Best of Artificial Intelligence and Predictive Advanced Control, for

full autonomous grinding control

Dirk Schmidt, KIMA Process Control 2. April 2020

This article describes the experience and actual opportunities using ARTIFICAL INTELLIGENCE in the
day-to-day process control in cement plants. Case studies from three plants give a snap-shot of the
AI use in our industry. Most important: Results given by the best mixture of Advanced Process
Control -APC- and Artificial Intelligence -AI- will be reported. E.g. by Emir Cilimkovic of Lukavac
Cement who’s conclusion is:

“We need today 2 hours less to produce the same amount of cement as before.

The power consumption has been reduced by 9 – 11 %”.

Looking for Industrial 4.0

The task is “Industrial 4.0” and everywhere I look, “big data” and “artificial intelligence -short AI” is
announced to be the future. The target is to convince you – the cement producers - to use latest
technologies that we use day-to-day also in our mobile phones. Interested? – Of course, nobody can
avoid that future technologies have to be considered sooner or later also in very conservative
industries. Especially when it comes to process optimization and automation other industries show
how production process can be increased. And -maybe they didn’t know- full autonomous mill
operation (using parts of AI) is happening already since 2009, as you will read at the end of this article
in the case studies!

There are actually business consultants that serious want to copy-paste the tools and control loops of
the industrial revolution 4.0 from chemical plants and refineries to cement production with rotary kiln
and ball mill / VRM grinding. Latest example was a report about “the first installations with
fundamental success by converting the control to AI (artificial intelligence)”. Under the headline was
written that it is a break-through in the most conservative building materials industry to use this kind
of technologies. Careful please – the capabilities of AI are still limited as the history shows. But
alternative routes has been found already. From our perspective AI delivers these last lost puzzle
pieces and we are enthusiastic that we have found the right mixture of AI and APC.

Picture no.1 Central Control Room in a larger cement plant

How “AI” started in the cement production

After a short talk and discussion with these new suppliers it becomes clear that this “revolution in the
cement plant control systems” is to operate with Model Predictive Control and Soft Sensors. The
“intelligence” is (still) limited to a prediction of a non-measurable process signal or a measurable one
predicted in the future. Instead of “MPC” the child gets a new name and the talk is now about ‘artificial
intelligence’. To clarify: To support serious stable control systems, e.g. Advanced Controllers using e.g.
Fuzzy Logic using predictions, is using “modules” of AI, but not more. It is not this “self-thinking” and
“learning” machine everybody thinks about, it is adaptive model predictive control.

Self-learning adaptive model predictive control was introduced in 2001 already from the company
Powitec Intelligent Technologies (Germany), the first comprehensive black-box controller that
operates a rotary kiln full autonomous for more than one day without manual interaction. Core was
an image processing camera looking into the kiln and an online prediction of the free-lime. Various
tools of AI was used during these days in 2002 already. Using adaptive MPC, the energy input to kiln
main burner and calciner was automatically adjusted. Pioneers in the use of AI during these days were
the cement producers LEUBE (Austria) and Maerker (Germany) Zement.

Short later companies like ABB, FLSmidth, Pavillion and Rockwell entered the market with similar
model-based controllers – and again not soft sensors only (like today), but serious black-box control
engines. Today we can resume that all expertise companies went back to the more robust Advanced
Process Control using complex fuzzy logic control and use predictive models for soft sensors. The
reason for that is serious difference of the cement manufacturing process compare to all other
common production processes.

Special Process Conditions

Producing clinker is unique complex! We speak

about two competing process circles plus a
giant portion of wear during each operational
campaign. If you teach a so called multi-
dimensional non-linear process model of a kiln
or a mill, tomorrow is already different
compare to today. Self-Adaptivity and self-
learning software features was tried to be
implemented. But we have to consider a
change in each maintenance stop: liners, balls,
chutes, feeders, valves, refractory, fuels and Picture no.2 Clinker bed in a pet-coke and coal
last but not least the raw materials – think fired rotary kiln – a unique complex process with
about this more-dimensional changes. plenty of changing conditions. Picture no.3 Not
The quarry components as well as the additives less complex is the grinding process in cement.
change and you thought about your fuel
heating value, water and ash changes? The
change of coal and pet coke particles size
distribution from their mills and the related
change of combustion (ignition point, out burn,
flame shape etc.)? All these changes are
effecting directly the chemistry of clinker and
cement – so what a challenge for a controller.

If you support a multi-dimensional process

model with signals that have a drift, or are not
stable all-time-long, they fail. They work for
some days and lose permanently performance/quality. And the most significant process signals which
are necessary for the control of a mill or a kiln show exactly this phenomenon and avoid a continuous
full-autonomous operation. We speak about MPC and/or AI of course.

A most robust control solution for such permanent exchanges is still a rule-based control structure
that follows the experience of the most intelligent source in the plant: the operators. And so the
mixture of APC and AI is the key as this represents the human at most.

