Products
Process control and optimisation
Process optimisation
ECS/ProcessExpert® advanced process control software

ECS/ProcessExpert® advanced process control software

Increase production, cut costs, and reduce energy consumption and carbon footprint

Specifically designed for the challenges faced by the cement industry, our ECS/ProcessExpert solution - the software commonly referred to as "PXP" - is your platform for improved performance. Based on state-of-the-art process optimisation and artificial intelligence technologies, it enables your plant to raise production, reduce costs, and extend equipment life.
ECS/ProcessExpert® advanced process control software

What we offer

An intelligent control solution for the cement industry

Our ECS/ProcessExpert software provides advanced process control and optimization for the cement industry. Bringing together our experience and knowledge of the cement making process with the most advanced control technologies, it delivers maximum efficiency and higher profitability, while also supports your sustainability ambitions, including reduced carbon emissions and higher alternative fuel substitution rates.

HMI for ECS/ProcessExpert software

Key Benefits

Improve your bottom line

01

Increase production and cut energy consumption by up to 7%

Our advanced process control software delivers unparalleled process stability for optimal productivity and efficiency. A typical production increase of up to 7% is the result, alongside a similar reduction in energy consumption – with significantly higher values in the double digits reported at some plants.
02

Lower CO2 emissions by up 2% and cut NOX emissions

An unstable pyroprocess is a headache. Our advanced process control software offers the cure. By stabilising kiln and cooler operations, it not only improves process efficiency, productivity, and product quality; it also reduces CO2 and NOX emissions.
03

Reduce equipment wear and minimise downtime

Running your plant under less-than-optimum conditions takes a toll on your equipment, reducing the life of assets and potentially resulting in costly downtime. Our advanced process control software reduces wear on your assets by ensuring optimum and stable operating conditions throughout the process.
04

Deliver ROI with a year

We’ve built the ECS/ProcessExpert solution to increase productivity by reducing costs and lifting output. The result? It quickly has you producing more with less for rapid return on investment.
05

Reduce process and quality variability by up to 40%

Using the latest process control techniques to continuously analyse and precisely adjust process conditions, even correcting for process disruptions, our advanced process control software delivers a significant reduction in process variability, which is reflected improved consistency in product quality.
Product features
Developed by cement experts for the cement industry

What set’s our ECS/ProcessExpert software apart from competitors? Two words: domain expertise. Our software is the only known advanced process control solution built for the cement industry by cement industry experts. It means you can be confident in the ability of our software to make an impact at your plant. You’ll also have the support of our remote team of experts to make sure the system is working as you need it to. ECS/ProcessExpert solutions are available for:

Pyroprocess
An unstable pyroprocess is a headache, leading to inefficient production and variable clinker quality. The ECS/ProcessExpert® software avoids these negative outcomes by stabilising kiln and cooler operations, resulting in an increase in production, fewer cyclone blockages, reduced kiln ring formation, more consistent clinker quality, and lower emissions. In addition, a customisable fuel distribution module enables plants to increase alternative fuel substitutions rates by ensuing the optimum fuel mix, based on cost and heat value, to deliver a reliably stable process, however variable the input material.
Vertical roller mills
Vertical roller mills are recognised for their higher efficiency compared to ball mills; however, they operate in a fast-changing, dynamic environment that requires close attention to process conditions. Fully automatic control via the ECS/ProcessExpert software improves the mill’s operating capabilities and efficiency, resulting in a reduction in specific power consumption and tighter control of the mill conditions. The solution also includes a ramp-up option, to deliver a smooth, controlled start-up of the mill that rapidly achieves process stability and minimises machine wear.
Ball mills
Ball mills are energy intensive machines. The ECS/ProcessExpert software is designed to deliver lower specific power consumption, while ensuring correct product fineness is achieved. It automatically adjusts fresh feed to ensure best-possible throughput and quality for any given cement recipe. For grinding circuits that produce a range of different cements, it also automates the switch between product types, via a range of predefined recipes, for quicker, more efficient changeover.

MODULES AND TECHNOLOGIES

Combining process control and AI technologies Our ECS/ProcessExpert software uses advanced techniques such as self-adaptive control, model predictive control fuzzy logic rules, and user defined programs to handle a wide range of process challenges and deliver best-possible operation of pyroprocess and milling operations.

Out-of-the-box features and functionality

• Smart objects: intelligent process objects that integrate process and control engineering knowledge. • Modelling tool that helps find the process variables and actuators correlating to the model. • Fuel distribution (pyroprocess) module for controlling the use of alternative fuels in the kiln. • Module for controlling recipe changes in the raw and finish mills. • Mill ramp-up facilitates ramp-up of grinding circuits, ensuring nominal production is achieved faster and with less process variability. • Target adaptation continuously adapts the operational targets to ensure maximum production and minimum fuel/energy consumption are achieved. • Advisory mode recommends actions to the operators when the system is not in operation. • Holistic solutions that optimize mill and kiln operation, customized to each plant. • Decision tree component illustrates the process status and reveals the underlying reasons to the operator.

downloads

Brochures

ECS/ProcessExpert Advanced process control for ball mill circuits

(0.78 MB) | Language: English

ECS/ProcessExpert Advanced process control for kilns and coolers

(3.56 MB) | Language: English

ECS/ProcessExpert Advanced process control for vertical roller mills

(1.54 MB) | Language: English

ECS/ProcessExpert Solution - Advanced process control

(2.40 MB) | Language: English