Optimering av processer vid cementklinker- och kalktillverkning. Ett projekt inom MinBaS Innovation

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2 Optimering av processer vid cementklinker- och kalktillverkning Ett projekt inom MinBaS Innovation

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4 Mål Ny kunskap om när vi använder biobränslen och restmaterial klinkerbildningen klinkermineralernas struktur ny termodynamiska data Hur MgO påverkar smälttemperaturen Utveckla för bättre processtyrning befintlig modell ny modeller för stoftbildning ny modell för kemi och flöden i schaktugn MinBasdagen

5 Projektet är indelat i tre delprojekt WP1 Klinkermineralbildning och smältfasens egenskaper WP2 Optimering av kalk och cement processerna WP3 Utveckling av schaktugnsmodell MinBasdagen

6 Projektet Koordinator Projektledare Rainer Backman Industridoktorander Matias Eriksson Erik Viggh Forskare Bodil Hökfors Anders Lyberg Stefan Sandelin Kjell Dahlberg Mikael Wendel Process Automation Michael Lundh Torbjörn Ottosson Johan P. Sandstedt MinBasdagen

7 WP1 Klinkermineralbildning och smältfasens egenskaper I temperaturområdet mellan C sker det många reaktioner på partikelytorna Undersöka om reaktioner mellan partiklar Inverkan av cirkulerande ämnen som MgO, S, Na och K som i ugnsystemet på smältfasen. Kan vi med SEM, XRD och optisk mikroskop 'se' reaktionsprodukterna? MinBasdagen

8 WP 2 Optimering av kalk och cement processerna Task 1: Task 2: Task 3: Task 4: Task 5: Task 6: Syrgasanrikning för energieffektiv kalkproduktion (pågår) Oxyfuel förbränning för energieffektivitet vid kalkproduktion (pågår) Råmaterialsegenskaper för kalkproduktion (pågår) Aktiveringsenergi Modellering av stoft i gasfas vid kalkproduktion Modellering av stoft i gasfas vid cementproduktion Hur uppstår dammet i processen Utveckling av energibalansberäkningar för cementproduktion Förbättring av ASPEN/CHEMAPP simuleringsverktyg. MinBasdagen

9 Modellering av stoft i gasfas vid cementproduktion MinBasdagen

10 WP3 Utveckling av schaktugnsmodell Upprättande av kravspecifikation för modellering Val av modellverktyg Insamling av basdata för modellen Modellering Teoretisk validering av utfall av modelleringen Framtagning av teknik för utökad datainsamling från processen Rökgasdata online från schakt och kanaler, ej enbart från rökgaser efter ugn Temperaturmätning på fler och rätt ställe i ugnen Validering av modell och framtagen mätteknik med fullskaleförsök Utvärdering av modell Översättning av utvald data till programkod. MinBasdagen

11 Alf Isaksson, SECRC ABB Research in Control MinBas,18 March, 2015 ABB Group April 1, 2015 Slide 1

12 A Global Leader in Power and Automation Leading Market Positions in Main Businesses ~150,000 employees $ 42 billion In revenue (2013) Present in +100 countries Formed in 1988 merger of Swiss (BBC, 1891) and Swedish (ASEA, 1883) engineering companies ABB Group April 1, 2015 Slide 2

13 How ABB is organized Five global divisions Power Products $10.9 billion 35,300 employees Power Systems $8.1 billion 19,600 employees Discrete Automation and Motion $8.8 billion 28,500 employees (2011 revenues, consolidated; including Thomas & Betts revenue for LP division) ABB s portfolio covers: Electricals, automation, controls and instrumentation for power generation and industrial processes Power transmission Distribution solutions Low-voltage products Low Voltage Products $7.7 billion 31,400 employees Motors and drives Process Automation $8.3 billion 28,300 employees Intelligent building systems Robots and robot systems Services to improve customers productivity and reliability ABB Group April 1, 2015 Slide 3

14 Power and productivity for a better world ABB s vision As one of the world s leading engineering companies, we help our customers to use electrical power efficiently, to increase industrial productivity and to lower environmental impact in a sustainable way. ABB Group April 1, 2015 Slide 4

15 ABB Corporate Research Local Lab Locations Västerås SE Raleigh US Baden CH Krakow PL Ladenburg DE Beijing CN Shanghai CN Bangalore IN Close to major customers, universities and ABB s business responsible units ABB Group April 1, 2015 Slide 5

