Model-based kiln control for green cement production

1 Diagram of the thermal clinker firing process

2 Contour of the coal and fluff flames for a multi-channel burner

3 Progression of the gas temperature and material bed in the kiln

4 Phase diagram along the rotary kiln resulting from the simulation

5 Phase diagram of the simulations with flames of varying heat

6 Methodology for developing the model-based controller

7 1D balance element for the kiln [4]

8 Comparison of the temperatures of the 1D-model (MODELICA) and the CFD-model [4]

9 Principle of the model-based observer

10 KHD kiln optimization system PYROEXPERT^®

12 Constant energy yield level at the kiln burner during the operational trial

13 Control actions in the operational trial

14 Model-based estimation of the temperature profile for solids and gas phase in the rotary kiln

11 Test runs on rotary kiln 5 in the Rüdersdorf plant

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Rüdersdorf cement plant

After the development of the models and the entire automation system was complete, the application of the model predictive control was successfully proved in an initial connection trial at the reference plant CEMEX OstZement in Rüdersdorf.

1 Introduction

Today numerical flow simulation (computational fluid dynamics; CFD) is an established tool for calculating combustion processes. The CFD simulation can demonstrate chemical and thermal interactions and provide local data for unknown process variables that cannot be measured. The information gathered in this way is used not only for detailed plant engineering for optimizing conditions for full combustion, product quality and the formation of hazardous substances, but it also provides an additional benefit for advanced process control.

In this article, the authors describe a tool...

Issue 3/2022 WUHAN UNIVERSITY OF TECHNOLOGY | ANSHAN JIDONG CEMENT CO. LTD

Numerical simulation of oxygen-enriched combustion in a rotary kiln in the primary air and the secondary air respectively

1 Introduction China is a major cement producer and consumer. According to statistics, China produced 2.4 billion?t of cement in 2020 [1]. The cement industry is also the main coal consumption and CO2...

Issue 7-8/2019 KARLSRUHE INSTITUTE OF TECHNOLOGY (KIT)