We pick the best out of it: AI and APC

Of course, the operator, the human, and his copy the “Advanced Process Controller -APC”. APC has
had its own continuous development over the last years and the border between APC and AI becomes
open. APC should not be mentioned as “old fashioned” or “historic”. This would ignore the
experiences made by the earlier mentioned companies using these tools already some 10 to 15 years
ago. Until today Advanced Process Control using Fuzzy Logics is the most reliable and robust solution
for the cement manufacturing processes. And if you operate your mill or kiln with this technology, you
are not “old fashioned”. Added by most modern modules of AI these systems reach a new level in
automation: Predictive Advanced Process Control. Below we will report from first plants which drive
their mills full autonomous over days. Further it has to be mentioned that the level of “auto-pilot”
function is not limited to smooth operation only. The KIMA Process MILLMASTER allows a fully
automated start of the mill, automated stop, emergency recoveries and full automatic switch from
one cement type to the next.

Within the following case studies, we would like to take your attention to some plants which increased
their performance using ‘SMARTCONTROL’, the acknowledge and software from KIMA Process Control
GmbH, Germany. The software-platform was supplied in nearly 200 rule-based expert systems called
‘MILLMASTER’ using state-of-the-art fuzzy logics and model predictive soft sensors globally.

Please consider that there are 2 companies operating in Germany under the name ‘KIMA’. Our sister
company KIMA Automation supplies also to the cement Industry. The KIMA Process Control GmbH in
Juelich, is the one which developed and sell the products SMARTCONTROL, MILLMASTER and
SMARTFILL.

MILLMASTER – predictive APC

In the year 2008 KIMA Echtzeitsysteme (the previous company name of KIMA Process Control)
published an article about the project to supply 30 SMARTCONTROL APC packages for ball mills
(inclusive the fill-level measurement SmartFill) to a selection of Holcim group plants in Eastern and
Central Europe. After the commissioning and later during steady operation of these plants the
development of MILLMASTER continued separately in the group of Holcim and as well as in the
company KIMA Process Control.

New designs of the human machine interface, programming logics as well as new software modules
was developed to follow new trends in automation and advanced process control. The following case
studies show the results and experience of the today users of this product. New sensor devices like
the V-Sens (vibration sensors) and T-Sensor (the new contactless torque sensor from KIMA Process)
copy the success of SMARTFILL from the ball mills to all Vertical Roller Mill applications.

Key of a serious performance increase in the application of ball mills is once again the SMARTFILL
system. The only reliable fill-level measurement for individual measurement of chamber 1 and
chamber 2 plus the temperature of the grinding material entering chamber 2 is the recommended
measurement device in nearly all large cement producer groups. The combination of SMARTFILL with
APC systems is not only successful with MILLMASTER but also with the control software plattforms
e.g. of LafargeHolcim, HeidelbergCement and BuzziUnicem. SMARTFILL has made KIMA P.C. to the
market leader in this instrumentation. As it provides most robust and drift-free process signals it can
be excellent used in combination with other process variables for predictive solutions – as Soft Sensors
for fineness in the MILLMASTER system for instance.

AI plus APC – the mixture makes the success today

After this long introduction we need to summarize that the today’s best performance is reached
with a mixture of the well-established “Expert Systems” using robust fuzzy control modules as well
as modules/tools from AI. Compare to the black box control of MPC or NMPC and the fundamental
need along of self-learning components or regular re-trainings, the practise shows that fuzzy rules –
finally working like a human based on “if….then….” show the necessary availability. Within the
following three case studies we show a wide variation of tasks/targets and successful integrations
this automation tools are offering in cement plants today.

Case Study 1: Full autonomous mill operation at EQIOM Ciments

Autonomous mill operation using modules of AI is not science fiction any more. Already in 2009 the
MILLMASTER based on the software SMARTCONTROL (by KIMA Process Control) was implemented
in a Vertical Roller Mill project in Northern France:

The EQIOM Ciments VRM of Loesche type LM 46.2+2 S, produces in Dunkerque mainly slag cement
while MILLMASTER system is controlling every weekend (Friday afternoon to Monday morning) fully
autonomous when the plant is operated completely unmanned. Under the regular ‘week’-operation
the control system is switched to “Maximum Production” while during the autonomous ‘weekend’-
operation the mode “Stable operation” is selected by the process engineer.

Pierre Vonstein, Operations

Manager for North and Normandy
Grinding Stations: “MILLMASTER
system is used daily and gives us
the opportunity to concentrate on
performance optimization while
the mill is running. It also protects
the equipment in case of
important change in mill behavior
faster than an operator. It would
be hard today to run without this
expert system on a long period.”

Picture no.4 The Loesche type LM 46.2+2 S vertical roller mill in Dunkerque

Case Study 2: Increased production at Fabrika Cementa Lukavac

A serious advantage of the MILLMASTER system is that the operators does not see much from the
system. Just the button “MILLMASTER on / off” allows them to start or stop the “auto-pilot”. And to
switch it on has mainly one task: increased production. More than 200 plants today operate their
mills with this expert system.

