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BrainWave HB filter

The solution for stabilizing hyperbaric filters and reducing energy consumption

Control stabilization with BrainWave

BrainWave is a patented advanced controller that outperforms traditional Proportional-Integral-Derivative (PID) control because of its two main components: an adaptive model and a predictive controller. BrainWave builds its own live models during normal plant operations, a powerful feature not offered by traditional Model Predictive Control (MPC) systems.

BrainWave’s predictive controller accurately forecasts process responses and accounts for multiple objectives. It adapts to process conditions, such as changes in production rate, keeping the process on target. BrainWave can also accept measured disturbance inputs, like raw materials properties, and takes corrective action before the process is pushed off target (PID, by comparison, must wait for the error to occur, and then react).

BrainWave easily integrates with existing control systems and its patented Laguerre technology means an average implementation time of just a few weeks. Best of all, the plant’s own staff can support and deploy BrainWave.

Control stabilization for hyperbaric filters

BrainWave is a proven control system that stabilizes the operation of hyperbaric filters, resulting in improved control of the final product moisture and reduced energy consumption.

One of the main issues in hyperbaric filter control is the over-drying of product, which can increase energy consumption. BrainWave accounts for transport delay times as the product moves through the filter to the online moisture measurement sensor. Further improvements to control are possible by monitoring incoming moisture content, either online or offline, and including this in the control strategy as a measurable feed-forward. This allows BrainWave to make control corrections as soon as the incoming moisture changes, instead of waiting for the exiting moisture to respond.

BrainWave is also able to reduce spikes in air pressure, which cause increased wear and excessive maintenance on equipment. It accomplishes this by stabilizing the moisture content measured at the filter exit by continuously adjusting air pressure.

Variations in fines or particle size cause the filter dynamics to change dramatically – a scenario not addressed by PID control. BrainWave, however, utilizes the particle size distribution, either as an online measurement or as a laboratory input, to adapt the control automatically, further improving filter efficiency consumption of the air blowers.

Hyperbaric filter at a mineral processing facility

Hyperbaric filter at a mineral processing facility

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ANDRITZ Inc., USA

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