PiT NAVIGATOR | IT Solution (Cement)

Powitec's PiT Navigator guarantees an optimal sintering process despite fluctuating calorific values (especially regarding use of alternative fuels), inconsistent raw material and quickly changing process conditions:

+ Optically based intelligent process control

+ Self-learning and re-training NMPC

+ Easy to use with low follow up costs

+ Burner control

= Reduction of primary fuel consumption

= Increase alternative fuels

= Low complexity and reduction of work load for operating personnel

= Stable clinker quality with low fluctuations

Features
Functional Overview
Advantages
Brochures/Documents

Adaptive self learning software.
Integration of digital optical information.
Fast start up and little customer personnel burden.
Permanent optimizing software for calciner, kiln, burner, and cooler.
PiT Navigator includes features of PiT Predictor.
'Seeing' and 'learning' control.
Intelligent burner adjustments.
Permanent prediction of free lime or other key parameters.
RGB camera technology: Precise temperature extraction not affected by distances to the object (no body radiation thermography)
Electronic Dust Filter: Digital filter against cyclical dust development.
High Temperature Range: 800 – 2000°C
Flame Characteristic Extraction: Precise information from the flame, clinker bed and coating behaviour
“Polylines”: chronological illustration of temperature development
Regions of Interest: Free definable measuring zones
Color Coding: Easy understandable thermographic pictures
Highly suitable source for digital image processing
Applicable to any existing DCS.
Low follow up costs.
Open and flexible solution.
Fast success and payback.

Powitec's PiT Navigator controls and optimizes the complex clinker production process in rotary kilns. Powitec's state-of-the-art kiln control combines self-learning, re-training software based on neural networks (NMPC – Non-Linear Model Predictive Control) and digital image processing of the sintering zone. Contrary to expert systems and conventional NMPC optimizers the PiT Navigator needs no manual re-training in case of changes in the process conditions (e.g. wearing of plant components, equipment modifications etc.). Powitec's PiT Navigator automatically adapts to these changes, determines their influence on the process results, re-adjusts the process models and steers the process according to the given targets. Even competing targets can also be controlled simultaneously! The PiT Navigator computes the ideal settings of the process actuators and automatically transmits set-point corrections to the DCS.

Stabile kiln operation and clinker quality.
Increased clinker production volume (up to 5%)
Reduced primary fuel consumption (up to 5%)
Increased alternative fuel usage (up to 100%)
Reduced emissions (NOx and CO2)
Increased kiln reliability and availability.
Long-term reduction of maintenance and repairs costs (refractory material!)
Vs. Expert Systems: No additional reprogramming and follow-up services. necessary (total cost of ownership!)
Reduction of NOx and CO in flue gas, reduction of flue gas treatment costs (lower NH3 and urea consumption)
Quick implementation: 12 weeks until start up.
Stress reduction and less routine work for kiln operators -> working results improve.
Reduced dependency on highly qualified and experienced operators.
Gain in flexibility with regards to changes in energy/fuel types.
Documentation of operation procedures for security and training purposes.