Method for optimally processing materials in a machine

A method for processing material in a machine having at least one processing zone, said method comprising:

• providing at least one modular environmental control unit measuring at least one processing performance parameter;
• and
• at least partially controlling the at least one processing performance parameter in accordance with a predetermined optimal control strategy by deliberately applying a gas flow conditioned by at least one controlling parameter, said gas flow being applied to the at least one processing zone of the machine by at least one modular environmental control unit;
• the modular environmental control unit including
• at least one of a gas flow source element and a gas flow capture element,
• a mechanism for selectively positioning said at least one of a gas flow source element and a gas flow capture element in a mechanically predetermined operate position proximate the at least one processing zone, or in a mechanically predetermined retracted position,
• elements to control conditions of the gas flow, and
• at least one blower for causing gas flow through the at least one processing zone of the machine.

A method for optimally processing input materials into output materials wherein the method is carried out in a materials processing machine having at least one processing zone, with said machine operating near target operating point parameters, said method comprising the steps of:

• providing a range of input material having parameters corresponding to a usable range of such input material, including a substantially complete set of samples of various usable qualities of the input material available;
• operating the machinery over the entire range of provided input materials to generate output materials having a range of output material parameters;
• varying environmental parameters within the at least one processing zone over a range of environmental parameters while operating the machine over the range of input material to generate the output material such that substantially all combinations of input materials and environmental parameters are used to generate output materials;
• testing the input and output materials to determine various output material parameters at substantially all combinations of input material parameters and environmental parameters;
• generating a database of substantially all combinations of input material parameters, process zone environmental parameters, and output material parameters;
• selecting a target operating point including at least one parameter selected from the group consisting of input material parameters, process zone environmental parameters, and output material parameters;
• defining a model of machinery performance based upon a selected portion of the database which is within a predetermined region of the target operating point;
• using the model for determining at least one optimal parameter from the group consisting of the optimal input material parameters, the optimal process zone environmental parameters, and the optimal output material parameters;
• and
• operating the machinery to process input material and to produce output material in accordance with the selected optimal parameter being within acceptable variability of the target operating point.

A method for selecting input materials having optimal input material parameters for input into materials processing machinery to achieve an output of material parameters corresponding to a target operating point, comprising the steps of:

• determining a machinery model which simulates the operation of a materials processing machine given a range of input materials parameters by:
• a. measuring materials processing machinery characteristics over ranges of operational settings and environmental parameters within processing zones, said characteristics defining the interrelationships between input materials parameters and output materials parameters over said ranges of machinery settings and environmental parameters;
• and
• b. defining said machinery model from said machinery characteristics;
• determining characteristics of a desired output materials parameter or profit;
• introducing said output material parameters into said machinery model which determines the optimum range of input material parameters;
• selecting input materials having parameters coinciding, within an acceptable range of variability, with the determined optimum range of input materials parameters;
• providing said selected input materials as input to a materials processing machine;
• and
• operating the machinery with the selected input materials to produce the output corresponding to the target operating point.

A method for optimally processing materials in a plurality of sequentially related materials processing machines, each of which has a material input, a material output and a processing zone, said method comprising the steps of:

• determining a composite machinery model which simulates the operation of the plurality of materials processing machines by:
• measuring materials processing machinery characteristics over ranges of operational settings and ranges of environmental parameters within the processing zones for each of the machines, said characteristics defining the interrelationships between input material parameters and output material parameters over said ranges of machinery operational settings and environmental parameters within the processing zones, and
• defining the composite machinery model from said measured characteristics;
• measuring input material parameters at the inputs to said material processing machines at least at a second, later time;
• introducing said input material parameters into the composite model and then determining settings and environmental parameters for each machine, within a predetermined range of acceptable variation;
• adjusting said settings and environmental parameters to optimize at least one output parameter;
• and
• processing materials with said optimally adjusted machines.