Professional Documents
Culture Documents
C
ement is a fundamental commodity in any industrial These materials are purchased or quarried and then
society. As a key ingredient in concrete, it is the transported to the cement factory by road, railway, or con-
world’s most widely used building material. With ap- veyor. The raw materials are crushed, usually in the quarry
plications ranging from residential and commercial buildings but sometimes in the factory, to a size that the machinery
to key infrastructure elements such as roadways and bridges, can handle or grind.
it is hard to imagine life without it. Worldwide cement produc- The prepared raw materials are stored in silos, ready for
tion totals some 1.5 billion tons annually. Such large volumes the next production step (i.e., the material grinding and
place it among the top ten power consumers in many coun- blending operation). In this step, which can be either a wet
tries and, along with the precision required for raw materials or a dry process, ball mills are used to crush and blend the
blending, make it a prime candidate for automation. materials in varying proportions according to the required
The techniques of cement production have been known quality of the final product. The materials are proportioned
for centuries and are discussed extensively in the literature. using a control system to ensure the desired chemical com-
The main problems with automation of cement production position of the final ground mix.
are also well known, as discussed in several survey papers Adding water to the raw materials makes them easier to
(e.g., [1]-[3]), and thus it is difficult to introduce new ideas. grind and mix (grinding can also be done separately), but a
We believe, however, that recent advances in computational major disadvantage of the wet process from an energy
power have considerably increased the possibility of apply- standpoint is that the water later evaporates. Thus, we will
ing certain modern control theory methods and algorithms
Raw Material
Raw Mill
the control engineering background and the design of the re-
Blending
Storage
alized controller. Finally, the control algorithm is discussed
Homogenization
in a technology-independent manner.
Storage
Rotary Kiln
factory, but those denoted by thick lines are found in most
cases. Cooler
Storage
The raw materials for cement production are selected
based on their chemical composition. The primary compo-
Grinding
Cement
Cement Mill
nent is the calcium oxide (CaO) source, which is usually
Storage
limestone, but chalk, marl, dolomite, and oyster shells can
also be used. The next two components are silica (SiO2) and
Shipping
Shipping
alumina (Al2O3), obtainable from clay or shale. Quartz and
bauxite or other minerals can also be used. The fourth, and
last, component is ferric oxide (Fe2O3), which can be ob-
tained from iron ore, pyrite, or blast furnace slag. Figure 1. Typical basic technological operations for a cement
plant.
Keviczky (keviczky@sztaki.hu) and Bányász are with the Computer and Automation Research Institute, Hungarian Academy of Sciences,
H-1111 Budapest, Kende u 13-17, Hungary. Vajk is with the Department of Automation and Applied Informatics, Budapest University of
Technology and Economics, H-1111 Budapest, Hungary.
1053-5888/03/$17.00©2003IEEE
February 2003 IEEE Control Systems Magazine 87
concentrate on the dry process. In this process, cement is • silica modulus
made by baking (at about 1450 °C) and grinding the homoge-
neous raw materials mixture with a prescribed oxide con-
centration. The continuous process is divided into serially S
MS =
connected subprocesses by using large material storage ar- A+ F
eas and applying several parallel elements to increase pro- (3)
duction capacity. Together, these large material storage
areas and parallel working elements ensure the safe and eco- and their possible linear combinations. (Here, the oxide
nomic operation of the overall cement plant. contents are given in percentages.) The most difficult prob-
Control of the chemical composition of the raw meal is lem of composition control is the measurement of oxide
necessary because the relative amounts of dicalciumsili- compositions having a considerable time delay in the closed
cate (C2S), tricalciumsilicate (C3S), tricalciumaluminate control loop. Its value is so large (30 minutes to one hour)
(C3A), and tetracalcium-aluminoferrite (C4AF) formed in the that many experts expect greater improvements in the qual-
kiln strongly depend on the oxide composition of the ground ity of control due to decreasing the delay than to applying
mix. (For simplicity, the four most important oxides, CaO, the most sophisticated algorithms. Earlier, the chemical
SiO2, Al2O3, and Fe2O3, are denoted by C, S, A, and F, respec- analysis was made by laboratory tools using material sam-
tively.) The purpose of the control is to maintain the relative pled by hand. Recently, automatic sampling has been intro-
proportions of these oxides. The relative proportions can duced, and an X-ray fluorescence analyzer (RFA) typically
be expressed by their so-called modulus values. The most provides the oxide compositions.
