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Enhanced Process Control – Maximizing Coal Handling Preparation Plant Productivity

The benefits of various enhanced methodologies in process control are well documented and include safer operation, reduced environmental impact, and improved efficiencies, qualities, and throughputs [1, 2]. Numerous applications of these techniques exist in the fields of petrochemical, oil and gas, pulp and paper, and mineral processing. However, the application of these has been slow to filter through into coal preparation [3]. Variability associated with plant feed rates and the coal seam(s) often results in problems in achieving plant throughput and the desired quality. Since plants are generally designed to average feed specifications and as the feed material qualities change (more or less ash, fines, etc.), the plant operators and control system must compensate accordingly. This article will present two different case studies demonstrating the benefits achievable through improvements in process control techniques. The performance of industrial plants is significantly affected by control loop configuration and the effectiveness of the operator and the interface in use. The first case study will highlight the benefits of prototyping and simulating enhanced control schemes before implementation on the actual plant. The second case study demonstrates how to improve operator situation awareness through enhanced graphics techniques and process alarm rationalization.