MPC For Sugar Processing

Sugar Processing MPC
Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Zilor.
Plant MPC
Milling
Juice Treatment
Evaporation
Crystallization
Boilers/Steam Turbines
Delivering Value to Market Leaders
Chemicals / Polymers Cement Biofuels
Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2
Minerals & Metals
Consumer Goods
Pavilion MPC Best Practice for Ethanol Production
What we do
Minimize operational variance
DV
CV
Transition effectively
Experienced Referenced Successful
Leverage Our Technology and People to
deliver highest value through ValueFirst
Copyright 2011 Rockwell Automation, Inc. All rights reserved. 4 4
CV
Follow operational plan
CV
SPECIFICATION OR LIMIT
BEFORE MODEL
PREDICTIVE CONTROL
WITH MODEL PREDICTIVE CONTROL
AND OPTIMIZATION
TIME
K
E
Y

T
A
R
G
E
T
MPC Model
Development
Pavilion
1 2 1
L
E
N
E
N
E
T
RIO
10-17
RIO
00-07
EI RM
328K
LP
1MEG
PLC
MMI
Process Control
Where MPC fits in Plant Automation
Process
Historian
Model Based
Incorporates Physical and Neural Models
Handles Linear and Non-Linear
Models are Fully Differentiable
Same Models Used for Control and Optimization
Import Existing Models
NN
Phys
u
+
y
FP error
Physical
output (y)
y = a
1
x + a
0
input (x)
input (x)
output (y)
y = a
3
x
3
+ a
2
x
2
+ a
1
x + a
0
Linear
Non-Linear
Artificial Neural Network
What We Do MPC Control
MV set point
MV measured value
MV prediction
Use first step of horizon
Manipulated Variable (MV)
CV prediction
CV measured value
MPC optimizes future trajectories
using an internal simulation
CV desired value
current time indicator
Controlled Variable (CV)
The question is not just how much the process will move,
but how fast the change will occur.
1
CV
Multivariate Dynamic Coordination
1 2
MV Air Temperature
2
CV
MV High Pressure Pump
By understanding this MPC can be used to
coordinate and enable the process to respond faster.
ClO
2
Generation Solution
Pavilion8
TM
Control Strategy
Plant Assessment
Mill Discussions 10/19-20, Mill testing 10/21, 24
Sugars Discussions 10/21, 24, Sugar testing 10/24-25
Utilities Discussions 10/25
Meeting Prep 10/26
HMI Screen Captures: M54, M78, Sugars, Boilers, Generators,
HMI Screen Captures: M54, M78, Sugars, Boilers, Generators,
P&IDs
Data PIMS
Data Lab
Data Historian
Step Test Data
Plant Tests
Mill Test on Extraction Water Temperature: increasing water
temperature increases bagasse sugar.
Mill Test Mud Flow % (Sugar Clarifier): decreasing mud flow
increases mud Baume, but does not impact clarified juice
transmittance significantly.
Juice to Sulfidation Temperature: decreasing this temperature
increases sulfur, reduces time to stabilization and we need to
increases sulfur, reduces time to stabilization and we need to
compare evaporator brix (unknown currently)
Sulfur Motor Speed test: not complete. Desired to decrease sulfur
5% each motor, increase up to 10% (as possible in burner) and
decrease back 5% for 2 hours and measure sulfur, sulfur juice pH,
time to stabilization into clarifier.
Mill Control
Mill Anticipated MPC Solution
The Mill MPC solution manages Table Speed(s), Mill Pressure, Superior Roll
speed and water flow in response to Bagasse Moisture, Sugar and Juice Brix
quality estimation models. From typical variability five-roller mills in series, MPC
would deliver benefits:
Reduce Bagasse Moisture and Juice Brix Variability 30-70%.
Increase capacity through mill responding to variation in cane quality and table,
picador amps
Increase/stabilize Bagasse sugars
Extracted Juice
Increase/stabilize Bagasse sugars
Primary Juice
Secondary
Juice
Mixed
Juice
Extracted Juice
Phases
Water
Bagasse
Shredded
Cane
Rotary
Screen
Filtered
Juice
Bagasse
Pressure
Roll
Gap
Adjustment
Roll
Positioner
Drive Shaft
Speed
Cane In
Cane
Out
Combs
Mills (54 & 78) Anticipated MPC Scope
Uncontrolled Influences
(Disturbance Variables)
Mill 78
Controller
Table Speed (2)
Mill 1 Infeed Level
Fiber in Cane
Hours since Burn
Water to Mills Temperature
TPH Estimate (VOA)
Conveyer Level (operator input bias, VOA)
Bagasse Moisture (VOA)
Process Setpoints
(Manipulated Variables)
Process Results
(Controlled Variables)
Controller
Table Amps (limit)
Picador Amps (limit)
Superior Roll Speed RPM (6)
Mill Pressure (6)
Water Flow
Mill Positioner (10, limit)
Juice Treatment and Evaporation Control
Juice Treatment & EvaporationMPC Solution
The Juice & Evaporation MPC solution manages juice rates, temperature, S motors, mud flow
ratios and evaporator balance in response to settling times, residual chemical, color and
evaporator brix quality estimation models along with steam availability. From typical variability
carbonation/sulfidation MPC would deliver benefits on the order of:
Reduce Sulfur/Lime addition based on variation on residual chemical numbers.
Reduce clarified Juice color variability. This provides more stable crystallization and average
color reduction.
Increase sugar/syrup to crystallization by maximizing energy usage as available. Reduce filter
sugar losses. Review unidentified losses in data.
sugar losses. Review unidentified losses in data.
