PROCESS OPTIMISATION using MODEL BASED CONTROL IN THE

PROCESS OPTIMISATION using MODEL BASED CONTROL IN THE MELTER

“We have millions of dollars invested in our plant…” “…are we getting the most from our processes? ”

“We’re designing a complex integrated process…” “…how do we know it’s going to work? ”

“We have a complex control scheme…” “…how do we know it will run our plant to it’s optimum efficiency? ”

The Answer – Adaptive Model Based Control ADVANCED CONTROL SOLUTIONS INC

The way PID control works • Cannot easily control long dead time processes • No action taken until process pushed off target • Doesn’t respond well to non-linear processes • Can’t handle process disturbances quickly Most PID control loops are detuned or not performing as intended because the loop is out of tune with the dynamics of the process

The result of poor PID control: • • • Increased process variability Inconsistent product quality Lower production rates Higher energy costs Decrease in overall plant efficiency Leads to Acceptance of controlling what you can – not what matters • Dependence on experienced operators to manually run, start up, and recover critical processes

MBC out performs PID because of its two main components: • An adaptive model • A predictive controller

The MBC advantage • Integrates with existing control systems • Average implementation time is less than 2 weeks • Ease of use — customer can deploy and maintain with existing manpower • Attractive project economics (Payback) • Operates reliably 100% of the time

Adaptive Model Based Control • Builds and adapts its own live models during normal plant operations – Models are built in closed loop while the plant is running • Patented methodology builds high fidelity models in real time without disrupting operations – This patented method is the key to our fast implementation • Models adapt as the dynamics change due to weather, wear, and other factors

predictive controller • Accurately forecasts process responses and accounts for multiple objectives • Predicts and prevents disturbances before process is pushed off target – (PID cannot do this, PID must wait for the error) • Start ups and grade changes are automated and uneventful • Solves difficult process control problems • Achieves automatic control of manually controlled processes

MBC runs where YOU decide, in one or multiple places DCS Engineering Station DCS Operator Station DCS Controller § If you have OPC, you can run Model Based Control Ethernet § MBC can run on your DCS or on its own server MBC SERVER PLC Ethernet, Modbus Plus, Data Highway Plus § MBC can simultaneously communicate to multiple PLCs

Building the Adaptive Model

The impact of improved control, closer upper and lower set point limits Low Set Point. Limit Operating Average Shift Low Set Point. Limit Energy Cost Productivity and Yield Product Quality High Set Point. Limit

MBC Applications • Glass melter • Gob exit temperature • Glass furnace level • Large Energy consumers • Channel temperature • Bottlenecks • Forehearth • Annealing oven temperatures • Bottle weight • 9 point grid temperature

Results • Float Glass – Stabilize at new setpoint in 4% of the previous time. • Fiberglass – huge reduction in variability and improved machine availability. • Float Glass Level Control – reduction in variance. • Lighting Glass – Reduce Temperature variation in Furnace and Forehearth. • Container – increase in line efficiency – increase profit annually.

MBC How to set it up? • Installed on an NT desktop PC • Communication to Existing Control System via Ethernet / OPC Server • Initial Models Developed from Historical Data Review • Models validated with one setpoint change • Entire system installed and operational in less than one week

MBC Results n Improved process dynamics l Reduced level control variations l Steady state control improved by 7 X l Scrap rates reduced l Product change time reduced:

Product Changeover MBC vs PID

Level Control – Steady State

Level Control - PID

Level Control-MBC

Container Application • MBC installed and connected to existing Forehearth PLC or SLC control system • Goal was to improve stabilization time in forehearths after pull / product change. • Allow operators to focus on machine changes and control loops stay in automatic.

Container Glass Results • Forehearth Temperature stabilization time reduced by 50% after job changes – leading to more machine availability at optimum conditions • Ability to control using Mass Flow Temp (9 -point grid as control parameter • Ability to control using Gob Exit Temperature as control parameter • Increased yield, 0. 5 to 1% due to improved process stability.

Pull Change – conventional

Pull Change - MBC

Steady State Control

Fiberglass Manufacturing • Goal is to stabilize process & reduce variability in downstream processes. • Level control in melt tank is primary cause of defects. • MBC connected to existing DCS via OPC server.

Fiberglass Results • Profoundly stabilized system • Better bushing control • Reduced spinner blockage • Better quality • Higher production rates

Fiberglass Melter Temp

Float Glass Project • Major manufacturer of Flat/Float Glass • Level control variability decreases product quality • Installed to existing DCS • Commissioned in only 2 days • Immediate profound effect in operation

Increased Glass Level Stability

Melter Crown temperature stability

Reduction In Exit Temp Variation

Float Glass - PID

Float Glass - MBC

Float Glass Results “The control continues to be excellent. We had a port failure Tuesday night that took the MBC offline. For the 8 -10 hours that we were back in DCS control, our level control was +/0. 015", while MBC was able to maintain +/- 0. 002". I printed the 24 -hour trend chart for that period showing MBC controlling for 7 hours, Bailey DCS for 10 hours, and back to MBC for the remaining 7 hours and the charts show a graphic picture of why we need MBC for controlling glass level in our furnace!” – Ernie Curley, QA Manager, Cardinal Glass – Portage, WI

Testimonial “ In PID control, our level control was +/- 0. 015", while MBC was able to maintain +/- 0. 002”; the charts show a graphic picture of why we need MBC!” Ernie Curley, QA Manager, Cardinal Glass PID Level Control Brain. Wave Level Control >7 times better level control with MBC

Lighting Glass Optimization • Major manufacturer of Lighting Glass • Temperature Control Critical for proper forming • Installed to existing TI PLC environment • Commissioned in only 1 week • Immediate profound effect in operation

Lighting Glass Results • Dramatic Reduction in variability • Complete Automatic Control • Improved recovery from disturbances • Reduced operator workload • Reduced scrap • Increased profits

Testimonial “MBC stabilized our toughest loops – ones we have spent countless hours working on. ” Steve Holmes Senior Process Controls Engineer Bowater Newsprint

Testimonial “ This was something that could be done immediately with very little cost. And it did not require any outages; it was done on the run. ” Andrey Pawelczak Contract Engineer, Syncrude Canada

Mead. Westvaco Testimonial “ Reducing Lime Kiln temperature variability with MBC was easy and it reduced our fuel consumption over $400, 000/year!” Our operators love it and rely on it for efficient operation. Terry Canup, Process & IT Manager, Mead. Westvaco Before: +/- 90 degrees or more MBC +/- 5 to 10 degrees 88% improvement by control with MBC