ABB Modelling & Optimisation

Tomas Lagerberg, Manager Automation Technologies, ABB Corporate Research, Scandinavia
Modeling & Optimization

An ABB Speciality
Outline
ABB
Advanced Process Control (APC)
Modeling & Simulation
Process Optimization
Outline
ABB
Facts about ABB
Headquarters: Zurich, Switzerland

About 120,000 employees in around 100 countries
Orders in 2008: $38.3 billion
Revenues in 2008: $34.9 billion
Listed on Stockholm, Swiss and New York exchanges;
traded on SWX Europe
© ABB Group
December 15, 2009 | Slide 4
ABB’s vision
As one of the world’s leading engineering companies, we

help our customers to use electrical power efficiently, to
increase industrial productivity and to lower environmental
impact in a sustainable way.
Power and productivity for a better world
© ABB Group
What we offer:
divisional structure and portfolio
$11.9 billion Ultrahigh, high and medium voltage

Power 34,000
Products employees
products (eg, switchgear, capacitors);
distribution automation; transformers
$6.9 billion Electricals, automation and control for
Power 16,000 power generation; transmission systems
Systems employees
and substations; network management
$4.8 billion Low-voltage products; contactors, soft-
Low Voltage 19,000 starters, DIN rail equipment, LV
Products employees
breakers, LV switchgear
$8.4 billion Control systems, instrumentation and

Process 29,500
employees
application-specific automation solutions
Automation
for process industries
$6.6 billion Robots, PLCs, motors variable speed
Discrete 19,000
Automation employees
drives
and Motion
2008 revenues (US$) and employees per division
© ABB Group
Innovation: Key to Competitive Advantage
* Comprises Total R&D spending* 1'242

1'173
non-order (in $ millions) 1'066
related R&D and 971 966
order-related 870
development 746
2002 2003 2004 2005 2006 2007 2008
Steadily increasing R&D has paid off in market-leading

technologies in every business
R&D investment rose 5.9% in 2008 vs 2007
Focus on energy efficiency and breakthrough technology
6,000 researchers and developers worldwide
© ABB Group
Global Labs…
… and Local Lab Locations
Västerås SE
Krakow PL
Baden CH
Ladenburg DE
Raleigh US Beijing CN
Shanghai CN
Bangalore IN
Automation Technologies Power Technologies

SE, DE, CH, US, IN, CN SE, CH, US, PL, CN
Close to major customers, universities and
ABB‘s business responsible units
© ABB Group
Corporate Research in Västerås
Västerås: ~230 employees, ~40 nationalities

Oslo: ~20 employees Focus on both automation and power
technologies
Very well equipped labs:
High voltage, high power, cables, power electronics,
motors, isolation
Chemistry, mechanics, acoustics, material
Robotics, User Interaction, electronics, communication
Research cooperation with leading universities and
research institutes globally and domestically
© ABB Group
Outline
ABB

Benefits of Advanced Process Control
Reduce the
variance
Actual limit
New
setpoint
before after
© ABB Group
Steps to Achieve Advanced Control / Optimization
Build process model:

First principle (White Box)
Black box
Grey box
Design controller / optimizer / product
Engineer / implement
Commission
Operate / maintain
© ABB Group
Month DD, Year | Slide 12
1 - Build a Process Model
Mathematical description
Complex enough to
describe the process nature
Simple enough to enable
real-time optimization
2
Nst
1 1
min el ti Pi ( x, T0 ) fuel f( Mc p (T0 Tinit ))
( x ,T0 )
1 motor ugn
© ABB Group
2 – Optimize Using The Model
2
Nst
1 1
min el ti Pi ( x, T0 ) fuel f( Mc p (T0 Tinit ))
( x ,T0 )
1 motor ugn
© ABB Group
Model Predictive Control (MPC)
”Based on a process model, starting from current process status –

optimize the sequence of outputs that will minimize the control
deviations and size of output signal changes considering the given
restraints. Use the first output signals in this sequence.
Perform this procedure every cycle”
x1L x1H u1L u1H

x1 u1
x2 u2
x3 MPC
up
xn
r1 r2 r3 rm
© ABB Group
MPC
Model Builder
Simulator
Process
MPC Engineering
Tools
MPC Run-time
MPC Operator
User Interface
© ABB Group
MPC – Why?
Natural way to handle multi variable control problems

