Soluções em Pelotização (Controls)
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Transcript of Soluções em Pelotização (Controls)
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
15
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
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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
28 All rights reserved.
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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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