AI and cascaded control loops keep timekiln running smoothly
July 2002
System Integration & Control Systems Design
Optin has recently installed a lime perfecter kiln controller on the LK7 limekiln at PPC Lime Acres. The controller optimises the production and operation of the kiln in terms of production, quality and efficiency. The controller is a nonlinear multivariable model-based predictive controller, which is based on the patented Pavilion Technologies Process-Perfecter as well as the G2 'Wrapper' technology from Gensym. Process Perfecter performs both dynamic and steady-state optimal control, whilst G2, a real expert system, performs intelligent signal processing, data validation and other communications and MMI tasks for the Perfecter. G2 is a realtime expert system and intelligent application deployment environment.
The Optin team, together with PPC Lime Acres experts and operational staff have developed and deployed this controller in record time with actual installation and commissioning taking less than one week. Benefits were derived from time of installation and include increase in kiln stability and lime quality as well as ease of operation and consistency of production. It is still early days and the controller is not yet complete, thus quantitative results with respect to production and efficiency improvements are looking very promising but not currently available.
The final controller is to consist of two cascaded controllers, although currently only the thermodynamic controller is active. The thermodynamic controller is currently a 7x6 multivariable matrix, which will increase in size due to recent additional instrumentation that has been added to the cooler. The LK7 kiln is a complex plant due to the large S/P preheater, which exhibits some unusual and complex dynamics and behaviour due to the counter flow feedback between the cooler, kiln and preheater.
Optin is a Johannesburg-based process control company which specialises in optimal and intelligent solutions using some of the world's most powerful artificial intelligence (AI) control tools, in particular those from Pavilion and Gensym. PPC Lime is the largest lime producer in South Africa and is part of the Barloworld group of companies.
For more information contact: Optin, tel: 011 782 8585.
Further reading:
PCS Global
PCS Global
System Integration & Control Systems Design
Project and industry:
PCS Global led a digital infrastructure initiative in a southern African data centre setting, aiming to merge several essential operational systems into one cohesive platform.
...
Read more...
Seamless migration from ET 200M to ET 200SP HA for future-ready automation
Moore Process Controls
System Integration & Control Systems Design
Project and industry:
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O
...
Read more...
Proconics Modernises Refinery Tank Automation with Compliance-Focused, Brownfield Upgrades
Proconics
System Integration & Control Systems Design
Project & Industry
Proconics was engaged to modernise automation and SCADA systems across a refinery tank farm. The project involved complex brownfield integration, aligning new automation with existing
...
Read more...
Project & Industry
System Integration & Control Systems Design
Project: Upgrading essential automation and SCADA systems at a coal mine.
Outcome: A modern, stable automation and SCADA environment with reduced technical debt and easier support, ready for expansion.
...
Read more...
Major digital transformation project for Isuzu Motors
System Integration & Control Systems Design
Isuzu Motors South Africa, in partnership with NoMuda and S4 Integration, has kicked off a major two-year digital transformation project to modernise its production environment.
Read more...
Modernising Vertical Filter Press Machines with Future-Focused Control Systems
Scibotron
System Integration & Control Systems Design
Project and Industry
Pressure Filter Specialists approached us to modernise vertical filter press machines for the Minerals and Metals industry. The goal was to improve reliability, reduce downtime,
...
Read more...
Project & industry
Abacus Automation
System Integration & Control Systems Design
Project and Industry
This project involved delivering a complete electrical, instrumentation, and automation solution for a new OEM drum-twister machine, replacing an ageing unit in a major cabling production
...
Read more...
It’s a risky business not to challenge standard language
System Integration & Control Systems Design
On the surface, contracts all look alike. Once you’ve seen one, you’ve seen them all, or so it seems. Maybe so, but hidden within the standard language can be language that shifts the other party’s risk to you.
Read more...
Containerised Electrical & Control System Powers Paste Plant in Botswana
PCS Global
System Integration & Control Systems Design
Delivering a complete, containerized solution for a mine’s paste plant in Botswana, this project stands as a model of modern EC&I execution — integrating electrical, control, and automation systems into
...
Read more...
Control system upgrade: Smelting
SAM Systems Automation & Management
System Integration & Control Systems Design
Systems Automation & Management recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.
Read more...
printer friendly version