Takes you one step up in the value chain, i.e. closer to
control what you really want to control
Efficient handling of constraints
Efficient handling of output signal limitations
Allows you to operate closer to process limits, and
thereby optimize the profit
Can manage known future setpoint changes (e.g. grade
change)
Can handle structural changes
Well proven
BUT…
It is still rather demanding to engineer and commission

an MPC controller
© ABB Group
MPC Project Example – Flotation Process at Boliden
Project to develop new methods for automatic control of flotation circuits

ABB Corporate Research
ABB BU Minerals
Boliden Mineral AB
Targets:
Achieve automatic control with close to 100% up-time. Relieves operators from
constant focus on keeping the production stable and on reasonable level
Improve the economic output of the flotation plant
Main Activities
Initial modeling using Modelica
Experiments in Garpenberg
Identification of linear models
Installation of Expert Optimizer
Short experiments with the controller
A weeklong test of the controller
Performance test and evaluation
Customer acceptance and take-over
© ABB Group
Mineral Separation using Flotation
Flotation cell:
Huge tank with mixture of
Ground ore
Water
Chemicals making mineral
hydrophobic
Air flow from bottom
Froth at surface with
concentrate flows over edge
Continuous process with
Feed flow (in)
Concentrate flow (out)
Tailings (out)
Normally there are several
flotation cells in series
© ABB Group
Process overview in Garpenberg
Zinc flotation circuit in Garpenberg

100-220 ton ore/hour
3-11 % Zn in ore feed
Objectives
Minimize Optimize value of zinc
production
Concentrate purity
Tailings losses
Limitation on circulating load
Main Control Signals

Maximize Cleaner air
Rougher air
IBUX (isobuthylxanthate)
Boliden: We do not believe that you can do this! addition
© ABB Group
Modeling
Describe the process with a linear time-invariant discrete time

state-space model
x(k 1) Ax(k ) Bu u (k ) B ff u ff (k )
y (k ) Cx (k )
A, B and C matrices are estimated from process inputs and outputs

System identification toolbox in Matlab
Experiments done 2007 and 2008 using PRBS signals

© ABB Group
Model Predictive Control
Tuning
Objectives for PVs

Penalizing errors in set-point for
product concentrate
tailings concentrate
Penalizing Volumetric Flow Circulation when exceeding
threshold
Objectives for MVs

Penalizing moves for
Cleaner air flow
Rougher air flow
IBUX rate additions
Penalizing IBUX rate additions when exceeding threshold
Limits
© ABB Group
Step 2 - Setpoint Optimization
Method to find best setpoints to maximize the value of the

production.
The value of the production depend on the amount of
produced zinc, the purity of it, and the market price of zinc.
One degree of freedom static model for the high gain direction of
the flotation process
Easy to move process along blue lines
© ABB Group
Results
Final Tests in February - May 2009
95
Model Predictive Control and set-
point optimization
Four months on-line testing and
A n rik n in g s e f f e k t iv it e t Z n - k r e t s
comparison with existing manual

90
strategy
Two days on, then two days off,
etc.
Uptime of MPC: 97.4 %
85
Evaluation
On 2 days Off 2 days
Enrichment efficiency
Ratio of the revenue of the
concentrator and the
theoretical maximum
revenue that the
concentrator could have,
assuming the same inputs.
Improvement is at least one
percentage unit
© ABB Group
Outline
ABB

