2014-15

Oil extraction plant automation

     The plant is designed to operate on two types of feedstock - sunflower seeds and soybeans, in this regard, the technological process at certain stages forks.

       Technological process of sunflower oil production contains:

  • cleaning of seeds on huller machines;
  • dividing of processed mass into fractions (kernel, husk, not fully processed, over processed);
  • heat treatment of seeds with steam conditioning;
  • hot pressing of the treated seeds in a screw press;
  • filtering of the oil after first pressing;
  • cooling of oil cake and transfer to extraction unit;
  • oil extraction;
  • oil gathering and storage;
  • gathering, storage and shipment of oil cake after extraction.
  Find more detailed information on oil extraction plant automation here:
Oil eaxtaction plant automation services in Ukraine Oil eaxtaction plant automation services in Ukraine
2012-13

Grain reception, storage, processing and preparation complex automation

Automated grain reception, storage, preparation and processing complex consists of several branches:

  • Department of feedstock weighing and receiving from road transport (carrying capacity up to 30 t);
  • Feedstock storage silos(concrete - volume about 20 thousand m3, metal - volume about 50 m3);
  • Dryers unit (capacity - 15 t/h 40 t/h 50 t/h).
     Main purpose of the complex is effective storage of the product, and provision of an oil extraction plant raw material for the manufacture of oil - sunflower seeds and soybeans. The versatility of the system allows to accept for storage and other bulk culture, read more:
2012-13

Boiler automation for biofuel combustion (sunflower husks)

     Boiler is designed to provide plant technological system with the steam (steam dryers, steam conditioning, filtration line , extraction unit). Sunflower husk is used as a fuel, which is the main waste product of the oil extraction plant.

Main technological equipment of the boiler is divided into several subsystems with separate control systems:

  • water treatment subsystem;
  • boiler control subsystem;
  • precipitator control subsystem.

      By means of transport equipment sunflower husk enters through the intermediate hopper the solid fuel boiler, where it is burned. Prepared feed water enters the boiler, where it becomes steam, which is used for production needs. Cleaning of flue gases is carried out by electrostatic precipitator. Dust, which is caught by the precipitator and products of combustion move to the ash hopper.

     Given process control systems is a top level automation system, which provides control, display, interchange and archiving of the whole boiler control process. It is shown on the boiler operator screen, read more:

 

2008-09

Fodder production line management system

     Combined feed (fodder) is a homogeneous mixture of forage resources (grain, bran, fodder of animal origin, mineral supplements) high in protein, vitamins and minerals for farm animals and poultry nutrition. Depending on fodder feeding value it is divided into: full fodder, mixed fodder concentrates, balancing fodder supplement (protein-vitamin, protein-vitamin-mineral) and premixes.

     Extrusion method is the most popular among all methods of animal feed production. It allows to improve the qualitative properties of the end product compared to traditional methods. During the production process the feed is effected by brief and very intense mechanical and barothermal impacts, which are followed by structural, mechanical and chemical feedstock changes. Due to the short duration of the process, vitamins and amino acids, which are contained in grains, are almost completely saved. And digestibility is increased to 90%. Extruded feedstock is practically not affected by bacteria when stored under normal warehouse conditions (for 3-4 months). This fact is of special value for the fattening of young animals (cattle, pigs, horses, rabbits, etc.). Feeding young animals with extruded feedstock 1,5-2 times reduces their gastrointestinal disease mortality. It should be noted that the quality of the finished product is not affected by humidity of the processed raw materials and possible small number of seeds of other crops.

     Flowsheet and equipment are selected depending on formulation and the manufactured feed, find out more:

 

2003-04

Automated control system of the fish processing unit

     Due to sterilization, canned food can be stored for a long period of time. There are lots of reasons in the canned food production, which may result storage period reduction. Some of the causes are: heterogeneity of heating of the jars in the autoclave, incomplete observance of technological process parameters - temperature, time intervals, in other words, sterilization formula and others.

     Therefore, constant equipment condition and production process monitoring are integral part of a technological process and necessary condition for the high quality products production.

     System development purpose: to provide modern means of process control, technical accounting of energy resources and ability to view and analyse archive process parameters

     As a result of implementing automated process control system, administration and staff of the fish processing plant got convenient and versatile tool to control technological process, as well as ability to archive process parameters, find out more:

 

2008

Software and hardware conveyor control complex

     Our team has developed and implemented hot rolled coil conveyor process control system for thin-sheet hot rolling mill, JSC "Zaporizhstal". The system provides emergency situations control, alarms and automatic shut down sections of the plant conveyors. SCADA TRACE MODE system and WinCon 8000 controllers have been selected as a tool of the process control system development.