A very representative example is Fabrika Cementa Lukavac D.D. in Bosnis and Herzegovina. In 2018
the system was installed on a 65 tph design ball mill which reached usually a base line of 67 tph as
Emir Cilimkovic reported. Emir is the Process Manager in Lukavac and send us the final report of the
MILLMASTER performance test. Here the results for the two cement types produced in the pant:
Certified Production Increase

Cement Test Production Production Production Increase

Type duration (tons) (tons/h) (tons/h) (%)
(h)
PID*-control MILLMASTER

CEM II/B-M 12 898 67.0 74.8 10.46

(V-L) 42.5 N

CEM I 52.5 N 13,1 712 50.0 54.42 8.1

*(PID regulation on fixed value of total amount of fresh feed and rejects)

Additional Results:

• Less fluctuation in quality compared to the baseline situation

• Filling level of the mill chambers at higher level than before (less wear for balls and liners).
• By the crash stop method and according to the physical check of the filling level inside the mill it was
observed, the SMARTFILL measurement was calibrated perfectly and obviously there is still more
potential to increase capacity
• Filling level of the mill chambers at higher level than before – highly important for this type of cement
because of specific cement quality demand (and again saving the lifetime of the inner parts and balls)
Picture no.5 - MILLMASTER Cement type configuration screen for CEM II/B-M (V-L) 42.5 N

General notes from Fabrika Cementa Lukavac

Emir Cilimkovic reported: “The MILLMASTER today is a highly useful tool for us to achieve lower
standard deviation on cement fineness and blaine which was recognized to our full satisfaction.

We need today 2 hours less to produce the same amount of cement as before.
 The power consumption has been reduced by 9 – 11 %.”

“The SMARTFILL electronic fill-level measurement comes along with the MILLMASTER. It is a highly
reliable equipment for detection of potential clogging of the diaphragm in the chambers. This issue
becomes highly important especially due to increased usage of alternative fuels in cement kilns and
the along going change of our clinker chemistry. Our Operators appreciate this helpful tool which is
such a big improvement compare to the former microphone systems and helps them to be more
efficient and relaxed at the same time. Especially considering the rise of obligations due to the quality
and environmental demands the grinding optimization has helped a lot.”

Picture no.6 - The SMARTFILL device on the mill with chamber 1 and chamber 2 sound sensor

Emir continued: “We as Process Engineers are able to optimize the MillMaster system effortless and
at the highest level of production all the time. The system helps us to be more efficient and to have a
better knowledge of our cement production. The equipment was easily mounted on the mill with
minor adjustment from the local mechanical workshop
as well as electrician work. Everything was done in two
days only and ready for calibration procedure. Only the
first calibration was provided by KIMA Process
personnel according to typical procedure and according
to the needs for cement without any kind of a problem.
We had to empty the mill to adjust the lowest value for
filling levels and afterward we had been producing
cement normally. The signals are used from
MILLMASTER for the fully automatic mill control at the
optimum of our mills.”

Finally, the production manager of Lukavac reveals: “For

maximum production level we check the system from
time to time seriously. By “crash-stop method” the filling
level inside the chambers and the condition of our balls
and liners is checked and we want to see if there is still
a possibility to increase the limits. Production and
process optimization on a new and much higher level of
course.”

Picture no.7 – LUCAVAC Cement, Bosnia-Herzegovina

Case Study 3: Increased production at Adelaide Brighton Cement

While the performance tests in Lukavac was made in 2018, the Australian cement manufacturer
Adelaide Brighton Cement ordered their first system for the integrated plant in Adelaide in 2019. John
Murphy, Senior Process Manager reported now from the commissioning in November until today the
positive performance was measured in various points and not only in an obvious production increase.

First the operators use it in their day-to-day work very consequent. The ‘auto pilot’ frees up time to
concentrate on other thinks in the production day. Second, the process-control has become very
complex for the mill operators as the variation/mix of clinker composition -import as well- was
becoming larger and larger. Here the fill-level measurement (SMARTFILL) helps to compensate this
with a permanent indirect measuring of the grindability.

Finally, as third- and fourth-point, John reported that the mill has a much quicker start and change
between the types of cement. As this is automated now it is faster and more reliable. The system will
be now installed onto the two other mills in the plant as well.

Picture no.8 - The MILLMASTER in

integrated with 2 control loops
(Technology Modules) in Adelaide:
Separator and Fresh Feed control!

Picture no.9 “A more detailed article about

the project and the results in Adelaide
Brighton will be published soon.” John
Murphy, Senior Process Manager
promised.

Conclusion:

Most people believe that AI - Artificial Intelligence is self-learning and complete adaptive automation.
This is not completely wrong as AI delivers the right final modules to complete the “nearly perfect”
control. The significant modules of AI we are using today are the similar to those we used already 20
and 10 years back but faster and they have the larger data basis. A phenomenal development of this
AI software tools has taken place and the practise has shown that the right mix of technologies AI and
APC seems to be the optimum way. Within the next few month another 10 MILLMASTER systems will
be commissioned in cement plants all over the world. Another advantage is the fully remote
commissioning possibility. But this is another report and article as promised with Adelaide Brighton
Cement soon. ◼◼