Iron Ore Straight Grate Pelletizing Seminar

Controls

Rev October 2014

Control SystemA control system is a device, or set of devices, that

manages, commands, directs or regulates the

behavior of other device(s) or system(s).

Industrial control systems are used in industrial

production for controlling an equipment or a

machine.

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General Plant Wiring

3

(At Burners)

(At Feed End)

Power SystemDistribute Electrical Power Safely To

All Electrical Devices

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Complete Power Design & Installation

Date5

Switch Gear

Motor Control Center

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Complete Power Design & Installation

Date6

Transformers & Soft Starts

Variable Speed Drives

Motor Control Center

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Complete Power Design & Installation

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I/O Control Center Room

HMI (Human Machine Interface)Provide a visible way for operators

to view and control plant

Provide operating data so management can

improve equipment and procedures

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Total System Layout

DANVILLE - AUTOMATION9

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Pellet – Trend Menu

10 DANVILLE - AUTOMATION

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Pellet – Controller Menu

11 DANVILLE - AUTOMATION

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Pellet – Motor Control

12 DANVILLE - AUTOMATION

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Pellet – PLC Status

13 DANVILLE - AUTOMATION

PLCTo provide a interface to plant equipment

Provide logic to allow interlocking and operation of equipment

Insight into the equipment and how it works

Metso is diverse in many hardware manufactures

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Steps Of Developing PLC

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Layout / System Design

IO wiringTag

DatabaseHardware

Configuration

ProgrammingFactory Testing

Of ProgramFactory Testing Of Enclosures

Commissioning

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Pellet – PLC Interface for programming

16 DANVILLE - AUTOMATION

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PLC

Pick PLC:

Allen-Bradley, General Electric, Modicon, Siemens

17

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PLC Enclosures

DANVILLE - AUTOMATION18

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Control System Simplified Layout Diagram

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Controls SummaryMany years of experience programming

Clear understanding of operating requirements

System SummaryControl the heat and duration in each zone

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Tempering

Damper

|

Simplified Straight Grate System Flow

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600 oF

315 oC

550 oF

290 oC

1800 oF

980 oC

700 oF

371 oC

Heat Recovery From 2nd / Final Cooling Zone

Heat Recovery From 1st / Beginning Cooling Zone

Heat Recovery From Firing Zone

All Air Flows

230 oF

110 oC

230 oF

110 oC

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Seven Processing Zones

Drying Section Heating SectionHeat Recovery

Section

Pre-

heating

(Ramp)

Firing After FiringFirst

Cooling

Second

Cooling

Updraft

Drying

(UDD)

Down-

draft

Drying

(DDD)

1 2 3 4 5 6 7

Travel

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Preheating Zone

TEMPERATURE RANGES IN DIFFERENT ZONES

Hood TEMPERATUREs Increase Gradually

Combustion of Coal (aprx. 500oC)

Calcination of Limestone Begins CaCO3 CaO + CO2 (aprx. 850oC)

Chemically combined water & hydroxides driven off (aprx. 330oC)

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Firing Zone

Pellets in Upper Portion

of Bed Are Heated to

Indurating

TEMPERATURE

Down DraftDrying

Up DraftDrying

AfterFiringZone

Both CoolingZones

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Risk Damage To Pallet Car

Layer Between Hearth Pellets Are Partially Uncured

OCS

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OCS© for Iron Ore Pelletizing PlantsIntroduction

• OCS© optimizing control

- Continuous real-time expert level process assessment

- Supervisory level decision making

• Provide consistency through operating shifts

• Utilize deep process knowledge and understanding

- Automatic set point optimization

• Balling process

- VisioPellet™ technology

- Optimize pellet size distribution & feed rate

- 21 systems (Vale, Brazil)

• Induration process

- OCS© advanced control technology

- Optimize production, energy usage, product quality, environmental emissions

- 14 systems with on-line modeling

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VisioPellet™ Technology

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Regulatory Control

DCS or PLC

Expert System

OCS© Optimizing Control System

Vision Software

VisioPellet™

Analyze pellet

size distribution

Optimization

algorithm

Adjust disc

operation

Optimized feed rate

and disc speed set

points

Pe

lle

tizin

g D

isc

Ca

me

ra a

t d

isc

ha

rge

of

dis

c

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OCS© & OCS-4D© Technology

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Plant with

DCS / PLC-SCADA

Expert System

with Fuzzy Logic

Soft

Sensors

Neural

NetworkAcoustics

Vision

HMIStatistics

Trending

Optimizers

Advanced

Controllers

Image Miner

Data Miner

VisioPellet™ embedded in vision module

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OCS© for Iron Ore Pelletizing PlantsImplementation

• Provide complete solution

- Hardware

- Software

- Advanced control engineering

• Synergy of expertise

- Metso has wealth of experience with iron ore pelletizing plant optimization

- Client has experience with their plants

- Both parties have ownership in results

• Simple & smooth integration

- Metso manages integration and commissioning

- No plant disturbances necessary

- Minimize client resources needed

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