Next generation of ECS/ProcessExpert® (PXP) solution

V9

The key quantifiable performance benefits include a 2-3% improvement from the previous version in terms of capacity and energy consumption, with an additional 10% reduction in standard deviation. However, the most significant enhancement is in utilization – the new version enables PXP to operate in automatic mode for more than 95% of the time. This allows plant operators to focus on other important tasks, representing a fundamental operational improvement compared to previous versions.

For cement producers with multiple kilns operating at different locations, the cloud-based PXP insights module provides essential visibility into performance across sites. It enables users to easily compare individual plants against group averages for metrics like heat consumption and production efficiency. This benchmarking capability helps identify both high-performing plants and those requiring attention, allowing more focused resource allocation. The entire analysis can be performed with just a few clicks, eliminating time-consuming manual data collection and comparison.

The new self-adaptive controller is specifically designed to handle varying process conditions more effectively than traditional controllers. Unlike static mathematical models where the rate of action is fixed, the adaptive controller can intelligently respond based on the deviation from target – acting more aggressively when needed and more conservatively when appropriate. This dynamic response capability enables the system to recover quickly from upset conditions and return to normal operation, significantly improving utilization rates and maintaining stable production.

The subscription model typically includes regular upgrades to the latest software versions. While I can't make absolute guarantees about major version upgrades because they may sometimes incorporate significant new technologies with additional costs, in general scenarios, an upgrade from version nine to ten would be included in the subscription model. This approach ensures customers maintain access to the latest features and improvements without requiring new capital expenditure approvals for each upgrade.

Our self-adaptive controller is based on patented technology from our US-based partner, Lin & Associates, who developed it initially for the oil and gas industry. Unlike traditional MPC systems with static parameters, this controller is self-learning and can predict outcomes using real-time data rather than historical information. The parameter tuning is dynamic, automatically adjusting based on process conditions, which eliminates the need for regular retuning or retraining. This built-in intelligence ensures long-term stability and high utilization rates without requiring constant adjustment by process engineers.

There is no hard limit on the number of kilns that can be controlled. Each kiln requires its own dedicated ProcessExpert application, but multiple applications can be implemented across a facility or enterprise. This modular approach ensures optimal performance for each piece of equipment while allowing for centralized monitoring and management across multiple production units.

In traditional Model Predictive Control (MPC) systems, we work with mathematical models that have static parameters – fixed values for process gain, time delay, and time constant. These fixed parameters determine how the controller responds, and if you want different responses for different process conditions, you typically need to configure multiple controllers. In contrast, our adaptive technology allows the tuning parameters to automatically change over time based on current process conditions. This dynamic adjustment capability is the fundamental difference that enables a single controller to effectively manage a wide range of operating scenarios.

Yes, the system is designed to be highly flexible and can be integrated with various control systems, including ABB. We've developed the architecture specifically to enable this type of cross-platform compatibility. The integration with existing equipment from different manufacturers is typically straightforward and doesn't require replacing your current control infrastructure.

The cement manufacturing process is inherently nonlinear, with constantly varying inputs like different alternative fuels and raw materials with varying properties. When these inputs change, the process naturally becomes disturbed, requiring quick, intelligent responses to maintain stability and efficiency. Version 9.1 excels specifically in these situations, providing very rapid responsiveness to process disturbances and maintaining stability at levels superior to any other control system we currently offer. This capability has been proven in real-time site operations, not just in simulations.

One of the system's key advantages is that it doesn't require specialized technical expertise beyond what's typically available at a cement plant. Process engineers or chemical engineers can be trained to operate and maintain the system. The user-friendly interface and intuitive design make it accessible to plant personnel, eliminating the need for specialized programming or automation expertise. Many of our customers run PXP applications on their own after receiving training, which demonstrates the system's approachability and ease of use.

Implementation typically begins with a detailed assessment of your current operations to identify specific optimization opportunities. We then configure the system to address your plant's unique characteristics and challenges. The commissioning phase is notably more efficient with version 9.1 due to the self-adaptive capabilities – we see high utilization rates even during initial implementation, which is unusual for advanced process control systems. Throughout the process, we provide comprehensive training to your team, ensuring they can effectively manage the system long-term.

With the subscription model, you pay only the implementation costs at the project start. After final acceptance and meeting the agreed success criteria, the service agreement begins with a fixed annual fee. This approach converts what would traditionally be a large capital expenditure into a predictable operational expense. The agreement typically runs for three years, during which you receive all software updates, proactive support, and remote monitoring services. At the end of the term, you can choose to renew or transition to a different arrangement.

Customers have reported heat consumption improvements of up to 5% and production increases of approximately 3%. Perhaps most impressively, we've seen alternative fuel usage increase by 16-17% at implementation sites. The system has also demonstrated exceptional utilization rates – even during commissioning, when traditional advanced control systems struggle to maintain automatic operation. These benefits translate directly to improved profitability, reduced environmental impact, and more consistent product quality.

The self-adaptive controller constantly monitors multiple process parameters and their complex interdependencies. When disturbances occur – such as changes in raw material properties or alternative fuel characteristics – the controller automatically adjusts its response parameters based on the specific conditions. This intelligence allows it to maintain target quality parameters with minimal deviation even during significant process variations. The result is more consistent product quality and reduced standard deviation in critical parameters like freelime, C3S, and LSF.

Three key factors separate our solution from alternatives. First, the self-adaptive technology provides unmatched performance in cement's highly nonlinear environment compared to traditional static control models. Second, our domain expertise in cement manufacturing – built over decades – is embedded in the system, making it specifically optimized for cement processes rather than being a general-purpose control solution. Finally, our flexible implementation approach and subscription model reduce financial barriers and ensure you always have access to the latest technological advancements without requiring new capital investments.