widely used ones are: The complexity of the control problem of raw material
• lime standard (or modulus) proportioning depends on the number of materials neces-
sary to blend the desired chemical composition. In many ce-
100C ment factories, the most important three to five basic
ML =
2.8 S + 11
. A + 0.8 F (1) materials are used; however, there are cases where eight to
ten different materials are to be mixed. The achievable qual-
• aluminum modulus ity specifications of this control depend on changes in the
basic material compositions. In the best case, there is no
A need for control. In many cases, however, the makeup of the
MA =
F (2) raw materials is so variable that only computer control can
achieve the desired composition. It is no accident that the
Feeder Tanks first computer control appeared at this point in the process.
The simplified scheme of a raw material blending sys-
Component nof
Component 1
RFA
Control Engineering Model of the Process
Computer A simplified control engineering discrete-time model of the
mill-silo system is shown in Figure 3 (see the details in [5]),
where r ( t ), v( t ), and q ( t ) are the input feed, the mill outlet
Reference Values (silo inlet), and the silo content, respectively. The vectors ox
and M denote the oxides and modulus values; w stands for
Figure 2. Simplified technological scheme of a raw material the scale factors of the weighs (feeders), and C is the compo-
blending system. sition matrix. The linear noninteracting (diagonal) dynamics
is the associated Y-parameter [8]; furthermore, Here, Pr and Pn are stable and proper transfer functions,
which are partly capable of placing the desired poles in
Qr = Pr K r = Pr Gr S −+1 , K w = Gw S −+1 , K r = Gr S −+1 , (11) the servo and the regulatory transfer functions; further-
more, they are usually referred to as reference signal and
assuming that the process is factorable as output disturbance predictors. They can even be called
reference models, so reasonably the gains Pr (ω = 0 ) = 1 and
S = S + S− = S + S− z − d , (12) Pn (ω = 0 ) = 1 are selected.
The G2DF control system has a specific form, shown in
where S + means the inverse stable (IS) and S − the inverse un- Figure 6, representing the so-called invariant model part
stable (IU) factors, respectively. z − d corresponds to the dis- S − z − d of the process, which cannot be canceled or elimi-
crete time delay, which is the integer multiple of the nated by any method. Only the influence of S − can be attenu-
sampling time. ated by the optimally selected embedded filters Gr and Gn .
It has been shown [8] that the optimization of the G2DF When Gr = 1and Gn = 1(which are optimal selections only for
scheme can be performed in H2 and H∞ norm spaces by an IS plant), the regulator is
proper selection of the serial K r and embedded K n filters
(compensators). These optimizations will be reduced to the Pn S −+1 Pn
R= −d
= R S −+1 ; R = ,
1 − Pn S − z 1 − Pn S − z − d
(14)
R n
yr + Q + + y
Qr S S which results in very simple closed-loop characteristics [8]
1−QS + +
−
Internal Linear Plant
Model y = Pr S − z − d y r − (1 − Pn S − z − d ) n = y t + y d . (15)
Figure 4. The general form of the K-B-parametrization. In control engineering practice, another interpretation of
the plant factorization (12) can be used when S − does not
contain only the IU factors but includes any part of the pro-
n cess model that is not desirable to cancel. Mostly poorly
+ +
yr + PnKn y damped zeros are considered here that could result in un-
Pr Kr S 1−PnKnS + S + wanted intersampling ripples.
−
Ro It is widely accepted that “all 2DF configurations have ba-
sically the same properties and potentials” [9]. However, it
Figure 5. The G2DF control system. has been shown that the above scheme is primus inter pares,
and therefore the term generic applies to more than just the
equivalent feedforward/feedback closed-loop control sys-
True n tems. The generalization of this scheme for general multi-
Process ple-input, multiple-output (MIMO) systems is not very
+
yr Pn G n y difficult, but it is a time-consuming and not obvious task (con-
PrGr S− z−d + S−1 S+S− z−d
1−PnGnS− z−d + + sider the noncommutativity of matrix products). In such spe-
−
Invariant Inverse S cial cases (see the following sections), when the decoupling
R
Model Part Model
of the MIMO system can be solved with some special (not al-
Controller ways linear) algebraic algorithm, the above generic scheme is
applicable for the decoupled “channels” and is the simplest
Figure 6. The G2DF control system for the IS plant. structure for reaching optimal control performance.
