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“In the name of Allah, the Beneficent, the Merciful”

Grinding Circuit Control Systems

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Summary

1. Why a control / What to control

2. Available Tools

3. Control Strategies

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1. Why a Control Systems

• Optimum Production Rate


• Consistent Quality
• Smooth Operation
• Quick Mill Stabilization (disturbance)
(quality change)
• Operator relief

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What to control ?
FOR THE OPTIMUM EQUIPMENT EFFICIENCY
Ratio material/air
steady

Material flow
steady

Reject Flow
Finish product

Feed rate

Ratio fines/rejects Material level


steady steady

Reject flow Total mill flow


steady steady

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2. Available Tools

• Functional layout
• Controller objective
• Controller ON-OFF
• Controller P.I.D.
• Expert system

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Disturbances

Manipulated Controlled
Quantities Quantities

PROCESS

Setpoints
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PROCESS

Manual Control
Disturbances

Manipulated Controlled
Quantities Quantities

PROCESS

Actions
Needed
Measured
Values
Feedback Control

Hardware

Setpoints
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Functional Layout of a Feedback Loop

Disturbances

Manipulated
Setpoints final Controlled
input + feedback transmission
controller system control PROCESS
elements error element
- signal

sensor

transmission
system

Controllerbox On site

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Controllers Objectives

1. stay on the setpoint


2. track a setpoint change
Controlled variable:
Ideal reject flow rate , p.e.

Setpoint Manipulated variable:


feed rate , p.e.

Time

Reality

Setpoint

Time

Setpoint

Time

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Controllers : On - Off

Controlled variable:
room temperature

Dead Zone

Setpoint

On
Fuel valve
Off

Time
Manipulated variable:
quickly changes to either a maximum or
a minimum value (minimum = 0 or off).
Discontinuous control
Mechanism = usually a simple relay
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Controllers : Proportional

E Kc E

e K c m

Control algorithm: m = K e c

K C= proportional sensitivity or gain


1/KCX100 = proportional band (PB)
E = error
m= Manipulated variable

+ Rapid response
Dynamicaly relatively stable

- Offset

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Offset
Equilibrium

Steam

Undercharge 3

Steam
2

1
Rotational Charge
speed application Offset
Setpoint

Time

Integral action
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Controllers : Integral
Et
E
Ti
1
e Tp m
i

Control algorithm: m = 1/Ti e dt

Ti = integral time
p = action of integration with respect to time (dt)
m= Manipulated variable
e=error
P+I:
+ Combines advantages of proportional
and the reset of the offset

- Tuning difficulty increased


Less stable

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Controllers : Derivative
Adds lead to the controller for lag around the loop
It's based on the rate of change of e

E
Ed Td
e Tp d
m

Control algorithm: m = Td d/dt (e)

Td = derivative time
p = action of derivation with respect to time (dt)
m= Manipulated variable
e=error

D: Not alone in practice, because huge error


If unchanging error rate
P+D:
+ If extensive lag
More stable if well tuned

- Tuning difficulty increased


Reduced but not eliminated offset,
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Controllers : P I D
On -Off:
Inexpensive
Extremely simple

P:
Simple
Inherently stable when properly tuned
Easy to tune
Experiences offset at steady state
P+I+D: the most sophisticated P+ I:
No offset
Characteristics of controller algorithms Better dynamic response than reset alone
Possibilities exist for instability due to lag
introduced

P + D:
Stable
Less offset than proportional alone
(use of higher Kc possible)
Reduces lags, i.e. more rapid response

P + I + D:
Most complex
Most expensive
Rapid response
No offset
Difficult to tune
Best control if properly tuned
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Expert Systems

• Rule-based
• Combines several methods, and tries to emulate human
responses to given conditions
• Based on a decision table, which gives each possible
combination of conditions which could occur for x number
of measured parameters
• Although these systems are becoming more and more
common, it must be remembered that a considerable amount
of study and tuning is required to get the program right.
The programmer must, in essence, teach the computer
to operate the mill
• The current restriction on these systems is that they act only on one
parameter at a time.

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3. Control Strategies

• HOME MADE SOLUTIONS

• Elevator Control
• Ear Control
• Reject Flow Control by Fresh Feed
• Total Feed Control
• Reject Flow Control by Separator Speed

• COMMERCIALIZED SOLUTIONS : - HOLDERBANK (Canada)


- SCAP
- MILLTRONICS
- K-TRON/HASLER
- GO CONTROL

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Strategies

• SIGNAL USED FOR CONTROL

- MILL MOTOR POWER


- MILL SOUND (1st OR / AND 2nd COMPARTMENT)
- ELEVATOR POWER
- REJECT FLOW
- SEPARATOR SPEED
- (FINISH PRODUCT FINENESS)

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Fresh Feed Control by Elevator

Separator speed

Reject
Finish product

P.I.
Elevator Fresh feed
+ -
Set Point
- High Lag time
- Poor Signal from Elevator

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Fresh Feed Control by Ear Signal

Separator speed

Reject
Finish product

P.I.
Sound Fresh feed
+ - EAR
Set Point
- Uneven Mill Flow

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Reject Flow Control by Fresh Feed

Separator speed

Reject
Finish product

-
+ P.I.
Total feed Fresh feed
Set Point
- Long lag time
- No detection of build up in mill

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Total Flow Control by Fresh Feed

Separator Speed

+
Reject
+
Finish product

-
P.I.
+
Reject setpoint Fresh feed

- Long lag time


- Material build up not detected

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Reject Control by Separator Speed

Separator speed
+
Reject
P.I.
setpoint -

Reject

Finish product

Fresh feed
- Not suitable with uneven clinker

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SCAP Strategy
Commercialized solutions
Elevator Filling Feed
Power Degree
Set Point Set Point

Master Dependent Dependent Process


Loop Loop Loop

Filling Degree

Elevator Power

Mill Power

Feed

STRATEGY : Maximize Feed Rate and Mill Power

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Milltronics Strategy

Set Point
ear k1 %

reject + Feed
k %
2 PI D
+ +

elevator k %
3
power

k +k +k = 100 %
1 2 3

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HOLDERBANK (MISSISAUGA)
Mill Load Control Strategy

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Mill Load Control Strategy

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K-TRON / HASLER Control Strategy

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K-TRON / HASLER Control Strategy

Pid-1 :
Fresh regulation set point = Fresh set point + F (pid) (Mill set point Mill flow)
« Grits/fresh » Fresh Setpoint
Mill set point = Fresh set point (1 + Grits/fresh)
Mill flow = SFresh + Grits

If full mill : Ear < Full level (ear)


Ear P3
Elevator Then :
Mill Setpoint
Mill set-point =
Σ Fresh Fresh regulation set point
Mill Flow = PID 1
+Grits
Ear Full _ level (ear)
Mill set-point (1 +
Empty (ear) +Full (ear) PB (elev)
*
2 100
% WF 1 % WF2
If full mill : elev > full level (elev)

Then :

WF 1 WF 2 Mill set point =

Empty_ level (elev) - Elev


Mill regulation Mill set point (1 +
Empty (elev) +Full (elev) PB(elev)
*
2 100

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Slegten Multivariable and Fineness Control
Laboratory
Fineness SP Sampling

Prediction

Separator

Speed

Finish product
Finish product

Reject Reject

Mill

Feed rate

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Conclusions

Regardless of the control system, the


grinding will still be done in the mill, and
the mill should be optimized to be both
effective and efficient

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