ProcessSuite-Mill
ProcessSuite-Mill®: Advanced Control for Optimal Grinding
Efficiency
The grinding process, whether for raw meal, coal meal, or
cement, critically influences the quality of both intermediate
and final products as well as manufacturing costs. It faces
operational challenges due to variations in the physical and
chemical properties of raw materials, changing conditions of
grinding wear surfaces, and constraints imposed by core
equipment.
ProcessSuite-Mill® is an Advanced Process Control (APC)
solution, meticulously designed by cement industry experts to
address these challenges. It ensures robust operational
performance through real-time response to disturbances in mass
flow and particle size distribution, resulting in minimized
power consumption, maximized throughput, and reduced quality
variation.
Customizable for various grinding circuits—including single or
combinations of ball mills, vertical roller mills, and roller
presses—ProcessSuite-Mill® also integrates with digital systems
such as condition monitoring, emission monitoring,
at-line/in-line analyzers, and laboratory equipment. This
integration captures critical data and continuously optimizes
operational points for enhanced grinding performance.
Advanced MPC and Prediction for Superior Grinding Performance
ProcessSuite's "squeeze-shift" Model Predictive Control (MPC)
technology delivers exceptional process stability by minimizing
variations and continuously adjusting operational parameters
towards optimal targets. This advanced technology dynamically
identifies and fine-tunes the best operating points, ensuring
that process performance aligns with desired outcomes.
Enhanced by advanced Kalman Filters, ProcessSuite-Mill offers
precise prediction and regulation capabilities. These filters
improve control efficiency by accurately forecasting process
changes and enabling real-time adjustments. This approach's
effectiveness is demonstrated by trend traces showing how
ProcessSuite-Mill detected and managed disturbances in a
Vertical Roller Mill (VRM) within ProcessSuite mode,
autonomously recovering the mill and restoring normal operation
without operator intervention. Additionally, for a Roller Press
plus Ball Mill configuration, ProcessSuite-Mill maintained and
improved key parameters over manual operation, ensuring greater
stability and efficiency.
By integrating sophisticated MPC with predictive filtering,
ProcessSuite-Mill provides a comprehensive solution for
maintaining optimal process conditions and achieving superior
performance in complex industrial environments.
Global Leader in Efficient, Sustainable Cement Grinding
ProcessSuite-Mill is deployed worldwide, with installations
in Turkey, Africa, Azerbaijan, Kazakhstan, India,
Bangladesh, and the Philippines. Its robustness is
demonstrated by high utilization rates, delivering
significant economic benefits to users through reduced
operating costs, especially in energy consumption.
The system excels in minimizing clinker components in cement
by meticulously monitoring product quality parameters such
as Loss on Ignition (LOI) and Sulfate (SO3). Reducing
clinker content directly correlates to lower clinker
production from limestone, significantly cutting CO2
emissions while maintaining consistent cement quality,
thereby bolstering carbon reduction initiatives.
ProcessSuite-Mill seamlessly integrates with both online and
laboratory-based quality systems, ensuring superior cement
quality management. Ramco provides standard analytical tools
to evaluate the potential of existing systems and assess
benefits, guaranteeing transparent and effective
implementation.
This comprehensive approach underscores ProcessSuite-Mill's
capacity to enhance operational efficiency and support
sustainable practices in the cement industry.