Soluções em Pelotização (Controls)
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Brian Morgan Staff Engineer, Pyro Brian Morgan é formado em engenharia elétrica e tem 22 anos de experiência em design de sistemas de controle, startup e comissionamento. Sua carreira inclui vasta experiência nas áreas de pelotização de minério de ferro, calcinação de coque e cal hidratada.
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Soluções em Pelotização (Controls)
- 1. Iron Ore Straight Grate Pelletizing Seminar Controls Rev October 2014
- 2. Control System A 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.
- 3. General Plant Wiring © Metso 3 (At Burners) (At Feed End)
- 4. Power System Distribute Electrical Power Safely To All Electrical Devices
- 5. Complete Power Design & Installation 5 © Metso Date Switch Gear Motor Control Center
- 6. Complete Power Design & Installation 6 © Metso Date Transformers & Soft Starts Motor Control Center Variable Speed Drives
- 7. Complete Power Design & Installation © Metso 7 I/O Control Center Room
- 8. 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
- 9. Total System Layout 9 © Metso DANVILLE - AUTOMATION
- 10. Pellet – Trend Menu 10 © Metso DANVILLE - AUTOMATION
- 11. Pellet – Controller Menu 11 © Metso DANVILLE - AUTOMATION
- 12. Pellet – Motor Control 12 © Metso DANVILLE - AUTOMATION
- 13. Pellet – PLC Status 13 © Metso DANVILLE - AUTOMATION
- 14. PLC To 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 14
- 15. Steps Of Developing PLC © Metso 15 Layout / System Design IO wiring Tag Database Hardware Configuration Programming Factory Testing Of Program Factory Testing Of Enclosures Commissioning
- 16. Pellet – PLC Interface for programming 16 © Metso DANVILLE - AUTOMATION
- 17. PLC © Metso Pick PLC: Allen-Bradley, General Electric, Modicon, Siemens 17
- 18. PLC Enclosures 18 © Metso DANVILLE - AUTOMATION
- 19. Control System Simplified Layout Diagram © Metso 19
- 20. Controls Summary Many years of experience programming Clear understanding of operating requirements
- 21. System Summary Control the heat and duration in each zone
- 22. 230 oF 110 oC © Metso Tempering Damper | Simplified Straight Grate System Flow 22 600 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 230 oF 110 oC All Air Flows
- 23. Seven Processing Zones Drying Section Heating Section © Metso Heat Recovery Section Pre-heating (Ramp) Firing After Firing First Cooling Second Cooling Updraft Drying (UDD) Travel Down-draft Drying (DDD) 1 2 3 4 5 6 7 23
- 24. © Metso 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) 24 Firing Zone Pellets in Upper Portion of Bed Are Heated to Indurating TEMPERATURE Down Draft Drying Up Draft Drying After Firing Zone Both Cooling Zones
- 25. 25 © Metso
- 26. 26 © Metso Risk Damage To Pallet Car Layer Between Hearth Pellets Are Partially Uncured
- 27. OCS
- 28. OCS© for Iron Ore Pelletizing Plants Introduction • OCS© optimizing control - Continuous real-time expert level process assessment - Supervisory level decision making © Metso • 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. © Metso Cisa
- 29. VisioPellet™ Technology 29 © Metso All rights reserved. © Metso Cisa Optimized feed rate and disc speed set points Regulatory Control DCS or PLC Expert System OCS© Optimizing Control System Optimization algorithm Vision Software VisioPellet™ Analyze pellet size distribution Adjust disc operation Pelletizing Disc Camera at discharge of disc
- 30. OCS© & OCS-4D© Technology 30 © Metso All rights reserved. © Metso Cisa Plant with DCS / PLC-SCADA Statistics HMI Trending Expert System with Fuzzy Logic Soft Sensors Neural Network Acoustics Data Miner Vision Optimizers Advanced Controllers Image Miner VisioPellet™ embedded in vision module
- 31. OCS© for Iron Ore Pelletizing Plants Implementation • 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 31 © Metso All rights reserved. © Metso Cisa
- 32. 32
Editor's Notes
- This slide was created to give a general understanding of all parts of a control system. The red line shows how electrical power is transformed and distributed to the plant. The blue indicates signals to control. These are signals from sensors, or signals to command action to the plant. They can be wired, wireless, or some form of communication highway.
- Power system designs are something that Metso is very familiar with. Our large equipment requires large motors to run, move, or function. We have even wound motor coils around a mill system because a proper motor and drive system could not be purchased. These photos are from a turkey job that Metso did using MCC, switchgear, and medium voltage and low voltage drives.
- Power system designs are something that Metso is very familiar with. Our large equipment requires large motors to run, move, or function. We have even wound motor coils around a mill system because a proper motor and drive system could not be purchased. These photos are from a turkey job that Metso did using MCC, switchgear, and medium voltage and low voltage drives.
- Power system designs are something that Metso is very familiar with. Our large equipment requires large motors to run, move, or function. We have even wound motor coils around a mill system because a proper motor and drive system could not be purchased. These photos are from a turkey job that Metso did using MCC, switchgear, and medium voltage and low voltage drives.
- It is important to select parts that can be scaled. This means can grow. Every system has its limit but it is important to know what the limit is. This will allow the entire system to handle additional equipment, features, and customization. When the control systems are new there should be three scalable aspects to look at. 1) Communications (The network should not be loaded, this will make your screen updates slow, could cause PLC problems and jeopardize networked interlocking.) 2) Graphics (Every graphics system has a tag count. This is how many different pieces of data one can look at. It is important that this count is not to low. This could stop you from being allowed to create additional functionality. The good thing is s scan normally be easily upgraded but required a more expensive license) 3) PLC (Expansion in PLC can be measure in having: Spare memory – to enhance and change the program Spare IO points – wired to terminals in the panel Spare slots – were new cards can be added and wired Spare terminals in the panel or spare space to put terminals Spare racks – were new racks and cards can be added) Metso can do the total system of any size system. We can layout control room, MCC rooms, or distribution of all electrical components.
- Another detail screen showing kiln and cooler.
- Another detail screen showing kiln and cooler.
- Another detail screen showing kiln and cooler.
- Another detail screen showing kiln and cooler.
- Read
- Another detail screen showing kiln and cooler.
- Each PLC “Programmable Logic Controller” contains: Power supply Processor Communication Cards IO - Inputs/Outputs Digital/Analog This is what connects to the real world or the field instruments. This also were the logic is put to make the plant run. The logic can contain: interlocking, sequencing, group starts/stops, calculations, loop control.
- The PLC although made for industrial applications still require an external enclosure. The enclosure also includes auxiliary equipment needed such as power supplies, breakers, and terminals. The enclosures are to keep all contents dry and at proper temperature.
- The layout of the system should include all the details of required hardware. What networks are required and where do they run. In addition, knowing if there are any special requirements or interfaces that are needed.
- Sizing: Feed size is: +8 mm to -18mm Harth layer size is: +12.5 mm to -18 mm Product size is: +6 mm to -18 mm Initial updraft drying is to preheat bottom layer (Car 7 Hearth layer) to not condense water in next zone No flame radiation to pellets, All heated air