Development and Application of AI+APC(Advanced Process Control)Intelligent Control in Limestone Crushing
ZHANG Chuang
GU Zhibin
MA Chunhui
LI Zhidan
WEI Can
Abstract：To address the issues of manual operation dependence,delayed oversized material identification,insufficient production optimization,and crude dust collection control in the limestone crushing system of a cement production line in Huaikan,Huzhou,an intelligent system solution based on"AI Video Analytics+APC Intelligent Control"was developed.The technical solution primarily includes:AI Video Analytics(Cameras deployed at the unloading pit utilize the YOLO object detection algorithm to identify large/oversized material blocks and mud chunks in real-time,triggering voice alarms and interlocking control with the control system)、APC Intelligent Control(Centered on multivariable model predictive control(MPC),it establishes production optimization and dust control loops;dynamically adjusts the speed of the plate feeder and optimizes current setpoints;Automatically sets negative pressure values based on dust escape detection and regulates the dust collector fan's damper opening)、DCS Function Upgrades(Added one-click start/stop functionality with standardized start/stop durations;Implemented differentiated responses to active/passive material interruptions;Enabled seamless APC-group control handover).After deployment,the system reduced average power consumption to 0.975kW·h/t,increased integrated unit output to 877.24t/h,significantly lowered operator workload,reduced blockage risks,and simultaneously improved capacity utilization and environmental performance.
Keywords：limestone crushing systemAI video analyticsAPC(Advanced Process Control)intelligent controlOne-Click start/stopproduction optimization
Publication Date：2025-07-25
Online Publishing Date：2025-08-15(First online date of this platform, not the publication date of the document)
Pages：7( 52-58 )