     Conveyors are an integral part of the hot-strip mill-1680. Continuous thin-sheet hot rolling mill has capacity of 3.5 million tons/year; is designed for production of steel strip with thickness of 2,0...8,0 mm, width 1000...1500 mm from the slabs coming from the blooming unit more info:

 

2007-09

Electrical diagnostics system of the winder unit of hot-strip steel rolling plant

     The winder unit of hot-strip steel rolling plant has been designed for production of steel cross-section strip of 1.5…10 mm x 500…1830 mm, in rolls weighing up to 16 tonnes of slabs with thickness 145…175 mm. Length of the strip – up to 800 m. Productivity per shift – up to 4000 T.

     Mill equipment consists of 5 heating furnaces for 8-ton slabs, rough crate group "Duo" and 4 crates "quarto", intermediate roller with flying shears, finishing group of the crate "Duo" and 6 stands "quarto", outlet roller conveyor system with laminar cooling of the strip, 6 winders (3 were designed for 16-ton rolls(winder 1…3) and 3 – for 8-ton rolls (winder 4…6)), and system of roll transfer to the warehouse and to cold rolling shop cold rolling unit.

     Electrical equipment and software were developed for the winder equipment diagnostics automation. The introduction was made together with the staff of hot-strip mill of JSC "Zaporizhstal".

     Winders diagnostic system collects signals from winders electrical equipment of areas 1-6. Some signals are taken directly from the winders control area. Second part of the signals come from the winders electrical control cabinets.

     Economic effect was achieved by improving the quality of service, timely elimination of anomalies of equipment operation, reducing unplanned downtime of the mill, read more information:

 

 

2007

System diagnostics of bell-type furnaces thermal separation

     Main indicator of metallurgical production is quality of the products. Thus one of the most important elements of the technological process is heat treatment. All kinds of hot-rolled and cold-rolled steel have to be heat-treated: sheets, pieces, wires, rails, pipes, tapes, etc.

     During cold rolling, stamping or drawing the grains of the metal deform and crush. This effect is called hardening. The hardening increases metal hardness and reduces its ductility, causes brittleness. Recrystallization annealing is used to eliminate hardening. In the shops of cold rolling, recrystallization annealing is used as:

  • procedure prior to the cold processing of metals by pressure - in this case, the material becomes more ductile, easier for its further processing;
  • output type of heat treatment - end product or semi-finished product get the required production specifications;
  • intermediate step in the metal cold deformation process: annealing makes possible to remove hardening effectively.
     To implement this type of heat treatment in cold-rolling shop of JSC "Zaporizhstal" bell-type furnaces are used,  more info

 

2007

The packing band cutting machine control system

     Packing band cutting machine control system is intended for:
  • automatic control of machinery and electrical equipment of packing band cutting machine to provide the functions of cutting the band;
  • ensuring reliable and safe exploitation of the machine equipment.
     The purpose of the automatic cutting machine control system is to obtain economic benefit... more info

 

 

2007

The hardware-software complex of controlling of on-off cull ejector of the cross-cutting machine APR-1.

     The complex is intended to:
  • round the clock automatic control of mechanisms and electrical equipment of the ejector in order to provide the functions of sorting second-class sheets and accounting products;
  • ensuring reliable and safe exploitation of the machine equipment. more info

 

 

2006

The speed modes convolution machines control system

     Convolutional machines are intended for coiling the strip by bending the band between the rollers. The alternating current motor drive of each convolution machine is individual (AC motors with squirrel-cage rotor type ARM 2P74-10b 10 kW, 500 V, 50 Hz, 550 rev / min). Energy delivery to eight motors of each convolution machine is carried out by reversing variable frequency inverter with rated current of 400 A, voltage of 380 V and cycles of 50 Hz. The system provides a backup inverter for three convolution machines. more info

 

 

2005

The system of ordering a blast for a blast furnace BF-2

     In the process of melting in the blast furnace is required a continuous and uniform flow of air under an excess pressure of 0.2-0.5 MPa, heated to a temperature of 1000-1400°С. The amount of air supplied is usually 2-2.5 m3 / min per 1 m3 of the furnace’s extent/ (up to 7,000-11,000 m3 / min).