Ladle Furnace Stirring
Gas EM
© ABB Group
Varying Demands on Ladle Furnace Stirring
De-sulphurization
High turbulence in the
border between slag/melt
Heavy stirring in the melt
Heating
Calm surface
Mixing
Reactions at the surface
under the slag layer
Cleaning(Final mixing)
Calm stirring, calm surface
Remove impurities
(bubbles help the cleaning)
© ABB Group
EM + Gas = EM Gas!
Complex
simulation
Verification
Idea
Modeling Experiments
Simulation
Large potential
identified!
© ABB Group
Outline
ABB
(Energy) Optimization in Hot Rolling Mills
Big Potential
Profile mills:
7% reduction =>
1.2 GWh/yr
(>1000 profile mills
globally)
Flat mills:
0,5% reduction =>
1.6 GWh/yr
(~400 flat mills globally)
© ABB Group
Hot Rolling Optimization (Profile & Flat)
Project Focus
PROCESS DEVELOPMENT,
r 3.0
”Next Generation”
Thermomechanical rolling, scheduling,
set-up w furnace, rolling principles
PROCESS OPTIMIZATION,
r 2.0
Asset optimization, product quality
true mathematical optimization
MODELS, r 1.0
Simulation for spread,
power, temperature, …
sensitivities, statistics
More Complex Models Gives New Possibilities
P-214
O626
V-1
V-11
P-123
P-154
E-99 T2
FI FI FI
424I301 424I302 424I303
P-167 LI
Vatten
424I450
Press7+
Blekeri2
P-112 P-113
HC2
FCA51
424I312 LI
FI 424I460
421I209 P-117
221Q105
CI
221I328 HC3
P-144
DI
LC 542I271
542I286
lab
542Q110
P-60
© ABB Group
Example From Pulp Mill
V atte n M 51 LI LI
FI M51
M 51 4 11 Q10 1 O4 72 C 625 4 13I57 1
304I40 9 O10 1 O4 01 O404 O 143 FC
Fli s Na/S förl uster
P-36 O6 02 4 13 I46 8 611 .dryou t
I m a ssan P-43 P-118
O101 MV FC P-37
FC M51
O11 0 4 11 I26 0 BT
4 11I11 8 O3 33 O3 31
O4 73 T1 QC V-2 C5 26 T18
P -1 08 pp 41 3i46 7 FA 01
411 Q10 6 P -44 O 779
A 51
FC Tvättvatt en 41 3I46 8
S K1 4 13Q1 09 O7 75
O25 8
O27 1 41 1I25 8 O3 34 O3 33 S K1 O4 25
Blekeri1
P -1 89
P-17 1 4 1Q1 05 Tvät t+ FCA 51
P -1 26
T17 P -131
25 Production units
P-2 01 S ileri 41 2Q10 2 4 12Q1 01 4 22 I61 8
FC A5 1 P -1 11
O 258 FC FC FCA 51 FC A 51 LI
4 21I441 FC
42 1I4 28 42 1I44 1 O6 48 FC 422I6 54 4 22I64 2 4 22I67 0 LI
FC A5 1 41 2I7 49 O79 9 T3 P -131
FC 4 22 I6 18 611 I611
4 21I428 FC88
P -1 A 51 E-100
42 1I37 5 FCA 51 S iler ifö rlus t
FC 4 22I62 2
P-12 LC FC05 1 4 22I2 55 O blekt fiber P-1 21
FC 4 22 I6 54 P-15 2
FC FC FC 4 22I55 2 42 1I10 3
FC51
4 21 I86 0 LI P -2 14
O626
42 1I409 4 21 I4 10 42 1I4 64 FC A5 2 LC 42 2I2 58 FC A5 1 FC A53 FC A5 2 P-12 0 V-1
P -3 4 22I50 1 T19
HC 1
38 Buffer tanks
42 1I4 28 4 21I445 42 2I5 66 V-11
Fli s 42 2I565 42 2I642 E -92
P -2 23
P -12 4 Tryck- Filter P-123
BT P -9 LI FC FC A51 P-22
P -22 1
42 2I506 T 114 422 I509
di ffusör FI P -15 P
4 -13 4
P-10 42 2I5 59
Tvätt+ 42 2I6 41
S K2 FC FC
A01 -SP LI Tvättvatt en Sileri FCA 55 P-11
P-12 5
E-99 T2
42 1I10 3 422 I510 422I5 59 E-96
SC A 51 7 21 I12 7 E -130 7 31 I1 77
S K2 Tv.vätska FI FI FI
4 21 I1 62 B V 24 V -5
P -2 00 A01 -SP P -9 1 LI 4 24 I3 01 424 I3 02 424 I3 03
7 21 I12 9 P-18 9 42 2Q1 04 HC4
250 Flows
FI P-110 731I1 01 P-13P-230 P -1 67 LI
FC P -15 0
3 03 I3 01 TC -S P KV M P-109 FC S iler ifö rlus t LC LC LI Vatten
424 I4 50
E -95
P -1 91 731I1 66 4 22 I6 29 42 2I639 T114
7 21 I12 7 731 I1 13 T17 8 42 4I30 9 P-1 51
FI P -2 P -9 2 T1 21 Press7+ P -129
P-22 2 T10 1
42 1I49 9
TC -E GU A0 1 A0 1
LI
U TSK B lekeri2
7 21 I3 31 72 1I3 41 A5 1 A51 A5 1 T2 26 V-7
7 21 I12 7 P -1 13
SC 7 31 I19 7 P -112
A 01 SC V atte n T105 T 103 T 119 423 I1 19 H C2
7 21I24 7 P -9 0 P -23
72 1I351 7 21I37 3 A5 1 FC A5 2 FCA 5 1
Fli s P-93 HC 5 E -91
T111 N aOH 42 3I1 05 424 I312 P -1 30
T1 07 XD LI
250 Measurement points

