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:
How certified industrial automation channels become co-creators in the AI era
Schneider Electric South Africa
System Integration & Control Systems Design
As industrial automation becomes software-driven and AI-enabled, the role of channel partners is shifting from equipment supply to outcome-based consulting, software integration and lifecycle services that require continuous certification and capability development.
Read more...
Why integration defines the next competitive edge in pulp and paper
System Integration & Control Systems Design
ABB’s Arvin Ramjee argues that fragmented automation, assembled from different suppliers at different stages of a plant’s lifecycle has become one of the pulp and paper industry’s most overlooked commercial risks, and that true integration, rather than surface-level connectivity, is what delivers measurable business value.
Read more...
Integrated automation enhances water treatment at dairy facility
Process Dynamics
System Integration & Control Systems Design
Process Dynamics delivered the electrical, instrumentation, control and automation integration for an advanced water treatment and reverse osmosis system at a major South African dairy processing facility, achieving a 50% reduction in the client’s water utility costs.
Read more...
Intelligent process control is reshaping cement production in Africa
System Integration & Control Systems Design
Advanced process control, predictive analytics and automation are helping African cement producers cut energy use and stabilise output as they contend with rising electricity costs and tighter margins.
Read more...
Schneider Electric’s Alliance Programme turns system integrators into trusted technology partners
Schneider Electric South Africa
System Integration & Control Systems Design
: Schneider Electric’s Alliance Partner Programme is helping system integrators across Africa move beyond one-off projects and build the skills and service models needed to become long-term industrial technology partners.
Read more...
Process Dynamics – Integrated Automation for Dairy Water Treatment
Process Dynamics
System Integration & Control Systems Design
Project and industry
Process Dynamics delivered the electrical, instrumentation, control and automation integration for an advanced water treatment and Reverse Osmosis (RO) system at one of South Africa’s
...
Read more...
New SI programme strengthens Schneider Electric’s partner ecosystem
Schneider Electric South Africa
System Integration & Control Systems Design
Schneider Electric’s SI Energise 2.0 programme offers system integrators a competency-based framework to develop deeper expertise in EcoStruxure and AVEVA software, enabling them to deliver full-lifecycle industrial automation solutions.
Read more...
AI and smart solutions for underground proximity detection systems
System Integration & Control Systems Design
Booyco Electronics explains why fitting proximity detection systems underground is far more complex than installing sensors, and how integration, data and intelligent analytics are helping mines manage the challenge.
Read more...
Why cloud-ready BMS is reshaping building operations
Schneider Electric South Africa
System Integration & Control Systems Design
Smart sensors and non-contact radar are reshaping industrial measurement, feeding connected platforms that predict failures before they happen.
Read more...
Flotation system modernisation for a gold processing and mineral recovery plant.
Moore Process Controls
System Integration & Control Systems Design
Moore Process Controls has successfully modernised a gold processing plant's flotation control system, replacing obsolete I/O hardware with Schneider Electric's latest M580 X80 platform.
Read more...
printer friendly version