     The temperature and amount of flow of air is determined by the physico-chemical processes of melting, which in its turn greatly influences the change of furnace productivity and fuel consumption. The exposure the hot blast to the blast furnace process is especially effective when enriching it with oxygen supplied to the intake manifold blowing machine. In addition, directly to the tuyeres of the furnace can be supplied extra fuel - natural gas, coal dust, oil. more info

 

 

2005

The System of precise stop and passing defects through the mill stand in the reversing mill stand 1200 Metallurgical Plant.

     After hot drawing and pickling of rolls steel surface has many asperities, leave alone the fact that during the pickling in continuous units rolls are welded together and seams are formed. Whereas, when a defect or suture enters the mill stand, it is necessary to reduce the speed of the strip to prevent deformation of the rollers and provide better rolling. One roll can be rolled in a reversing mill to 3-7 times (passages). During the first pass, the speed reduction is carried out by the operator (notes defects). The automated system detects defects and on the next pass will automatically reduce speed during their passage through the cage. more info

2003-04

The automated control system of the unit of the measuring cut of steel strip.

     The unit of the measuring cut is a part of the technological chain of the machine PGA 1-4x400-1500 includes leveling machine (LPM) and the lower cut scissors (NNR).

     The roll-forming machine works on the process of shaping by piece. The material is rolled steel. The range of sizes of the mill includes bent channels of various configurations: equal channels, furring channels, C-channels, special channels, goffered sheet channels. The leveling machine is located in the line of the roll-forming machine behind the decoiler for rolls and is intended for ultimate straightening band coming from the unwinder. After a leveler the band is delivered to scissors with the lower cut for trimming the front end of the hot rolled strip, and cutting strips on dimensional (> 6 m) length.

     As a result of implementing the system employees received convenient and multifunctional tool for the process control, automatic cutting the strip, as well as the ability to control and analyze the archive of technological process parameters.  more info

 

 

Hardware-software complex of measuring relative rolling mill 1700-1(2) strip compression

     Temper rolling is carried out to improve the surface of the steel, and to produce surface hardening which is significant for sheets undergoing to further cold forming. It is a cold-rolled the strip with the magnitude a relative deformation of 1%.

     The complex is intended for measuring relative compression on the temper mill 1700-1 (2) with the possibility of displaying the measured value to the operator and the registration on a paper chart recorder.  more info

Software and hardware device to set the pace of rolling NTLS-1680

     The control system is based on industrial controller for harsh environments made by Schneider Electric (Series Momentum) and which is programmable via tool system Concept V.2.6 +. For all external signals, both incoming and outgoing is provided...more info

 

Software and hardware complex of controlling «Quarto» measure cut machine

     The complex is intended for day and nightautomatic control of mechanisms and electrical equipment of measure cut machine. Apart from cutting the strip it also provides counting sheets in a formed pack.

     The existing old machine control system was replaced by a system based on modern industrial controllers for harsh environments, and advanced sensors. more info

 

The system of the automatic control of the length of the strip between the pulling rollers and mill stand DUO in the loop pit of continuous pickling line NTA-1

     Contemporary high-speed strip processing lines require additional devices, creating metal reserve to provide continuous operation of the line. In the cold reduction of the strip departments there are continuous pickling lines, galvanizing, electrolytic tinning, annealing and cutting.

     During the continuous strip moving at a constant speed through the technological line arises the need of stopping head or tail part of the machine for welding the ends of rolls, the weld cutting, installing the roll on the uncoiler and removal of the roll from the winder after handling on the line.

     Currently, at the head and tail parts of the machine are installed devices providing a stock the strip for the welding process, as well as installation and removal of the roll. Such devices are loop pits with freely sagging loop. more info

 

2012

Automated control system of railway wheel rim hardness measurement node

     Railway wheels are in the list of the most critical elements of the rolling stock of the rail transport. While train movement the wheels are affected by static, cyclic and dynamic load, and in local areas (while slowing down) – by cyclic influences of high temperature. Every wheel element has a rapid time-varying system of compressive and tensile stresses. The voltage wheel–rail contact lead to breakages, most of which can be classified as rolling surface wair, thermal and contact–fatigue defects, brittle metal fracture.

     The most important railway wheels quality parameter is hardness. Hardness requirements for wheels are established by national and international standards.

     Automated control system of railway wheel rim hardness measurement node was created to fulfill the railroad wheels quality requirements, and is based on EMKO hardness tester see more information:

 

2014

SCADA-system the chemical water treatment line

     Production of semiconductor silicon requires purified water with low content of suspended solids, metal and acid ions, gases, organic substances and microorganisms.

Tasks of water treatment for production are:

  • disinfection of water (purification from microorganisms);
  • mechanical impurities filteration;
  • clarification (removal of iron and manganese);
  • desalination;
  • degassing (oxygen removal).