P -8 8
P-89 PM 6 O2 424I46 0
FI NS M LC 4 23 Q1 13 FI P -13 5
721 I327 6ICO.ARTON H 52 3I5 40 T2 69 42 1I209 P -1 28
FC P-11 7
P -13 5
72 1I1 59 A 51 A 51 vatte n 22 1Q10 5 E-97
T17 1 T 233 CI
LI NS P -1 56 H C3
LC E -124 M IHA S T M gS O4 P-19 2 22 1I3 28
51 3I73 6
513 I7 72
TJL T5 5 23 T027
V-4
LI E lfitera ska A5 1
AI AI AI P -14 4
LV LI 5 13 I59 7 P -1 41 T25 8
B V25
DI 5 01I6 44 50 1I6 33 52 3I53 1
2500 Variables
51 3I90 1 P-21 2 5 13I12 4
DC
51 3I437 LI LI AI V -6 E-87 FC A01 DI
P -1 93 DC FC 5 13 I5 92 5 13 I7 98 P -1 40 52 3I2 84 LC 54 2I27 1
513 I762 FC V -1 0 5 13 I73 4 BU L LV A 01 P -21 0 52 1I53 2 LV A0 1
513 I109 A IM V 1 54 2I286 FC
5 13I73 3 P -18 1 51 3I912 LI lab
DI P-211
LC AI FD A02 523 I57 8 5 42I22 0 5 42 I9 03
FI E -103 FI
51 3I731 51 3I792 Rö kg aser 52 1I53 5 52 3I5 77 542 Q11 0
FC 513I8 23 513 I73 3 DI 52 3I62 6 P-60
TLB 513 I735 FI FI
A02 52 3I583
FC LV A0 1
P-180 LV 50 1I76 4 P-203 P -60 5 42 I9 06
51 3I723 TJL 5 42I21 2
513 I91 1 P-45 Skrubber 52 3I5 77
LI P -28 NaO H FIA01 P -5 7 LC
starkgas- P -5 7 FC LV A0 1
S oda- GL2
2200 Equations
5 13 I70 7 S va ve l i va rm va tten 5 23 I7 22 542 I293
B LB destr LC E -104 5 42I2 16 5 42 I9 09
pan na+
E -88 P -2 29 5 42I28 5 E -106
P -54 FC L 889
skrubber Sla m P-61
L8 87 P -71 FI FCA 03 FI
E -126 5 13 I7 21 lab
LV FC
Ind unst. N aOH 5 23 Q10 1 5 23 625 GL3 542 I2 12 5 42 I2 63
RL 51 3I90 3 P -20 7 FC
542 I29 1 P -2 18
P -51
K ondensat LI P-205 lab P -59 LV A 06
P -19 3 FC 54 2I2 82
P -1 79 5 01 I8 70 5 23 Q10 2 54 2I901
MV P -10 6 LI FC FI G L1 P -5 8 P -6 2
DI 5 23I51 3 V -9
FC P-34
17 Time steps forward

