QCX/BlendExpert

Controls the proportioning of raw material feed to stockpiles, raw mills and cement mills

Quality Control Blend Cement Mills QCX BlendExpert blending blenddesigner blendmaster Mixer
  • Application
  • Software Functionality
  • Features and Optimising

QCX/BlendExpert™ controls the proportioning of raw material feed to stockpiles, raw mills and cement mills or other process blending systems to obtain the desired chemical product quality with respect to chemical constraints, process constraints, material costs etc. Complemented by functionality for quarry operation planning and chemical mass balance and mix design calculations the QCX/BlendExpert suite of application modules supports quality optimization from quarry to bagged cement.

The typical application of QCX/BlendExpert is material feed set-point control based on periodical analysis of representative samples of the controlled material stream. The analysis data are received automatically from the laboratory XRF spectrometer and/or from on-line XRF or PGNAA analysis devices. Upon completion of an analysis cycle, new feeder set-points are calculated and automatically positioned. The control algorithms support off-line control modes (e.g. manual set point positioning or operator inserted analysis/production figures).

Stockpile accounting and associated application specific control utilities are supported by the QCX/BlendExpert-Pile application module. Recent software development focuses on PGNAA applications and offers unique accounting and graphic data presentation facilities. Raw and cement mill control applications are handled by the QCX/BlendExpert-Mill module.

The QCX/BlendExpert software is licensed to the number and type of stockpiles, number of raw mills and number of cement mills. The simulation option is also licensed separately. Key configuration parameters such as number of material sources for a stockpile, number of feeders for a mill, delay/retention times for the process equipment, silo system specifications and much, much more are accessible to the user. This Product Profile mainly addresses general QCX/BlendExpert features. Please refer to the QCX/BlendExpert-Pile respectively QCX/BlendExpert-Mill Product Profiles for application specific details. 

Applying object oriented programming techniques, the QCX/BlendExpert software features and associated data are structured in these functional blocks:
 
 
 

Feed/mix analysis

In a combination with the basic QCX/Laboratory features, the software offers support for:

  • automatic data acquisition from the laboratory XRF spectrometer and/or on-line analysis devices. Data from more analytical devices may be combined to support alternative control strategies as well as redundancy
  • off-line entering of product mix and raw material analyses
  • automatic feed forward of raw material analysis either from stockpiles or from raw material sample groups (incl data filtering/screening features)
  • calculation of cement chemical modules and quality deviations for product mix

 

Production accounting

Through it’s integration with the process I/O features of the ECS software platform, the QCX software facilitates on-line automatic process data acquisition and combines these data with analytical data as required for the mix optimization task. The accounting schemes comprise:

Stockpiles

  • individual or combined process streams from multiple sources through single or multiple crushers
  • product mix accounting on longitudinal or circular stockpiles

 

Mills

  • individual feeders, dust, fuel ash (and by pass) 
  •  single or multiple/parallel samplers
  • product mix and product type sorted feed to continuous type or batch type silo systems

 

Analysis estimation
When the raw material analyses - due to natural fluctuations - are poorly determined, these advanced analysis estimation and control bias compensation techniques are available (normally applied for mill control only):

Mills

  • single feed estimation (back-calculation)
  • multiple feed estimation using a time-varying Kalman filter with variable forgetting factors
  • control bias compensation

Features

Through it's integration with the QCX system structure and the involved process equipment and analytical devices, QCX/BlendExpert provides on-line and automatic data acquisition from the process and the relevant analytical device(s) and combines automatically the collected data as required for the mix optimization task.

QCX/BlendExpert optimization is based on a unique combination of linear and quadratic equation algorithms incorporating multi-variable adaptive or predictive control techniques. This combination ensures optimal solutions even when operating under various process constraints. The module includes advanced analysis estimation facilities for use in situations where the raw material analyses - due to natural fluctuations - are poorly determined in beforehand.

The optimising algorithms ensures at all times the best possible control under the constraints of the actual operational conditions. Chemical target set points can be defined using terms as 'greater than', 'less than', 'range' and 'equal to'.

The software structure allows the user to configure and later on modify the material accounting and associated control in accordance with the actual process lay-out and the desired control strategy. Standard software features for mill control - whether based on traditional lab X-ray analysis or on-line analysis techniques - include: 

  • On-line Production Accounting
  • On-line set point control
  • Sample Analysis Calculation
  • Composition Estimation
  • Raw Material Proportioning

 


Optimising 

QCX/BlendExpert optimization is based on a unique combination of linear and quadratic equation algorithms incorporating multi-variable adaptive or predictive control techniques. This combination ensures optimal solutions even when operating under various process constraints:

  • linear quadratic optimization techniques
  • adaptive and/or model based predictive control optimization in accordance with the relevant process equipment dynamics, material transport delays and storage system characteristics
  • advanced priority selection between multiple sets of control set-points/set-point ranges. For each so-called constraint set (or priority set), individual optimizing parameters can be applied. Where conventional control methods often under constraint situations results in poor control, this unique approach means that best possible expert control is always achieved.
  • Chemical target set points can be defined using terms as ‘greater than’, ‘less than’, ‘range’ and ‘equal to’.
  • material cost is possible as optimization parameter.
  • a wide range of coordinated optimizing and set-point control utilities for automatic handling of disturbances/events such as feeder blockages, feeder start/stop, deviation between demanded and realized feed, changes in total mill production etc.

 


Brochure:

QCX/BlendExpert
Download: English Russian French

 

QCX/BlendDesigner

 

QCX/BlendMaster

 

Automated Quarry Logistics

 

QCX/BlendExpert Case Story
Download: English