Automation og procesoptimering i produktion af

Transcription

Automation og procesoptimering
i produktion af fødevarer
Produktchef Per Thyme,
Rockwell Automation
Process optimization
in food production
Insert Photo Here
Per Thyme
Process Sales Manager
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Rockwell Automation At A Glance
Leading global provider of
industrial automation control
and information solutions
• Annual Sales: $4.3 billion
• World Headquarters:
Milwaukee, Wisconsin, USA
• Trading Symbol: ROK
• Employees: About 19,000
• Serving customers in
80+ countries
44
Serving You Around the World
North America:
300 sales & support locations
9,000+ employees
Latin America:
30 sales & support locations
3,000+ employees
Europe, Middle East & Africa:
90+ sales & support locations
50+ countries
3,800+ employees
Asia Pacific:
60+ sales & support locations
20+ countries
3,200+ employees
55
Sales by Region
Billions ($US)
$7
$0
2005
North America
2006
2007
Europe - Middle East - Africa
2008
Asia Pacific
2009
Latin America
(Includes Mexico)
Expanding Our Global Presence
66
Consumer-Driven Industries Include…
Consumer Packaged Goods
Automotive
Increase flexibility &
responsiveness while
reducing costs &
improving quality.
• Bridgestone
• DaimlerChrysler
• Ford
• GM
• Goodyear
• Hyundai
• JCI
• Lear
• Magna
• Michelin
• Toyota
Food & Beverage
Satisfy consumer
demand, while
reducing costs,
minimizing waste &
improving asset
performance.
• Anheuser-Busch
• Coca-Cola
• Kellogg
• Kraft/Nabisco
• M&M Mars
• Nestlé
• PepsiCo/Frito-Lay
• SABMiller
Household & Personal Care
Life Sciences
Meet regulatory
challenges & improve
quality, consistency,
flexibility &
time-to-market.
Reduce costs while
meeting the demands
of ever-changing
regulations.
• 3M
• Beiersdorf
• Colgate-Palmolive
• DuPont
• Henkel
• Kimberly-Clark
• L’Oréal
• Procter & Gamble
• Unilever
• Abbott Laboratories
• Johnson & Johnson
• Merck
• Pfizer
• Sanofi
• Wyeth-Ayerst
77
Heavy, Resource-Driven Industries Include…
Water / Wastewater
Mining / Metals / Cement
Oil & Gas
Achieve low
long-term cost &
on-demand engineering
expertise with scalable
solutions.
Execute real-time
control & maintain
critical process
parameters to respond
to customer demands.
React to changing
production conditions
while maintaining
operations at peak
efficiency.
• Alcoa
• BHP Billiton
• CEMEX
• Holcim
• Lafarge
• Rio Tinto
• US Gypsum
• Vulcan
• BP
• Chevron
• ConocoPhillips
• ExxonMobil
• Shell
• A & E Firms
• Consultants
• Design Engineer Firms
• Design Institutes (Asia)
• Global Municipalities
• Privatizers (Europe)
• Pump OEMs
• System Integrators
Semiconductor / Electronics
Increase yields
while reducing risk
& total cost of
ownership by using a
single automation
control & information
infrastructure.
• Agilent
• Applied Materials
• ATS Automation
• Axcelis
• IDC / CH2M
• KLA-Tencor
• Novellus
• Praxair
• Seagate
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Automation for the Process Industry
Field Device
Integration & Asset
Management
System Core
Process Information
Critical Control &
Safety
Batch Management &
Control
System Migration
Tools
Process
Optimization
9
Rockwell Automation APC Portfolio
Increasing Effort & Increasing Value
Real-time Optimization
Model Predictive
Control
Pavilion8
Dynamic MPC
Nonlinear Multivariable Control
Linear Multivariable Control
Pavilion8
Inferential
SoftSensors
Sensors®
BasicFuzzy
Supervisory
Designer
Control
Advanced
Logix IMC,
Regulatory
CC, MMC
Control
Logix
Regulatory
PID, PIDE,
Control
AOI
10
Pavilion8 Dynamic MPC Architecture
FT Vantage Point
FT Security
FT LiveData
• Multivariable, Model
Predictive Control
• Linear and Non-Linear
Models
• Fixed and Variable
Dynamics
• Steady-State and
Dynamic Optimization
FT Historian
11
FT VantagePoint Integration
12
You can’t control what you can’t measure
• What if in-line sensors are
unavailable, unreliable, too expensive
Process
Samples
Process
Adjustments
Analysis
One hour
to one day
delay !
Lab Results
143.0
13
Solution: Soft Sensor
• Software model that predicts
process values based on
real-time process data
Process
Samples
Analysis
Process
Adjustments
Real-time
measurement!
143.0
Soft Sensor
Prediction Lab Results
u
 2u
= c2 2
t
t
Uo
+1

