ProcessSuite-Pyro®
Advanced Optimization for Peak Pyro Performance
ProcessSuite-Pyro® integrates seamlessly with condition monitoring systems, emission measurement systems, refractory management systems, and other subsystems.
It continuously identifies the optimal operating points to stabilize and adjust process parameters towards critical limits. This includes optimizing fuel and air intake to improve combustion while managing mechanical, electrical, and process constraints. It also improves clinker quality by adapting to variations in raw meal and fuel characteristics, enhances cooling air usage for efficient recuperation and waste heat recovery, and balances heat by optimizing the use of alternative fuels within economic and process constraints.
Beyond merely managing control signals, ProcessSuite-Pyro® addresses both known and unknown disturbances, such as AFR shifts, mechanical issues like gearbox conditions, and compliance requirements including emission monitoring. This comprehensive approach ensures rapid recovery from process upsets, maximizing kiln availability and improving the utilization factor of the optimizer.
Unmatched Stability with Advanced MPC and Prediction Technology
ProcessSuite's "squeeze-shift" Model Predictive Control (MPC) technology offers unmatched process stability by not only minimizing process variations but also continuously pushing operational parameters towards optimal targets. This cutting-edge technology dynamically identifies and adjusts to the best operating points, ensuring that process performance is consistently aligned with desired outcomes.
Complementing this, ProcessSuite employs advanced Kalman Filters to deliver precise prediction and regulation capabilities. These filters enhance control efficiency by accurately forecasting process changes and enabling real-time adjustments. The effectiveness of this approach is illustrated by trend traces demonstrating how ProcessSuite predicted and managed Burning Zone Temperature (BZT) and controlled NOx emissions in a cement kiln.
By integrating sophisticated MPC with predictive filtering, ProcessSuite provides a robust solution for maintaining optimal process conditions and achieving superior performance in complex industrial settings.
Driving Operational Excellence and Environmental Gains
ProcessSuite-Pyro is deployed globally, with installations in Turkey, Africa, Azerbaijan, India, and the Philippines.
Its robustness is evident in its high utilization rates. Users experience significant economic advantages through reduced operating costs, particularly in energy consumption. The system enhances the use of Alternate Fuel Raw Materials (AFR), achieving a higher Thermal Substitution Rate (TSR) while maintaining consistent clinker quality, thereby supporting carbon reduction initiatives.
ProcessSuite-Pyro integrates seamlessly with both online and laboratory-based quality systems, facilitating superior clinker quality management.
Ramco provides standard analytical tools to assess the potential of existing systems and tools for evaluating benefits, ensuring transparent and effective implementation.