Intelligent dynamic modeling for online estimation of burning zone temperature in cement rotary kiln

Abstract

Cement rotary kiln is a complex multivariable, large-disturbances and nonlinear system which is full of mass transfer, heat transfer, and physical and chemical reactions. The burning zone temperature (BZT) in cement rotary kiln is a very important production index and has a significant role on the quality of the clinker. However, the BZT is generally difficult to be measured online using the conventional instruments. Although the BZT can be detected by using the expensive infrared pyrometer which located at the kiln head hood, it generally loses veracity due to the complex dynamics of the cement rotary kiln. Obviously, such an inaccurate measurement may guide the operator to do some improper operations in practice. To attack such a practical engineering problem, an intelligence-based dynamic soft-sensor modeling approach is proposed to online estimate the BZT in cement rotary kiln in this paper. The proposed approach mainly includes two digital filters which are used to pre-process the original measurement data, and an intelligent CBR soft-sensor system which is adapted to online predict the BZT in time, according to the measured secondary variables. At last, industrial tests have been performed to demonstrate the good estimation performance of the proposed method for a real cement rotary kiln process. Index Terms -Burning zone temperature, Cement rotary kiln, Dynamic soft-sensor, Case-based reasoning, Digital filter.

Industrial IoT enabled fuzzy logic based flame image processing for rotary kiln control

“…The temperature of the radiator could be accessed by the authorized person through the database. The factors of the oven such as secondary air pressure, fan speed and secondary air temperature have a high impact on producing the high-quality clinker (Zhou and Yuan, 2014). The controlled factors of the kiln are BZ temperature, kiln inlet temperature, the electrical flow of the kiln and clinker quality.…”

“…These clinkers are crushed to a fine powder and combined with a limited amount of gypsum to produce Portland cement. As clinker quality plays a major role in cement manufacturing, burning zone (BZ) temperature is an important factor in producing high quality products (Zhou and Yuan, 2014). If the temperature is excessively low, it may result in a poor quality clinker, which is referred to as under-sintering.…”

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“…There are many sources report about the systems development for production process analysis using machine vision, in particular, the works [27,28]. Several articles involve research based on the creation of remote control systems [29] and the development of expert systems based on Siemens PCS7 [30].…”