Roller Mill Control Simulator.

ulator.

Enter

Exit

CEMEX México
Exploitation Direction
 Cemet Mill Raw Meal Mill Coke/Coal Mill Regulation Feed Optimization Exit

Simulator of the Integral Control of Raw Meal Milling

RAW MATERIALS ANALYSIS LSF/MS/MA Calibration

Raw.Material MP1 MP2 MP3 MP4 MP5 Actual Objective Tests 1 2 3
%CaO 49.61 2.00 15.00 5.30 1.21 95.6 97.0 rpm 1200 1200 700
%SiO2 7.21 17.98 54.22 46.77 4.05 3.2 2.35 Select the mesh Dp exit 800 500 800
%Al2O3 1.20 6.47 8.83 18.71 0.37 1.7 1.60 Select. mesh.: 75 micron 40 40 40
%Fe2O3 0.40 67.46 2.91 8.34 84.64 Product Passing 75 microns
%MgO 0.80 0.00 1.58 5.92 0.01 Passing at 75 microns %Mill´s draft Product 79.0 81.0 74.0
%SO3 0.51 0.47 0.07 0.07 3.96 Calculated Objective 44 CALIBRATION RESULTS
%K2O 0.29 0.58 2.25 3.46 0.10 79.0 77.0 45 Pas32=a*(rpm^b)*(DpExit^c)
%Na2O 0.06 0.11 0.45 0.69 0.02 DpSal=a*(Pas32^b)
%Ti2O 0.08 0.36 0.12 0.14 0.29 Kw-I.D. Fan Coefficient a b c
% I.L. 39.86 4.57 14.57 10.61 5.39 1600 Passing75 47.70 0.12 -0.05
%Cl- 0.00 0.00 0.00 0.00 0.00 1620 Dp exit 4E+12 -5.20
%F- 0.00 0.00 0.00 0.00 0.00

SUM 100 100 100 100 100 %Recirculation LIMITS Máx Mín
KICK Work index 20.0 15.0 5.0 5.0 15.0 10 %Mill´s draft 60 30
10 %Hot Gasses 60 20
MP2 Material Percentage %Recirculation
Kw molino 30 1200
1200 0
MP1 Limestone 83.0 Exit Depres. Exit Temp. %Cold Air 15 0
MP2 Iron mineral 1.0 800 83 Kw I.D. Fan 1650 1450
MP3 Clay 12.0 Feed.T/h Kw Mill 1200 1100
MP4 Clay 4.0 205 T/h Exit Temp. 85 80
MP5 Iron Mineral 0.0 rpm Dp Diference Dp Diference 850 650
LSF 95.6 97.0 971 700 hydraulic P 130 95
MS 3.2 2.4 1200 Fortificación actuaciones 2
MA 1.7 1.6
Inlet Temp. Composition Propose Max Min
150 Limestone 80.0 100 54
Hydraulic P. Iron mineral 1.0 3 0
100 Inlet Depres. %Gases Cal %hot gasses Clay 15.3 20 0
Kw consumed in milling 100 %Cold air 40 Clay 3.8 20 0
1150 5 40 Iron Mineral 0.0 3 0
1160 5
Cemet Mill Raw Meal Mill Coke/Coal Mill Regulation Feed Optimization Exit

Simulator of the Integral Control of coke/coal Milling

Passing at 75 microns Select the mesh Calibration

Calculated Objective Select. mesh: 75 microns Tests 1 2 3
84.2 85.0 rpm 1200 1200 700
Kw-I.D.Fan Exit Dp 800 500 800
1600 %mill´s draft %Tiro Molino 40 40 75
1600 45 Product Passing 75 microns
45 Product 89.0 92.0 83.0
CALIBRATION RESULTS
Pas32=a*(rpm^b)*(DpExit^c)
HardGrove DpSal=a*(Pas32^b)
30.0 %Recirculation Coefficient a b c
Kick 10 Passing75 56.94 0.13 -0.07
Work Index Exit Depres. Exit Temp. 10 Dp Exit 5E+11 -4.57
49.7 800 80
Feed.T/h LIMITS Max Min
79 T/h %mill´s draft 60 20
rpm Dp Diference. %Hot Gasses 60 20
841 700 %Recirculatio
Kw mill 30 1200
1200 0
780 %Cold air 15 0
Kw I.D.Fan 1650 1450
Inlet Temp. Kw Mill 1200 1100
150 Exit Temp. 85 80
Hydraulic P. Dp Diference 850 650
100 Inlet Depres. %Hot Gasses Hydraulic P 130 95
100 40 Fortificación actuaciones 2
Kw consumed in milling % Cold Air 40
1150 5
1090 5
 Cemet Mill Raw Meal Mill Coke/Coal Mill

