What is more difficult to create? A charcoal burning kiln or automated control system? This question is difficult to answer. What is more important?
It turned out that these two components make, in aggregate, the charcoal burning kiln a common life form. After the semi-annual testing of a pilot kiln, which demonstrated all its advantages, lightning “response” and high sensitivity to manual operations of controls (in manual mode), we made a conclusion that the kiln is worthy of the automated control system. A decision was made: to complete the kiln with the automated control system (ACS).
We engaged expert programmers who would solve set targets for this system creation. Then a technical assignment (TA) had to be prepared for programmers. Based on our semi-annual experience in the pilot kiln operation, it was not difficult to prepare a TA. Equipment selection and programming started simultaneously.
Reliable and high quality Swiss servomotors manufactured by Belimo were used as actuators.
A controller with specifically designed control boards for the ACS made a basis of a control cabinet.
A server and notebook solved the problem of data display regarding the kiln operation and control on the notebook monitor. The semi-annual testing of the ACS resulted in a program which made the kiln we strived to receive. The programming path was the same as the kiln birth path – from experienced software control via an experimental option to a production prototype. Thanks to meticulous work, we received a kiln with automatic control. This is the first kiln with software in this capacity segment (60–70 tons).
What is the ACS responsible for and what does it control?
Time interval between drying starts in each next retort.
Time interval between pyrolysis starts in each next retort.
Temperature control in the hearth and actuator control to maintain the temperature within required ranges.
Temperature control in each pyrolysis section.
Flue gas duct control in terms of excess heat emission.
Fixation of all the modes in the form of charts.
Control of discharge quantities and weight of manufactured products for any period.
Control of temperature modes in the drying complex.
This is not the entire list of duties charged with the ACS. Only automatic control of temperatures in the drying complex increased in the kiln capacity by 12 % as compared to the manual temperature control of the heat transfer medium delivered to the drying sections.
In addition to the above stated, remote access control system (RACS) elements located on equipment were also connected to the ACS using up-to-date wireless digital communication technologies. It may be used to monitor the kiln operation from any point of the world. A smart phone, graphic tablet, computer and Internet access give now a virtual opportunity to be present at equipment even when you are actually absent and to monitor all the processes, temperatures, charts, discharges, etc. on a real basis, on a mobile device screen.