     Analysis of water used on semiconductor plants is generally done according to following criteria:

  • electrical resistivity (conductivity);
  • oxidation
  • silica content

     The main treatment technologies methods are distillation and ion-exchange resin transmission. After one or two stages of distillation water electrical resistivity reaches 0.3-0.5 MO*sm, and on the output of ion exchange units - 1-20 MOm*sm. find out more

 

2014

SCADA-system of aeration device.

   Transloading of bulk materials is the most common operation in processing of mineral raw materials. The process of moving of bulk materials is accompanied by significant dust emissions. The agglomerate transloading process results the biggest emission of dust. Additionally, you must clear air from harmful substances produced during the solid-fuel combustion.

   To reduce dust emission during such production aeration devices are widely used. Their usage allows not only to protect the environment from industrial waste, but also to get economic benefits by returning to the production cycle of dustlike raw material. more info

2013

Automatic control system of a cell-type cooling tower.

     The cooling tower is a device for cooling a large amount of water by directed air flow. Cooling towers are used in water recycling systems for cooling heat exchangers.

     In mechanical-draft cooling tower the cooling process is going on due to evaporation of a part of water when its runoff by a cooling tower filler along which in the opposite direction of the water movement the flow of air is supplied. Evaporation of 1% water leads to decrease in the temperature of the remaining water mass to 5,48оС.

     Automatic control system of a cell-type cooling tower is intended for the fan control using frequency converters. more info

 

 

2012

Automatic control system of the vacuum-ammonium drying section.

     To form a ceramic shell the refractory coating is subjected to air, air-ammonia and ammonium-vacuum drying. The practice shows, the drying duration depends on the number of applied layers and model complexity and differs significantly for different methods. Thus, it is possible to dry coating on air for 4-10 hours, air-ammonia drying lasts for 1-3.5 hours. The most rapid way is the ammonium-vacuum drying which takes from 15 to 30 minutes.

     At the end of the process the model composition is removed from shells by melting of different methods (in hot water; in the molten model composition of the same brand, with hot air) at temperatures of 96-200оС.

     To monitor the progress of the drying process and management of the unit the ACS is created... more info

 

2012

Remote control system of cylinder oxygen filling on the water ramps

     Nowadays oxygen has wide application in metallurgy, chemical, petrochemical, pulp and paper, food industries, power engineering, medicine and agriculture. It is obtained from air by cryogenic distillation and water electrolysis.

     Oxygen is transported in cylinders. To fill them up gas is supplied through the pipeline to the filling manifold—ramp, to which the cylinders are attached. Filling manifold consists of two identical branches, branch connection node and racks. There are valves for connecting the cylinders on each branch and one end valve for pulling the gas from the branch. The connection node of the branches consists of two valves (gas flow into the branches), pressure gauge and safety valve.

     Filling ramps are of two types:

  • 2 x 5 — fill up five cylinders in every branch of the ramp (used for oxygen plants, proizvoditlnost to 30 m3/h)
  • 2 x 10 — to each branch of the ramp are attached ten cylinders.
     When filling up a large number of cylinders, up to 20 cylinderscan be attached to each branch, read more:

 

 

2012

Mobile system for remote monitoring and control.

     Today, an important criterion of any enterprise is the ability to provide information on the results of its work. The ability to obtain this information should not be limited by the territorial location of the user and the presence of computer at the time of receiving the information. It is important that the data should be protected against unauthorized access.

     The widespread use of compact devices (phones, tablets), running on the Android operating system, makes it possible to affirm that you can create applications that provide users with obtaining information on this platform.

     This mobile system has been developed to monitor the production at the oil-extraction plant. Providing remote monitoring of the arrival of raw materials to the main technological line, as well as receiving information on the output of finished products. more info

 

The control system of sand-throwing machine PN-40

     In a case of batch production, large-scale and mass production of castings to improve the quality and increase the productivity of labor machine methods of making molds are used. At the same time, along with molding machines in cast shops sand-throwing machines are used.

     The sand-throwing machine is throwing molding machine, which throws a moldable mixture in the flask at the same time filling it and making compaction of the mixture. Usually, sand-throwing machine are used to stuff medium and large forms, since the size is too small flask obtained significant loss of molding sand, and since the size of the flask is too small there it can result significant loss of molding sand, because of missed sand while stuffing near the edge of the flask. The following types of sand-throwing machines are:

  • stationary two-armed;
  • movable console;
  • bridge;
  • outboard... more info