Calcination
Sulfitation
Elemental S
Lim
e
Condensate
Steam
Furnace
Agitator
Sulfitation
Column
SO2
Filtered
Juice
Sulfited
Juice
Heated Juice to
Clarifier/Dorr
Tank
Mud Box to
Vacuum
Filters
Mud
Flash Tank
Clarification
Tank
Juice
Overflow to
turbofilters
Juice Treatment & EvaporationMPC Scope
Sugars
Controller
Vacuum Filter Flow to Sugars Treatment
Secondary Juice to Primary Juice or back (2)
Steam Flow
Primary Juice Purity
Vegetal numbers on Cane
Clarified Juice Transmittance
Temperature to Sulfidation
Stabilization time into clarifier
Sulfito before Lime Addition
Total Juice to Clarifier Flow
Anticipated
Process Setpoints
Process Results
Controller
Syrup Tank Level, Clarification Tank Level
Evaporator Brix (4)
Evaporator Vacuum (4, limit)
Temperature to Sulfidation
Sulfur Motor Speed (4)
Mud Flow Ratio (2)
Flow to Evaporators (1, 4)
Mud Baume (2)
Exhaust Steam Pressure (limit)
Juice Treatment & Evaporation Instruments
Priorities for improvements and recommendations are (sulfidation):
1. Add TI on gas from the cooler (entering the column with SO2).
2. Add FI on flow to each sulfidation column (check pipe L/D).
3. Change hand valve on CW to automated, controlled valve and close loop with
gas temperature.
4. Ratio loop flow to each column and sulfur mechanical motor speed.
5. Add TI on gas from each column (and use this to manually balance motors, balance
periodically/twice/season? Adjust ratios).
periodically/twice/season? Adjust ratios).
Priorities for improvements and recommendations are (clarification,
vacuum filters, Water Supply and Pans):
Electronically store time-stamp and results on operator Mud Baume (4) and
Stabilization Time (2).
Bias various vacuum filter amps based on earlier study recommendations.
Review Control on Aspersor (spray pond) water tank level (for multi-jet).
Move density analyzer on Diluted Molasses A density to tank instead of line.
Continue to control density with dilution condensate (with slower dynamics).
Pavilion8 Solutions Evaporation
Density Before Pavilion8 Density With Pavilion8
Crystallization Control (Pans, 11)
Batch CrystallizationAnticipated MPC Solution
The crystallization MPC solution manages pan operations across the batch crystallization pans to
stabilize supersaturation point, manage crystallizers toward a more ideal trajectory and
balance consistency and supersaturation along with level objectives to:
Increase crystallization capacity (through maximal operation in stable supersaturation regions,
maximizing end of strike consistency.
Reduce variability on crystal size both through reduction in conglomerates and minimizing or
eliminating time in liable crystallization regions (e.g. maximize sugar kg/pan and sugar kg/pan
kg steam).
Through maximum strike effectiveness the solution will reduce time at high temperatures
Through maximum strike effectiveness the solution will reduce time at high temperatures
during crystallization (reducing extra batching of sugar) and increasing sugar yields slightly
(e.g. reduced molasses B sugars).
Syrup /
Honey
Water
Steam
Testing
Port
CALANDRIA
Condensate
Warm Water
Water
Vacuum
Slurry
Discharge
LUNET
Batch Crystallization Anticipated MPC Scope
Batch
Crystallization
Brix Tg or Feed VP
Syrup or A Mel Brix, Purity
Supersaturation (VOA/Calc)
Consistency (VOA/Calc, limit)
Condenser Pressure (TG)
Process Setpoints
Process Results
Controller
Level (limit)
Condenser Pressure (TG)
Condenser VP (limit)
Steam Valve pos
Control batch crystallizers to target supersaturation within
limits. Include models covering white/sucrose
high raw (A) and low raw (B) crystallization.
Use temperature, start and
approximated purity to
calculate Supersat real-time
Qsat at 70 DegC Qsat at 99% Purity
Use temperature, start and
approximated purity to
calculate Supersat real-time
Qsat at 85 DegC Qsat at 70% Purity
Utilities/Bagasse Boiler and Steam Control
Utilities/Bagasse Boiler and Steam MPC
Steam Generation Optimization to manage bagasse boilers loads,
turbine loads, let-down PRVs to manage steam pressure and exhaust
steam availability along with maximizing turbine MW.
Maximize boiler efficiency with improved coordinated boiler MPC to
manage bagasse boilers with feed/O2 within safety and environmental
limits at maximum capacity.
Steam/Bagasse Boiler Anticipated MPC Scope
Steam Flow CBC and AMD (TG)
Process Setpoints
Process Results
Steam Header
Controller
CBC and AMD Pres
CBC and AMD O2
Turbine load (4)
Steam Temperature (2, limit)
Steam Flow CBC and AMD (TG)
MW Produced (TG)
Steam Pressure (21 & 1.8, TG)
PRV Control (6)
Exhaust Steam Condenser VL (TG)
Relief VL (3)
Fisher Provox Operator Interface
Next Steps:
First portion assessment 12/2 or 12/5
Complete assessment 1/5 or 1/7
Assessment will include
Data Analysis
Benefits Assessment
Solution Description (update)
Costs and time estimate for delivery
Questions ?

MPC For Sugar Processing

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Sugar Processing MPC

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

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