Intelligent Optimization Control System for RASO Cement Production

1. Conventional DCS control algorithms are simple and have a single strategy. For the cement production system with large delays, strong coupling, and severe disturbances, it is difficult to achieve automatic and optimized production. On-site operations heavily rely on manual experience and manual operations, resulting in high work intensity;

2. The control precision of core control parameters is low, leading to fluctuations in product quality and energy waste. For example, the temperature fluctuations in the decomposition furnace of the clinker line are significant, the cooling effect of the grate cooler is poor, and the current fluctuations in the grinding line’s steady flow bin are large;

3. There are many control parameters, and there is a lack of consistent operational standards. For instance, the firing state in the kiln, the thermal recovery efficiency of the grate cooler, the circulation amount in the mill, and the grindability of materials all lack direct evidence. It is difficult to find the optimal state in operations, and different personnel have varying methods. In actual operation, there is still considerable room for optimization in coal consumption for firing and electricity consumption for cement grinding;

4. Given the complexity and strong time-varying characteristics of the cement system, the conventional expert system’s MPC algorithm is difficult to achieve long-term stable operation, let alone online real-time optimization, and it is even harder to ensure the comprehensive coordination of output, quality, and energy consumption for economical operation.

1. Achieve fully intelligent optimized operation of the kiln and grinding system, reducing operation frequency by over 90%, achieving near-unmanned production;

2. Key control indicators are significantly narrowed. The fluctuations of key parameters such as the exit temperature of the decomposition furnace, negative pressure at the kiln head, and current of the grinding system’s roller press steady flow bin are reduced, with standard deviation decreasing by 30% to 50%;

3. Achieve optimal coordination of quality, output, and energy consumption through optimized operation, enhancing the quality and efficiency of the production line, saving energy and reducing emissions, and reducing coal consumption for clinker by 1% to 3% and electricity consumption for the cement grinding process by 2% to 5%;

4. Implement early warning and forecasting for abnormal conditions of major equipment and processes, enhancing the intrinsic safety of the production line.

1. For the clinker firing line: A 2500t/d line can save over 2 million yuan in coal annually and over 200,000 yuan in ammonia water; the corresponding annual comprehensive benefit for a 5000t/d line is about 3 to 5 million yuan;

2. For the cement grinding line: On average, reduce the electricity consumption per ton of cement by over 0.8 KWh, leading to annual electricity savings of over 400,000 yuan for a 1 million ton/year cement grinding line;

3. Intelligent optimization will also bring potential benefits such as improved product quality, extended equipment maintenance cycles, enhanced safety production, reduced labor intensity, and optimized positions.

1. Conventional technical renovation contracts: Party A invests in construction, with low investment and quick returns, and project payback period of 8 to 24 months;

2. Contract energy management: Party B invests in construction, sharing project benefits for 5 years, and transferring to Party A for free after sharing ends;

3. Long-term leasing cooperation: Party B invests in construction and ensures reliable system operation, while Party A pays rent to use the optimization system.