The time delay and the time lag of the feeder-mill system may ∑α
j=1
kj ox j
be different for the different raw material components. The mk = nox
,
time delays are relatively constant and can be known a priori. γ k + ∑ β kjox j
j=1
These values are determined by the mechanical construc-
(20)
tion, the transportation method, the mill type, the capacity of
the mill, and the grinding property of the components. Since
whereα kj ,β kj , and γ k are constants characterizing the modu-
the time lag is relatively small compared to the total time de-
lus mk . Thus, the control objective can be expressed by a
lay, the mass flow of the components can be modeled by pure
unified formula.
time delay blocks. The content of the silo and its oxide con-
The ultimate control problem is as follows: determine the
centration cannot be measured. They are calculated from the
flow rates of the raw materials to fill the silos with the appro-
mill product. By applying the mass and concentration bal-
priate meal, taking into consideration that the oxide concen-
ances, the dynamics of the silo (see (5)) can be obtained:
tration of the raw material changes, the sampling is rela-
tively rare, the time delay is relatively large, the definition of
q ( t ) = q ( t − 1) + v( t ) (16) the moduli is given by nonlinear functions, the homogeniza-
tion of the silo is far from ideal, and the technological con-
straints must be satisfied.
q ( t − 1)ox silo
j
( t − 1) + v( t )ox out
j
(t ) Only quality control of the mill system was discussed
j
ox silo (t ) = , j = 1,K , nox, above. In this regard, the energy consumption for grinding is
q( t )
(17) very high and the efficiency of the process is very low, so
finding the maximum mill production that could result in the
j
where ox out ( t ) is the jth measured oxide concentration of lowest relative energy consumption is highly recom-
j
the mill product, ox silo ( t ) is the jth oxide concentration of mended. The usable set point for quantity control is deter-
the silo content, and nox is the number of oxides used. mined by the technological parameters of the mill system.
Figure 9. Calculation of the feedback signal. w ri, min ≤ w ri ≤ w ri, max i = 1,K , nof (23)
nof
k
M min ≤ M k ∑ C jiw ri , j = 1,K , nox ≤ M max
k
1
i =1 G2i = ,
k = 1,K , nom, 1 − [ai + (1 − ai )z −1] z −2
(24)
1
G2 = diag K , −1 −2
,K
where nom is the number of moduli to be controlled 1 − [ai + (1 − ai ) z ] z (28)
and M k (K ) denotes the calculation rule of the kth
moduli from oxides
• the moduli of the mill production corrected by the silo G3i = 1 ; G3 = I. (29)
effect in a given prediction horizon must be equal or
as close as possible to the output of the controller Here, the reference models Pr = Pn = 1 were selected,
Mreg : which correspond to a deadbeat-type regulator with no
intersample ripples. (If the delay times for the different com-
∑ d |M |
nom
ponents are significantly different, the exact decoupling and
k
k
reg − M silo
k
.
k =1 (25) deadbeat effect can be reached only by the real MIMO ver-
sion of the optimal controller given by (15)). It is easy to ver-
k
Here, M silo depends on the oxide quantity in the silo, the ify that the resulting channel regulators Ri = G2i are integrat-
previous commands, the reference values of the moduli, the ing ones having a pole at z = 1.
prediction horizon to control, the estimated oxide concen- In the controller → decoupling → feeder → mill → sam-
tration of the components, the model parameters of the mill pling analysis → modulus calculation process, the order of
system, and the feeder ratios to be calculated (see Figure the linear and the nonlinear elements cannot be changed,
10). dk is a properly selected weighting factor. but we would like to eliminate a special fail-operation. This
The above problem can be solved using a two-step linear is why the control system recalculates the controller state
programming algorithm. in every control step. The effect of the estimation and the
The task of the controller is to eliminate the disturbances control can be separated, and the disturbances caused by
that cannot be predicted from the a priori information and the parameter adjustment due to the estimation can be
the a posteriori estimation. As the process can be decoup- eliminated. At the same time, the integrator wind-up can be
led, parallel working single-loop controllers can be applied neglected and the limit values of the feeders can be taken
for control. The block scheme of the “semi-MIMO” control- into consideration.
