response were corrected by Optimizing PID settings.

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RESULT::Stable Pre-Calciner Temperature.

BENEFIT:: Small amount of coal TPH reduction can lead to big savings..3.6 TPD coal being saved ~ nearly 22000 Rs/day saving.

 


CASE IV ::Cooler Under Grate Pressure AUTO operation..

ISSUE::Cooler Chamber Pressure vs. Cooler Grate Speed PID was running in Manual mode as it is not stable in AUTO mode.

Diagnosis:: Operation in Manual.

Action:: Operated in AUTO mode + Fine Tuning of Controller parameters.

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Result :: Actual Under grate pressure is fluctuating around the required set point (+/-20 mmWC).

Stable and consistently above 400 oC Mid Tap Temperature.. >> stable WHR operation.

BENEFITS:: Cooler operation optimized to achieve higher outlet gas temperature (stable above 400 deg C). Which helps them to achieve higher power generation in WHR (waste heat recovery) plant.



CASE V ::Assessment of Diffuser Amps for Drum Level Control

                * CAPTIVE POWER PLANT * Drum Level Control

ISSUE:: Variability in Boiler Drum Level. Optimisation of variability in Boiler Drum level..

Diagnosis:: Sub-Optimal PID Settings. Action: PID Tuning.

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Result:: Lower deviation in drum level.

BENEFITS:: lower thermal shocks + lower variation in boiler pressure.


CASE VI ::Assessment of ID fan related fluctuation

                              Boiler House Draft Control (ID Fan) Stabilisation  

ISSUE:: Variability in Boiler Outlet Draft + Unstable operation of ID Fan (speed).

Diagnosis:: External Random Disturbances.

Action:: Applied PV Filter.

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RESULT:: Reduction in variability in boiler outlet draft.

BENEFIT::Stable Induced Draft fan (speed)..


CASE VII ::Hood Draft PID optimisation.

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CASE VIII::Cooler Vent Fan VFD optimisation.

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

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CASE I::Gypsum Feeder (in Cement Mill) Fluctuation Optimisation

ISSUE:: Gypsum Weigh Feeder showing higher variability (>5%) even for fixed set point.

Diagnosis:: Weight Feeder speed response issue (Panel Settings to be optimized).

Action:: Parameters adjusted in Schenck Panel (Gain factor increased from 0.2 to 0.6 mA%)

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Result:: More than 70% reduction in variability. No its operating with SP +/- .05 TPH (<1% variability) as compared to SP +/- 0.2 TPH (>5% variability across Set Point)).


CASE II::Optimization of Fly Ash Feeding (SFM) Fluctuations (critical to open circuit).

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RESULTS:: Stable Fly ash Feeding with lower Controller Error.

Benefit:: Almost 2KW of Power saving per Ton of Cement.


CASE III::TWO Chamber Ball Mill (Closed Circuit) – OPC Grinding

                                          Sound level vs Feed PID optimisation   

ACTION:: PID Tuning.

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CASE IV::PROGRESSIVE OPTIMISATION OF TWO CHAMBER CEMENT MILL – UAE

 

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CASE V::Progressive Assessment/ Optimisation of Raw Mill (Roller Press + Ball Mill) Operation.

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CASE I :: Drum Level Control

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)

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CASE I  :: 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 I:: 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 II:: Optimisation of  Fluctuations in PCT temperature.

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CASE I  :: 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

CASE I::Tablet Coating Machine Control Optimization.

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Result:: 82% reduction in Start-up cycle time. 

Benefits :: 82% reduction in Idle Time (higher machine and labour productivity) + 87% reduction in Steam Wastage (during the start Up period and also for Re-Starts during Power Failures) + Quality consistency as the Set Point is not allowed to deviate for longer time during any unscheduled stoppage

 CASE I::Oxygen Plant O2 Purity ImprovemenT.

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O2 Plant Optimisation:: Impact on LOX Consumption

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MIN. POTENTIAL SAVINGS FOR 3 MONTHS (remaining operation) ~ Rs. 30 Lakhs WITHOUT ANY CAPEX