I49 5 5 13 I73 8 5 13I34 5 P -21 5 LC 523 I5 14 P-56 52 3I5 10 lab
LI P D 11 L V A04
5 13 I70 9 54 1I62 1 5 23 Q11 3
LI P -53 5 42I9 01 LC
LC 54 3I3 26 FCA 01
513I71 0 51 3I718 P-19 5 S U LF LI M ix-P D31 5 42 I548
BLL 542 Q11 9 FC
54 3I328
AI
SO2
LV A 04 5 42 I21 6
P -1 82 DC A0 1 V itlu t
DC 50 1I6 83 Va tten 54 3I3 60 54 2I90 4 Ka lkgru s
FC FI 5 23I62 1
E-112 51 3I717 P-19 4 P -2 16 la b AI FCA 01
51 3I7 14 523I62 7 L VA 0 4
lab FC 5 42 Q1 02 FC 54 3I3 22 5 42 I21 2
P -1 48 AI ME S A 5 42 I90 7
M eOH 5 42I55 0
(non-equidistant)
620,000 ton
72 1I90 1 5 01 I76 1 50 1I6 44 P -7 5
FC P -21 7 lab LI FC 54 2Q11 4 FCA 01
TLL LI 5 41Q 10 1
5 13I70 6 542 Q10 1 54 2I249 5 43I306
P -65 5 42 I22 0
72 1I18 6 FC LC P -70
Containerboard
E -113
P-206
LV 54 1Q10 2 5 41 Q103 P -2 31
541 Q10 6
5 41I643 54 2I457
FCA 01
DC
P -34 7 21 I90 2
L V A02 LC
SVL LI
P-64
5 43 I30 1
P-17 4
5 13 I76 1 FC
A01 A05 5 41Q1 04 54 1Q10 7 541I9 01 P -83 542I45 8 54 2I2 47 FC DC
72 1I101 V atte n K ALK
7 21 I10 1 721 I10 1 LV A0 1 Sp ill, div FC
P -13 6
LC
5 43 I30 1 5 43 I30 2
FI
M esaugn+
P-1 96 AI VL FCA 0 2 Fi lter
Sack
P -8 5 54 1Q1 05 5 41 Q10 9 541 I9 01 5 41I6 14 5 42 I4 41 54 2I22 3 542 I506
Three fiber lines

5 43I31 5 FC A 01
E -89 FC A 01
P-21 9
FC 5 42Q 123 M 8 56 5 43I31 5
LI 54 1I62 0
54 1I62 0
FIA0 1 51 2I179
51 2I1 87 P-3 5 54 2Q1 28 4 21 Q10 3
LI P -77
Kraft
P -84
P -10 4 SPL 51 3I701 KV
P -79 5 42Q1 29 42 1Q10 5
TO OX
P-161 FI
P -3 3 Svavelugn+ Vi tlutsO x
LI 5 13I7 05 N aOH M a ke -up 5 42Q 126
A bs.torn
Six paper machines