ler used in our application is shown in Figure 10. It is easy to
Identification Strategy
see a one-to-one correspondence with the G2DF scheme in-
In every adaptive control system, two major compromises
troduced in Figure 6. The saturation of the controller limits
must be made: one is related to the time horizon, and the
the error signal and reduces the fail-effect of the occasion-
other is related to the information available for estimation. It
ally incorrect analysis.
is usually assumed that the parameters of the system are
To demonstrate the controller adjustment, assume that
slowly varying and the measurements are noisy. The parame-
the feeder → mill → sampling analysis system can be mod-
ter tracking can be realized by forgetting old data. The speed
eled by the following transfer function:
of tracking and the precision of the parameter estimation im-
[ ]
S i = ai + (1 − ai )z −1 z −2
pose contradictory requirements. The effect of the noise can
be reduced by averaging, but the speed of parameter tracking
S i
= [ a + (1 − a )z ] z −1 −2
= S −i z − d , d =2 can be increased by rapid forgetting of old data or old mea-
i i (26)
surements. One has to distinguish between the effects of
for the ith channel, which corresponds to an IU time delay
process, where the delay is common for all channels. We as-
Feedforward
sumed that the time lag effect is not significant and the sys-
tem can be modeled by pure time delay. The reasons for two S− z−d Compensator Inverse Model
+ +
parameters in the transfer function are that the delay time is
G1 Limiter G2 G3
not a multiple of the sampling period and the sampling device Mr − + Mreg
works continuously. This transfer function does not differ Invariant Part R
of the Model Mout
from a first-order lag, but it is not worthwhile to compensate
this effect by a lead block. The application of the optimal
G2DF controller results in the following transfer functions: Figure 10. Structure of the controller.
[ ]
−1 −1
P′ ( t ) = P ( t ) + r ( t ) r ( t )
T
.
(33) 1.4
Here, r( t ) is the filtered values of the ratios of the raw ma- 1.2
terial flows by means of which the moving average of the ob- MA Reference Value = 1.5
servation vector is estimated. 1
50 100 150 200
Operational Records Number of Samples [1 h = 3 Samples]
The normal operational records given in Figures 11, 12, and
2
13 show the time curves of the three adaptively controlled
(lime, aluminum, and silica) modulus variables for filling five 1.5
homogenization silos. While filling the first silo, a conven-
tional (PI-like) regulator was operating, and at the start of 1
50 100 150 200
filling the second silo (at t = 45), the adaptive control system
was switched on. The sampling interval was 20 min. The ap- Silo Filling Time = 45
plied reference values are MLr = 94, MA r = 1.5, and MS r = 2.1 Average
2
index. The continuously updated average (pseudosilo) val-
ues are also presented. These results came from actual ex- 1.5
periments with the real blending system.
It is obvious that the variances of the three standards 1
50 100 150 200
with the PI regulator are considerably higher than with the
adaptive regulator. Because the adaptive controller started Figure 12. Recorded operating data of the aluminum modulus.
to learn during the normal operation, no additional long ad-
aptation period is visible. 3
Adaptive Control Switched on at t = 45
The physical explanation of the better performance of
the introduced adaptive controller is simple. The applied 2.5
strategy decomposed the original multivariable nonlinear
control paradigm to subproblems, which are much easier to
handle using the special decoupling approach presented. 2
Thus, the adaptation relates only to the parameter estima-
tion of the oxide models, which are basically static relation- 1.5
ships. The dynamics of the process is not continuously MS Reference Value = 2.1
adapted because it is not time varying and can be identified
1
to a good approximation a priori. At the same time, the ap- 50 100 150 200
plied G2DF controller scheme provides the best achievable Number of Samples [1 h = 3 Samples]
performance given the process dynamics. In this low-order
3
case, the final controller is a minimum-variance-type con-
troller ensuring H2 optimality.
2
Conclusion 1
50 100 150 200
This article described a simplified scheme for an adaptive
composition control algorithm. The applied control system Silo Filling Time = 45
is based on a new generic controller structure and has the Average
3
following main features:
• estimation of the raw material composition using an a 2
priori dynamic model of the mill
• adaptive adjustment of the decoupling network based 1
50 100 150 200
on the identified composition matrix
• flexibility in modulus definition Figure 13. Recorded operating data of the silica modulus.