Implement supervisory/advisory control of pan and fugal stations
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Pan stage operations have a major influence on the quality of shipment sugar production, the processing efficiency of the centrifugal and dryer stations, the sugar recovery from final molasses and the steam consumption of raw sugar factories. As well, for many factories, the production capacity of the pan stage is often the rate limiting station of the factory, at least during mid-season operations. Several Australian factories now operate with only one pan stage operator and a management tool, such as the smart supervisory control system (SSCS) which was being developed in this project, would assist the operator in making better decisions for managing the stage. The SSCS compares the total projected boil-on rates for syrup and molasses (summed for each pan on the stage) with the forecast production of syrup based on cane receival data and the forecast production of A and B molasses from the centrifugals. By using the phase of each pan in an operational model the levels of syrup, A molasses and B molasses in the respective stock tanks are forecast and the information used to forewarn of potential problems or inefficiencies if current operating strategies are maintained. Alternative operating strategies such as changes to cycle times, use of swing pan(s) for A and B massecuite production can be explored to determine the preferred course of action. Unfortunately progress on the project had slowed due to unavailability of resources at CQUniversity and, as a result, SRA terminated the project. The project had almost reached the stage where the prototype SSCS was to be installed onto the pan stage at Macknade Mill. The development of the SSCS was undertaken in conjunction with Wilmar Sugar’s Computer Services staff in the Herbert region to suit the implementation onto Macknade Mill’s pan and fugal station. However the SSCS was developed as much as possible in modular form to facilitate the implementation into other Australian Mills. A final report “Implement supervisory/advisory control of pan and fugal stations – Final Report” is provided. This report describes the progress achieved in the project and discusses the aspects that require further development prior to prototype testing of the SSCS in the factory. The main outputs achieved in the project were:- • Upgrading of the models developed by Chief Investigator Dr Roland Dodd in his PhD thesis which was the forerunner to this project; • Preliminary development of the graphical user interface. The interface uses touchscreens to allow the operators, supervisors and factory management to input data in order to assess outcomes for various operational scenarios; • Procedures to estimate the sucrose and impurity quantities produced in syrup from juice analysis and the mass of each rake of cane; • Techniques to source CITECT and other factory data from read-only databases to suit the SSCS and the security of the factory’s data; • Procedures to determine the boil-on rates for syrup and A and B molasses for each phase of operation in each pan and the effect of net evaporation rate on the respective boil-on rates; • Procedures to determine the sugar production, and A and B molasses production and composition at the fugal station for intervals of 15 minutes; • Procedures to determine the appropriate operating conditions (e.g. steam rates, idle times) for each pan to suit a target cycle time; • Assessment of the potential to reduce and smooth the steam consumption on the pan stage. The evaluations undertaken at Macknade showed minimal scope for making large improvements in the pan stage steam consumption (rate and variation) but this outcome will be site dependent; and • Procedures that can be applied to recalibrate the key parameters in the SSCS because of inherent errors, assumptions and simplifications. Several parameters are available to assist with cross-checks and recalibrations. It is proposed that where possible the recalibrations of the key parameters will be undertaken frequently (e.g. every 24 h) using rolling averages and trends of data. At the time of termination the main work outstanding for the project was to implement the prototype SSCS into the pan stage control room at Macknade Mill on the dedicated computer and operator interface touchscreen. The original work program planned for a two year staged development within the factory once the prototype was installed, with the expectation that, after the first year of operation, further refinements would need to be implemented. A two year staged development program is still considered to be necessary. Once fully implemented the SSCS should result in improved use of the installed equipment on the pan and fugal stages to achieve increased sugar recovery, improved sugar quality and reduced steam consumption while fulfilling the production rate requirements. The outputs from the project address SRA’s Key Focus Area of providing technology to improve mill capital use, operating efficiency and sugar quality. Through the course of the project substantial support was provided by the management, supervisors and operators at Macknade Mill and by Mr Steven Dahlstrom of Wilmar Sugar’s Computer Services in the Herbert region. The project team greatly appreciates their assistance and support.
Please use this to cite or link to this itemhttp://hdl.handle.net/11079/14659
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