2c t 
-1
Real-time
Process Data
exp
( x -  )2
4c2 t
d
14
Announcing…
PlantPAx ModelBuilder
• PlantPAx Model Builder for off-line data
analysis and modeling
• SoftSensor Designer converts models to AOI’s
Process
Samples
Analysis
Process
Adjustments
Real-time
measurement!
143.0
Soft Sensor
Prediction
Real-time
Process Data
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Where can Soft Sensors be used?
Te Rapa D1 Moisture Prediction
IPT Moisture (% )
Raw VOA Moisture (% )
Biased VOA Moisture (% )
3.5
3.4
3.3
3.2
Moisture (%)
• Almost any continuous
process
• Examples:
3.1
3
2.9
2.8
– Powder moisture
– Polymer melt index & density
– Cement fineness and Blaine
– Ethanol concentration
– Crude oil distillation cut points
– Chemical distillation impurities
– Stack NOX emissions
– Paper strength properties
– Etc.
2.7
2.6
2.5
Time (h)
Prediction
Actual
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Starch Dryer Example
Output limit
SP
PID
Dried starch out
Tout
Time Delay
Tout Ctrl
Feeder Speed
SP
Tin Setpoint
PID
Valve
Position
VFD
Motor
Starch
feeder
Inlet temp
Inlet Temp Ctrl
Hot
Steam
Hot air & starch mixture
PID Temperature Control
12 bar
heat flow
2 bar
Hot
Water
Heat recovery
CTRL-valve(s)
Heat exchangers
T_Z1
T_Z2
Tin
Inlet air flow
inlet
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Starch Dryer Example
Moisture
Soft Sensor
Moisture
Lab Sensor
Output limit
Amb Air
Humidity
SP
IMC Moisture Control
IMC
Dried starch out
Time Delay
Starch density
Feeder Speed
Tin Setpoint
PID
Valve
Position
VFD
Motor
Starch
feeder
Inlet temp
Inlet Temp Ctrl
Hot
Steam
Hot air & starch mixture
Tout
Moisture Ctrl
SP
Sample
12 bar
heat flow
2 bar
Hot
Water
Heat recovery
CTRL-valve(s)
Heat exchangers
T_Z1
T_Z2
Tin
Inlet air flow
inlet
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Advanced Process Control & Optimization
ESTIMATED BENEFITS
IMPACT
Revenue
Increase production
Tighter product quality
2 – 10 %
10 – 50 %
Operating Cost
Reduce energy costs
Reduce off spec product
Reduce raw material use
2 – 10 %
5 – 10 %
2–5%
Working Capital
Increase asset utilization
Reduction in secondary material
5 – 20 %
2 – 10 %
19
Rockwell Automation APC Portfolio - 2009
Increasing Effort & Increasing Value
Real-time Optimization
FT Vantage Point
Model Predictive
Control
Nonlinear Multivariable Control
Pavilion8
Dynamic MPC
FT Security
Linear Multivariable Control
FT Historian
FT LiveData
Inferential Sensors
PlantPAx
Pavilion8 Soft
ModelBuilder
Sensors®
Basic Supervisory Control
Fuzzy Designer
Advanced Regulatory Control
Logix IMC, CC, MMC
Regulatory Control
Logix PID, PIDE, AOI
20
How We Maximize Operational Performance
Minimize operational variance
DV
CV
Transition effectively
CV
Follow operational plan
KEY TARGET
SPECIFICATION OR LIMIT
BEFORE MPC
WITH MPC
WITH OPTIMIZATION
TIME
CV
21
21
Pavilion Delivers Greater Value, Faster
Greater
Installed Value
Longer
Sustained Value
Project ROI Value
Faster Time
to Value
Alternate Investment
Pavilion’s Incremental
Value to Customer!
Copyright © 2009 Pavilion Technologies. All rights reserved.
22
22
ValueFirst® - Rockwell Automations
Business model for Process Opmization
23
Delivering Value to Market Leaders
Cement
Chemicals / Polymers
Minerals & Metals
Biofuels
Consumer Goods
24
24
Environmental Solutions
25
25
Questions?
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Automation og procesoptimering i produktion af

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