ppe13 conference at bradford

Prof Kang Li, Dr Jing Deng, Prof Eileen Harkin-Jones, Prof Mark Price, Dr Adrian Kelly

Dr Elaine Brown, Prof Phil Coates

Queen’s University Belfast , The University of Bradford

Energy and Condition Monitoring for Polymer Industry

– embedded with intelligent system optimization and control

k.li@qub.ac.uk

Save Energy from

• Unnecessary over heating

• Conservative setting

• Long machine start-up time

• Unacceptable quality

• Machine faults

• Changing materials

Killion KTS-100 laboratory single-screw extruder

PID

Controller

Heating band

Cooling FanExtruder

Barrel Zone

Temperature

Set

Temperature

DURAKOOL Mercury

displacement contactorTime-proportional control

Thermal energy consumption

Extruder Killion KTS-100

Material SABIC LDPE 2100TN00W

Cooling temperature setting: 25

Temperature setting: 170-180-190

(Feed, convey, metering)

Screw speed: 40 rpm

Energy and viscosity monitoring

Motor

Apparent

power

consumption

Power factor

Active power

Screw speed

Voltage

current

current

Screw speed

(amerature voltage model prediction)

V_a = 12.4222 * I + 0.0038 * N RBF network model trained by two-stage selection and

differential evolution

Proof of Concept

Integrating energy efficiency monitoring,

control and optimization for plastics industry

• Develop a new generation of low cost energy monitoring system which can be easily

integrated with existing or new processes and validate it on a wide range of extruders.

• Build intelligent energy efficient control and optimization system and merge functions

from 1.

• Patent the concept and develop a prototype system for dissemination and exhibition.

k.li@qub.ac.uk

Temperature controller