16 Corporate Research: Local Labs and Research Areas Chief Technology Officer Claes Rytoft, ad interim Global Research Manager Franz Schmaderer ABB Group April 1, 2015 Slide 6 Communication Stefan Svensson Control Alf Isaksson Electromagnetics Robert Chin Materials Jens Rocks Mechanics Xiaolong Feng Power electronics Waqas Arshad Sensors Andrea Andenna Software Roland Weiss Switching Riccardo Bini CHCRC Stefan Ramseier CNCRC QinJian Liu DECRC Jan-Henning Fabian INCRC Akilur Rahman PLCRC Marek Florkowski SECRC Mikael Dahlgren USCRC Le Tang

17 Research Area Control Scope The research area focuses on Control as well as Protection in a broad sense: Control: Manipulate a set of input variables in such a way that the controlled system produces the desired (optimal) output according to some performance measure. Protection: Based on measured variables detect and prevent malfunctions before they do occur, or at least before their effect becomes too costly ABB Group April 1, 2015 Slide 7

18 Research Area Control Sub Research Areas and Coordinators AE Automation Engineering (Rainer Drath, DECRC) Develop knowledge and methods to increase ABB s engineering efficiency and quality. D&S Diagnostics & Service (Michal Orkisz, PLCRC) Service-related research in monitoring, diagnostics, reliability and lifetime at component, system, fleet and process level. P&GM Production & Grid Management (Iiro Harjunkoski, DECRC) Planning, scheduling and tracking of industrial production processes and electrical grids. PC Process Control (Michael Lundh, SECRC) Techniques and technologies for modeling, control, and optimization of industrial processes. ABB Group April 1, 2015 Slide 8

19 Research Area Control Sub Research Areas and Coordinators cont d ESC Electrical Systems Control (Mats Larsson, CHCRC) Automation solutions for efficient operation of power and energy systems. GP Grid Protection (Przemyslaw Balcerek, PLCRC) Develop utility oriented protection solutions utilizing all available measurements, modern system thinking, and advanced computation. MC Motion Control (Luca Peretti, SECRC) Efficient and effective use of the electromechanical chain by exploiting position, speed and current regulators in suitable devices for drives and actuators. CC Converter Control (Tobias Geyer, CHCRC) Current control and modulation of three-phase power electronic converters. ABB Group April 1, 2015 Slide 9

20 Research Area Process Control Key Research Directions 1. Advanced control lifecycle considerations Simplified engineering and maintenance 2. Control platform considerations Scalability from device to cloud 3. Industry line specific advanced control applications Develop re-usable solutions for Minerals & cement Mining Oil & Gas Pulp & paper etc. ABB Group April 1, 2015 Slide 10

21 Historical Notes Cement 2005 Raw Mix Preparation Pilot site Buzzi Unicem, Guidonia (I) By end of 2007 more then 40 plants in operation 2009 Cement Mill Control Modelica integration into APC tools 2006 Precalciner Control Pilot site Holcim, Lägerdorf (D) In plants commissioned 2006 Mill Control Pilot site Jura Cement, Wildegg (CH) By end of mills in operation 2008 Kiln Control Pilot site Holcim, Siggenthal (CH) By end of plants in operation ABB Corporate Research April 1, 2015 Slide Cement Mill Fingerprint Nonlinear models to be used for advanced control benefit estimation

22 Historical Notes Grinding and GMDs 2010 GMD Remote Monitoring and Diagnostics Pilot site Xstrata, Collahuasi (CHI) By end of 2014, 36 GMDs in the system 2011 and 2013 GMD Stator Winding Optimization I&II Pilot site Newmont Mining Corporation, Yanacocha (PE) GMD Design tool in use since Grinding Circuit Control Pilot site Boliden AB, Aitik (SE) Pilot implementation in SmartMill - APC Integration Ongoing Target date Q ABB Corporate Research April 1, 2015 Slide 12

23 Mining 2.0 Transformation for productivity Project Goal Development of a automation portfolio for underground mines Benefit Extend ABB business in underground mining Improved operational efficiency, at least 20% Technical Solutions Mine ventilation control Integration of mobile machines Wireless communication in underground mines Asset and personell localisation Logistics operation optimization Automated scheduling for logistics operations Fleet management Real time material tracking ABB Group Slide 13 SECRC/A/COPAN Jan Nyqvist March 2015

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