MillMaster—Technical specification

MillMaster —Technical
MillMaster
Optimised control of your grinding processes

The control system for grinding processes

ball mill wet grinding mill center-discharge mill

Modular design
The control system MillMaster consists of two different components:
modular control structures

zzTechnology Module (TM)

A smart compilation of mathematical and logical func-
tions building high performant control structures. Technology Technology Technology Technology Technology Technology
Module Module Module Module Module Module

zzSmartControl
A powerful and flexible high-end control system of-
fering basic building blocks. This is the basis for the SmartControl base
system

MillMaster technology.

This combination allows a fast and flexible development with a sophisticated and target-oriented solution.

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MillMaster—Technical specification

TM Ball Mill
The Technology Module Ball Mill has two different con-
trol loops: Controller
The controller changes the fresh feed depending on the-
Set points (fill level 1 & 2) se deviations based on the fresh feed working point.
For the fill level control there is a set point per cham- The new set point is calculated by a powerful multi-term
ber and the controller gets the deviations from these set controller. It is limited by a minimum and a maximum
points. fresh feed value and a total feed also.

Limits (rejects, bucket elevator) Auto optimisation

For the limits (rejects, bucket elevator) there are ex- If the mill is stable the set points will be increased till
isting maximum values. That are the absolute maximum the maximum level is reached and the actual fresh feed
values for the mill. The MillMaster calculates set points value is stored as new fresh feed working point.
based on these maximum values. The controller gets the
deviation from that set point and the actual value.

Constant fresh material Constant level

100 100
Without MillMaster Using MillMaster

fresh material fresh material (+5%)

50 50

0 0
0h 1h 2h 3h 4h 5h 6h 7h 8h 0h 1h 2h 3h 4h 5h 6h 7h 8h

Properties

inputs (actual values) fill level 1

fill level 2
rejects
bucket elevator power
fresh feed

inputs (limits) fresh feed

rejects
bucket elevator power
total feed

outputs fresh feed

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MillMaster—Technical specification

TM Vertical Roller Mill TM Roller Press

The Technology Module Vertical Roller Mill has two dif- There are two different grinding facilities using roller
ferent operation modes: presses.

Save operation (for unattended operation) Stand-alone and pre-grinding

High production (for maximal production) The difference between these operation modes is that
on the one hand the grinding processes are linked close-
In both cases it is an event based strategy that reacts ly, and on the other hand they operate quite indepen-
with increase and decrease actions. The increase ac- dent.
tion will perform a slow increase of fresh feed and roller
pressure if the mill is under normal operation. Each time Pre-bin takes the focus
a limit is violated the fast decrease action will decrease A very interesting information is the size of the inter-
the fresh feed and the roller pressure. mediate bin. This is the key factor of the strategy. One
of the most important tasks of the controller is to con-
trol the fill level of this bin.

Applied in many variants

KIMA provides different solutions for both operation ty-
pes. If you operate your roller press in a special way
Controlled decrease events KIMA can adapt the technology module for your needs.

Properties Properties

inputs (actual values) mill vibration inputs (actual values) fresh feed
mill differential pressure rejects
main drive power roller speed
main drive temperature pre-bin level
torque signal
roller pressure

inputs (limits) mill vibration inputs (limits) fresh feed

differential pressure rejects
main drive power roller speed
main drive temperature pre-bin level
torque signal
roller pressure

outputs fresh feed outputs roller speed

roller pressure (optional) fresh feed
roller pressure

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MillMaster—Technical specification

TM Separator TM Hot Gas Generator

The Technology Module Separator takes care of a homo- The Technology Module Hot Gas Generator adjusts the
geneous product quality. Therefore the separator speed combustion of the burner in order to keep the air and
is adjusted everytime a new fineness value is available the material temperature at constant level. This leads to
(laboratory or online). a homogeneous drying of the material.

Steadiness by small steps

Also, the controller corrects the separator speed, if the
fineness is within the limits. This leads to many small
adjustments and thus to a more stable grinding process.
TM Water Injection
Homogeneity by steadiness
Due to the more stable process and faster reaction on The Technology Module Water Injection controls the
disturbances the variance of the product fineness (CoV) waterflow, so that the material temperature does not
will be decreased. violate any limit.

particle diameter [µm]

Properties Properties

inputs (actual values) fineness (blain or residue) inputs (actual values) air temperature
separator speed material temperature
air flow (hot gas)
burner temperature (hot gas)

inputs (limits) fineness (blain or residue) inputs (limits) air temperature

separator speed material temperature
burner temperature (hot gas)

outputs separator speed outputs fuel supply (hot gas)

burner capacity (hot gas)
waterflow (water injection)

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MillMaster—Technical specification

Visual software tool Trend software tool

Visual gives you the possibility to operate and monitor The software Trend offers the possibility to display all
your process with clearly arranged user interfaces. It data and intermediate results as trend. Therefore a his-
gives you the opportunity to design an easy-to-use inter- torical database is accessed, which goes back up to two
face with modern layout and trending elements. Admin- years depending on the resolution.
istration of recipe and control parameters is supported,
as well as actual set points and switches.

Properties Properties
• unlimited number of views • up to 10 curves per graph
• up to 3200 analogue values • unlimited number of graphs
• up to 3200 digital values • displays average
• value visualisation as bar graph or trend • displays standard deviation
• different views for operator & engineer • displays minimum and maximum
• continuously zooming
• historical data up to two years

Admin software tool Alarm software tool

The software Admin allows you to add all OPC items of Alarm enables you to display and monitor historical bit
the OPC server via drag and drop to the system. These states. You may create and save custom views for each
items are stored automatically in the database in chosen user, which—for example—provide the most important
intervals. They are available for monitoring and evalua- switching states of a facility at a glance. The software
ting by means of the tools on this page. calculates high and down time within any interval for
Connections to multiple OPC servers are also possible. any signal. Also, you may label the signals with different
user defined severities (e.g. alarm, information).

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MillMaster—Technical specification

What is the scope of supply? How to connect

The system consists of the following components: MillMaster is running on a Windows server hardware,
which is connected to the plant’s PLCs via OPC-protocol.
zzIBM server hardware
MillMaster MillMaster
(Windows OS, Raid 5)

zzsoftware
(all services installed)
d
zztechnology module
(due to your needs)

zzsoftware license s
MillMaster
(authorized via USB dongle)

Easy installation
The installation is easily done with just a few steps to switch to MillMaster:

1) Preparation
zzconnect server to the local network
zzconnect server to VPN
zzestablish OPC connection

2) Startup period
zzVPN
zzOPC items
zzswitching logic

3) Optimisation
zzparametrisation for different types

Switching logic Why using VPN?

After MillMaster is installed you still can switch back to We recommend our customers to set up a VPN tunnel
your old control strategy for tests or to evaluate new for MillMaster. This enables us to make the major part of
products. In order to ensure this functionality a ‘Switch- the commissioning from our position, which saves trav-
ing Logic‘ is added, which switches between the MillMas- eling costs and time. Also it allows us to help you fast
ter controller and the old one on PLC side. and uncomplicated in case of upcoming questions and
extensions.

KIMA Process Control GmbH

Güstener Straße 72 | 52428 Jülich | GERMANY www.kima-process.de | [email protected]

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