Sparrows Point On-line PSA

04/11/2004APS

SPARROWS POINT

SPP facts
SPP production: 80,000 mt/month of slag grade 120; Blaine target: 4700; fineness target: 8.0 - 12.0 2 to 3 type of raw slag used @ 100% or mixed 2 process lines
closed circuit w/ Aerofall ball mill @ 56 T/h and Humbolt-Wedag 2nd generation seperator @ 60 T/h. PSAs on each line

LUCIE installed on one process line since July 2003 but not fully operational
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Quality control overview

Pre-production: Quality lab has 24 to 48 hours to review chemistry of raw slag and predict relative hydraulic potential of the slag In production: Product fineness Post-production Physical testing: SAI or compressive strength, air content, retention on a 325 sieve, Blaine Chemical testing: sulfide sulfur and sulfur trioxide
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Past issues
Oil on windows
corrective actions: heatless dryer

Blockage of motor
corrective actions: add air flow at auger level to flush product and increased fuse amps

Inconstant flow: at mill stoppage and unidentified events

corrective actions: increase diameter of holes #1 and #3 to 3/8" in flute protecting sampling system screw in chute
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Modifications
air

sdsf sdfs fdg fdg df

Air flow at auger level

04/11/2004APS

Flute: holes changes

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Quality control parameters

Dv(50) ~ damper position for large scale control %<20 ~ separator speed for fine control

04/11/2004APS

SPARROWS POINT

Control logic for damper position

2 * 4-20 mA signals sent to plant PLC: Dv(50) scaled to 7-13 :
Particle size target is correlated to chemical composition Part_size analysis (X-Ray test every 6 hours)
SP
Process MALVERN

4-20 mA

Part_size PV
Plant PLC

7-13

Plant equipment

Operator OR % Wonderware correction OR LUCIE

7

04/11/2004APS

SPARROWS POINT

Control logic for damper position

Currently:
[Dv(50)] Damper position correct. Average time Wait time

< 0.2
0.2 [Dv(50)] < 0.3 0.3 [Dv(50)] < 0.4 0.4 [Dv(50)] < 0.5 0.5 [Dv(50)] < 0.6 0.6 [Dv(50)]

0%
1% 2% 3% 4% 5%

5 min
5 min 5 min 5 min 5 min 5 min

10 min
10 min 10min 10 min 10 min 10 min

04/11/2004APS

SPARROWS POINT

Control logic (ctd)

In June, when LUCIE is controlling the system,
Use of Dv(50) to control damper position Use of %<20 to control separator speed: initial thoughts are to average Part_size value over 5 min and adjust speed separator every 20 minutes

04/11/2004APS

SPARROWS POINT

Control logic (ctd)

[Dv(50)] correction Average time Wait time

< 0.2
separator 0.2 [Dv(50)] < 0.3 0.3 [Dv(50)] < 0.4 0.4 [Dv(50)] < 0.7 damper 0.7 [Dv(50)] < 1 1 [Dv(50)]

0%
? ? 5% 7% 10%

5 min
5 min 5 min 5 min 5 min 5 min

30 min
20 min 20 min 10 min 5 min 5 min

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Reliability&Utilization
Machines have not been in automatic mode for more than 1 day LUCIE team at SPP in June 04 to finalize installation on A mill circuit and set the controls to both circuits. Performance and benefits will be monitored once data have been gathered.
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Next steps
Installation of LUCIE on process line A Change correlation between Part. Size target and each type of raw slag Monitor Dv(50) (actual, target and STD), %<20, fineness, speed separator, TPH and kW Find correlation and % correction for control of separator speed control via %<20 Post and update results on Process portal
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Unresolved issues
Flow of product which creates drift of reading and long term instability Needs of close monitoring of the machine We hope to solve those issues by adding auto air purge to fight the stickiness of the product on the walls of flute. This purge would be controlled from the control room
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Thank you
Questions? Comments?

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Current system

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Process overview

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