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
Das hier ist Bild 14 links Das hier ist Bild 14 links
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...

This article appeared in

ZKG 02/2012

This article appeared in

ZKG 02/2012

Ressort:  Process
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