512I1 77 LC FI FC
Tal lolja fö r av sa lu 541I6 13
V-8
Market pulp
H arts- P-161
541 I6 58 54 1I647 541I6 45
Bj örkolja til l M esau gnsförb rä nnin g 5 42Q1 24
kokeri
FC A01 FI FC FC A 01
512I3 15
BO S va ve l M a ke -up 54 1I62 8 5 43I31 5
5 12 I16 3
V itl ut til l Ha rtskokeriskru bbe r
FC S ur va tten till C lO2
512I18 3 P -22 0
Main Mission: Reduce NaOH Consumption

H 2 SO4
© ABB Group
On-line Optimization
One cycle every 30 minutes
Optimization State Estimation

forward in time
Simulation
© ABB Group
Linking Several Roles’ View of Production
Linking production planning, mill info system
and control system
Setpoints to control system
© ABB Group
Pulp Mill Optimizer – ABB Exclusive
Patented technology
© ABB Group
Objective at Gruvön Mill
Without
Optimizer
With
ABB Optimizer
Capacity
Aiming to minimize:
Disturbance
and planned Deviation from production plan
stops
Production loss caused by disturbances
Production
Deviation from preferred liquor composition

Cost of make-up chemicals
© ABB Group
Functions
Planning for stops
and production
limitations
Soft sensors
On-line scheduled
operation:
State estimation and
optimization
Diagnostic tools:
”What-if” simulations
•Bottle-neck
analysis (Scenarios off-line)
•Measurement
points´ diagnostics
© ABB Group
User Display Example
© ABB Group
Mill Benefits at Gruvön
Decreased consumption of NaOH: >500 kUSD/year

(Gruvön)
2-4 % increased production
Quality improvements
Others
Increased understanding between control rooms and
production units
Common operating strategy between control rooms,
production units and operating shifts
Thorough update of documentation vs real-life
© ABB Group
Next Installation at Tiger Mill in China
To be Commisioned Spring 2010
© ABB Group
Process Optimization – Trends & Thoughts
Optimization is slowly gaining ground

Floating border between advanced control and
optimization
Requires considerable competence to succeed –
both process and theoretical
Increasing competition will drive more and more
optimization solutions
There is often large money to gain!
How to maintain advanced solutions?
How to get paid for this?
© ABB Group
© ABB Group

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Tomas Lagerberg, Manager Automation Technologies, ABB Corporate Research, Scandinavia

Modeling & Optimization

Headquarters: Zurich, Switzerland

As one of the world’s leading engineering companies, we

Power and productivity for a better world

$11.9 billion Ultrahigh, high and medium voltage

$8.4 billion Control systems, instrumentation and

* Comprises Total R&D spending* 1'242

2002 2003 2004 2005 2006 2007 2008

Steadily increasing R&D has paid off in market-leading

Automation Technologies Power Technologies

Västerås: ~230 employees, ~40 nationalities

Advanced Process Control (APC)

Build process model:

”Based on a process model, starting from current process status –

x1L x1H u1L u1H

Natural way to handle multi variable control problems

It is still rather demanding to engineer and commission

Project to develop new methods for automatic control of flotation circuits

Zinc flotation circuit in Garpenberg

Main Control Signals

Describe the process with a linear time-invariant discrete time

A, B and C matrices are estimated from process inputs and outputs

Experiments done 2007 and 2008 using PRBS signals

Objectives for PVs

Objectives for MVs

Method to find best setpoints to maximize the value of the

comparison with existing manual

Modeling & Simulation

250 Measurement points

17 Time steps forward

Three fiber lines

Six paper machines

Main Mission: Reduce NaOH Consumption

One cycle every 30 minutes

Optimization State Estimation

Deviation from preferred liquor composition

Decreased consumption of NaOH: >500 kUSD/year

Optimization is slowly gaining ground

How to get paid for this?

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ABB Modelling & Optimisation

ABB Modelling & Optimisation