MILLING OPERATION PROGRAM REGULATION

MINIMUM
EXIT T. LOWER FEED.
NO MIN ?
LOW
HIDRAULIC P.
NOT LOW ?
HIGH

MAX
NO YES NOT HIGH
DP DIFEREN LAYER LAYER FEED.
YES work? work? ? ? NOT MAX
NO

NO
LAYER DP DIFEREN
YES work? ? NOT HIGH
HIGH
ONE IS NOT
HIGH
DP.DIF & LAYER ASPIRATOR Kw
BOTH ? ?
HIGH NO MAX

Kwobj<Kwmin +-30? NO LOWER THE OBJECTIVE OF

? Kw IN THE MILL´S MOTOR

YES
NO MAX YES
ANOMALY ALARM Vasp allowance OPEN Vasp
GO TO MANUAL MAX ? ?
NO

NO MAX
Vrecircul OPEN Vrecirculation
 MAX ?

NO MIN
Vgases cal. CLOSE Vhot gasses
MIN ?

MINIMUM NO MAX
Kw ASP. Vcold air OPEN Vcold air
? MAX ?
NO MAX NO MINIMUM
VASP. OPEN Vasp
?
MAX

ANOMALY ALARM
GO TO MANUAL

NIVELES Kw MILL HYDRAULIC P. DPDIFEREN LAYER FEED Kw ASP TEXIT

DISCONNE. SUP. PROTEC

REGULATION

MAXIMUM

OBJECTIVE

MINIMUM

DISCONNE. INF. PROTEC

(*) MINIMUM SELECTABLE BY THE PANNEL DEPENDING ON THE GASSES NECESSITIES FOR COAL MILLING.

ALLOWANCE: THE FINESS CONTROL PROGRAM WILL OR WILL NOT ALLOW THIS PROGRAM TO INCREASE THE ASPIRATION VALVE OF THE MILL, BECAUSE IT IS
Coal Mill Regulation Feed Optimization Exit

LOW HIGH
MILL´S Kw DROWNED MILL NO
? ?
NORMAL HIGH Kw IN THE MILL´S MOTOR AND
LOWER FEED. VERY LOW Kw IN MILL´S ASPIRATOR Kw MUY BAJOS DE ASPIRADOR MOLINO
YES
HIGH
HYDRAULIC P.
? NOT HIGH

MIN DOWN
DOESN´T DESCEND YES NO
INCREASE FEED. LOWER FEED FEED LAYER LAYER DP DIFEREN
NO MIN ? ? work?
NO

LOW HIGH
Exit Depr.
? DOESN´T DESCEND NO
NORMAL DP DIFEREN
?
DOWN
ONE DOESN´T
MAX MIN DESCEND
SPIRATOR Kw Kw ASPIRATOR DP.DIF & LAYE
?
NO MIN

NO
LOW HIGH INCREASE THE OBJECTIVE OF KwObj>Kwmax-5
ASPIRATOR Kw Kw IN THE MILL´S MOTOR
?
NORMAL NO MIN
OPEN Vasp CLOSE Vasp Vasp
? MIN ANOMALY ALAR
GO TO MANUA
MAX MIN
TEXIT
?

NO MIN
OPEN Vrecirculation CERRAR Vcold air Vcold air
 ? MIN

NO MIN
CLOSE Vhot gasses CERRAR Vrecirculation Vrecircul
? MIN

NO MAX MAXUMUM
OPEN Vcold air OPEN Vhot gasses. Vhot gasses Kw ASP.
? MAX ?
NO MAXUMUM

PROCEEDING
OPEN/PLACE 1 ANOMALY ALARMA
NOTHING 0 GO TO NORMAL
CLOSE/REMOVE -1

Vasp Vrecirculation Vhot gasses Vcold air DPEXIT vibrations TINLET RPMSEP. LEVELS OF DROWN
Kw ASP

(*)

RATION VALVE OF THE MILL, BECAUSE IT IS ALSO AN ASPIRATOR OF THE SEPARATOR.

