A CAPE-Taguchi combined method to optimize a NPK fertilizer plant including population balance modeling of granulation-drying rotary drum reactor

Herce, Carlos; Gil, Ana Jesús Mateos; Gil, Miguel; Cortés, Cristóbal

doi:10.1016/b978-0-444-63965-3.50010-6

Cited by 6 publications

(6 citation statements)

References 5 publications

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“…Control and operation of a granulation loop is still challenging. Some research papers with focus on process control of the granulation process are (Buck et al, 2016;Ramachandran and Chaudhury, 2012;Herce et al, 2017;Ramachandran et al, 2009;Valiulis and Simutis, 2009;Wang et al, 2006;Cameron et al, 2005).…”

Section: Production Challengesmentioning

confidence: 99%

Fertilizer Granulation: Comparison of Modeling Languages

Farzin¹,

Vesjolaja²,

Lie³

2021

Linköping Electronic Conference Proceedings

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Industrially produced fertilizers are of key importance to produce enough food for a growing global population. Ongoing work deals with models of the granulation loop in fertilizer production, based on a population balance that finds the particle size distribution of the product. The model is intended for control design in order to dampen or remove production oscillation for reduced energy consumption and improved product quality. In this paper, efficiency of model implementation is studied in addition to the possibility to automate the computation of a linear approximation of the model for control synthesis. In the implementation study, the current tailor-made MATLAB solver for the model was cloned in computer language Julia. In addition, the implementations in both languages (MATLAB, Julia) were rewritten in a form that allows for use of the standard differential equation solvers of the respective languages. Results indicate that by changing from the tailor-made solvers to using the built-in solvers leads to a speed increase in the order of 6 times. Furthermore, results indicate that the Julia implementations are ca. 5 times faster than the MATLAB implementations. Overall, the fastest Julia implementation was 36 times faster than the current MATLAB implementation. The MATLAB execution can be sped up by using MAT-LAB Coder to convert the code to efficient C-code which is then used to generate a DLL. DLLs can be executed virtually without overhead from Julia. By measuring the execution time for the C-code/DLL vs. a similar implementation in pure Julia, the pure Julia code is ca. 12% faster than the compiled C code. Next, the possibility of automatic linearization of the population balance model in Julia is studied. This is shown to be relatively straightforward. The linear approximation is very good for an input perturbation of 10%, and relatively good for an input perturbation of 50%. This indicates that it may be possible to use a linear model approximation for control design.

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Section: Production Challengesmentioning

confidence: 99%

Fertilizer Granulation: Comparison of Modeling Languages

Farzin¹,

Vesjolaja²,

Lie³

2021

Linköping Electronic Conference Proceedings

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“…Mathematical modeling of the granulation processes for control studies is commonly performed using the population balance (PB) principle [26]. In [3], [18], [23], [31], [30], [7], [25], [28], [33], [32] mechanistic models using the PB principles are developed. Generic drum granulation models are presented in [24], [25], [28].…”

Section: Figurementioning

confidence: 99%

Comparison of Feedback Control Strategies for Operation of Granulation Loops

Vesjolaja

Glemmestad

Lie³

2021

ITC

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Granulation is a particle enlargement process during which fine particles or atomizable liquids are converted into granules via a series of complex granulation mechanisms. In this paper, two feedback control strategies are implemented to make granulation loop processes more steady to operate, i.e., to suppress oscillatory behavior in the produced granule sizes. In the first control strategy, a classical proportional-integral (PI) controller is used, while in the second, a double-loop control strategy is used to control the median diameter of the granules leaving the granulator. The simulation results showed that using the proposed control design for the granulation loop can eliminate the oscillatory behaviour in the produced granule median diameter and make granulation loop processes more steady to operate. A comparison between the two proposed control strategies showed that it is preferable to use the double-loop control strategy.

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“…Granulation processes are used in a wide range of industrial applications, including fertilizer industries. Fertilizer manufacturing using the granulation process has received considerable research interest during the last few decades, due to (i) the increasing requirements for efficient production of high quality fertilizers for increased food production in a growing global population, and (ii) difficult process control and operation, e.g., among others (Herce et al, 2017;Ramachandran et al, 2009;Valiulis and Simutis, 2009;Wang et al, 2006) and (Cameron et al, 2005) have focused their research on granulation processes. This paper is focused on the last part of the mineral fertilizer production, i.e.…”

Section: Introductionmentioning

confidence: 99%

Application of population balance equation for continuous granulation process in spherodizers and rotary drums

Vesjolaja¹,

Glemmestad²,

Lie³

2021

Linköping Electronic Conference Proceedings

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In this paper, a dynamic model for a granulation process is developed. A population balance is used to capture dynamic particle size distribution in the spherodizer model and in the rotary drum granulator model. Particle growth due to layering is assumed in the spherodizer simulation model, while particle binary agglomeration is taken as the main granulation mechanism in the rotary drum simulation model. The developed models are 2-dimensional(2D) models that are discretized in terms of its internal coordinate (particle diameter), external coordinate (axial length of the granulators). Simulations using the developed models provide valuable data on dynamic fluctuations in the outlet particle size distribution for the granulators. In addition, the simulations results give a valuable information for the control studies of the granulation process. The simulation results showed that the extension of the model from 1D model to 2D model using the discretization of the external coordinate in the model, introduces a transport delay that is important in control studies.

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A CAPE-Taguchi combined method to optimize a NPK fertilizer plant including population balance modeling of granulation-drying rotary drum reactor

Cited by 6 publications

References 5 publications

Fertilizer Granulation: Comparison of Modeling Languages

Fertilizer Granulation: Comparison of Modeling Languages

Comparison of Feedback Control Strategies for Operation of Granulation Loops

Application of population balance equation for continuous granulation process in spherodizers and rotary drums

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