 NOT HIGH

DP DIFEREN
work?
YES

LAYER
work?
YES
ONE DOESN´T
DESCEND
DP.DIF & LAYER
? BOTH
DOWN

KwObj>Kwmax-50?
?
Yes

ANOMALY ALARM
GO TO MANUAL
OMALY ALARMA
O TO NORMAL

LEVELS OF DROWN
Kw MILL
Cemet Mill Raw Meal Mill Coke/Coal Mill Regulation

PROCEEDING SCALING OVER FEEDING

POSSIBLE SET POINT RANGES

DISCONECTION
STABILIZER Z; Z=0.01*SP
ALARM
LL=SP-4*Z

4*Z +Z
-

ACT

DIMINISH a% 1
Kw - (SP+Z)
VALUE= ---------------
HL - (SP+Z)
(SP-Z)
NONE 0
Kw- (SP- Z)
VALUE= ---------------
(SP- Z) - LL
INCREASE b% -1
Regulation Feed Optimization Exit
CIMCRU

Kw

HL=SP+2*Z DISCONECTIONN

SP ALARM

+Z +- Z 2*Z
 Cemet Mill Raw Meal Mill Coke/Coal Mill Regulation

MILL OPERATION PROGRAM. OPTIMIZATION

A) LOGIC

TEXIT T2=TEXIT Vasp

Vrecirculation 0.324
MILL TENTRANCE(TE) T1=0,113* T11A1*(dp11A1-dp41) KILN
depressures in hot and cold stages
A Vcold air (closed) Vhot gasses Exit temperature in cold stage

4,6*Vg cal*T1 + Vrecirc *T2

TE THEORETICAL =
4,6*Vg cal + Vrecirc

ACTUAL SITUATION MAXIMUM TE

TE ACTUAL
Vhot gasses REALITY ADJUSTMENT FACTOR Vhot gasses MAX
Vrecirculation f=TE ACTUAL/TE THEORETICAL Vrecirculation MIN
A OPT1
TE THEORETICAL=FORMULA TE MAX= f * FORMULA

B) OPTIMIZATION PROGRAM

THIS PROGRAM WORKS WHEN THEY ARE INSIDE ITS WORKING BAND:

Kw MOTOR AND P.HYDRAULIC ; AND

ACTUAL SITUATION
Vhot gasses. actual FACTOR CALCULATION f
Vrecirculation. actual CALCULATION OF THE MAX.Tentrance

TE ACTUAL TE ACTUAL > TE MAXIMUM

?

NO

NEW VALVE POSITIONS

NEW Vhot gas = Vhot gasses. MAX.
 NEW Vrecirculat.= Vrecirculation MINIMUM

CALCULATION OF OPTIMUM FEED 1

CALCULATION OF OPTIMUM FEED 2

Kw ASP OPT. > MAXIMUM

AND Vasp >MAXIMUM
?
NO

CALCULATION OF OPTIMUM FEED 3

NEW FEED = OPTIMUM 3

NEW Vasp =Vasp OPTIMUM

OUTPUT TO THE NEW POSITIONS OF

Vhot gas Vrecirculat. Vasp FEED.

 Regulation Feed Optimization Exit

TE 1
TE 2
At Vasp and A CONSTANT
0.47 -0.35 0.47
TEXIT 1 A2 Kw 1 DPext 1 * TEXT 1 Vasp 1 *

TEXIT 2 A1 Kw 2 DPext 2 TEXT 2 Vasp 2

nd cold stages at Vasp and TE CONSTANT
0,072
Vasp 1 Kw asp opt: WITH :
Vasp 2 1 =OPTIMUM VALUES
at Vasp and A CONSTANT 2 = ACTUAL VALUES

OPTIMUM FEED 1 OPTIMUM FEED 2 OPTIMUM FEED 3

FOR Vasp and Texit CTE FOR Texit OPTIMUM and Vasp CTE FOR OPTIMUM Texit and OPTIMUM V
(ONLY IF Kw asp < MAXIMUM AND V
TE MAX Texit actual
A OPT1 =A actual * A OPT2 =A OPT1 * OPTIMUM Vasp
TE actual Texit optimum AT OPT3 =AT OPT2 *
WITH: actual Vasp
Texit optimum=AVERAGE (MAX,MIN) WITH:
Vasp OPTIMUM = AVERAGE(actual,MAX)

Texit <=Texit MAX

Vcold air CLOSED

LEVELS
Vhot gasses. MAXIMUM
Vrecirculation. MINIMUM

YES

KEEP THE ACTUAL POSITIONS

OF THE VALVES
 TAKE THE TE MAXIMUM = TE actual

YES

NEW FEED = OPTIMUM 2

NEW Vasp = ACTUAL

 -0.35
TEXT 1
TEXT 2

1 =OPTIMUM VALUES
2 = ACTUAL VALUES

PTIMUM FEED 3
M Texit and OPTIMUM Vasp
AXIMUM AND Vasp < MAXIMUM)
0,072
OPTIMUM Vasp

actual Vasp

RAGE(actual,MAX)