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Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †

The cement industry includes energy-intensive processes, e.g., clinker rotary kilns and clinker grate coolers. Clinker is obtained through chemical and physical reactions in a rotary kiln from raw meal; these reactions also involve combustion processes. The grate cooler is located downstream of the...

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Autores principales: Zanoli, Silvia Maria, Pepe, Crescenzo, Astolfi, Giacomo
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10007288/
https://www.ncbi.nlm.nih.gov/pubmed/36905011
http://dx.doi.org/10.3390/s23052805
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author Zanoli, Silvia Maria
Pepe, Crescenzo
Astolfi, Giacomo
author_facet Zanoli, Silvia Maria
Pepe, Crescenzo
Astolfi, Giacomo
author_sort Zanoli, Silvia Maria
collection PubMed
description The cement industry includes energy-intensive processes, e.g., clinker rotary kilns and clinker grate coolers. Clinker is obtained through chemical and physical reactions in a rotary kiln from raw meal; these reactions also involve combustion processes. The grate cooler is located downstream of the clinker rotary kiln with the purpose of suitably cooling the clinker. The clinker is cooled through the action of multiple cold air fan units as it is transported within the grate cooler. The present work describes a project where Advanced Process Control techniques are applied to a clinker rotary kiln and a clinker grate cooler. Model Predictive Control was selected as the main control strategy. Linear models with delays are obtained through ad hoc plant experiments and suitably included in the controllers’ formulation. A cooperation and coordination policy is introduced between the kiln and the cooler controllers. The main objectives of the controllers are to control the rotary kiln and grate cooler critical process variables while minimizing the fuel/coal specific consumption of the kiln and the electric energy consumption of the cold air fan units within the cooler. The overall control system was installed on the real plant, obtaining significant results in terms of service factor and control and energy-saving performances.
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spelling pubmed-100072882023-03-12 Advanced Process Control for Clinker Rotary Kiln and Grate Cooler † Zanoli, Silvia Maria Pepe, Crescenzo Astolfi, Giacomo Sensors (Basel) Article The cement industry includes energy-intensive processes, e.g., clinker rotary kilns and clinker grate coolers. Clinker is obtained through chemical and physical reactions in a rotary kiln from raw meal; these reactions also involve combustion processes. The grate cooler is located downstream of the clinker rotary kiln with the purpose of suitably cooling the clinker. The clinker is cooled through the action of multiple cold air fan units as it is transported within the grate cooler. The present work describes a project where Advanced Process Control techniques are applied to a clinker rotary kiln and a clinker grate cooler. Model Predictive Control was selected as the main control strategy. Linear models with delays are obtained through ad hoc plant experiments and suitably included in the controllers’ formulation. A cooperation and coordination policy is introduced between the kiln and the cooler controllers. The main objectives of the controllers are to control the rotary kiln and grate cooler critical process variables while minimizing the fuel/coal specific consumption of the kiln and the electric energy consumption of the cold air fan units within the cooler. The overall control system was installed on the real plant, obtaining significant results in terms of service factor and control and energy-saving performances. MDPI 2023-03-03 /pmc/articles/PMC10007288/ /pubmed/36905011 http://dx.doi.org/10.3390/s23052805 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Zanoli, Silvia Maria
Pepe, Crescenzo
Astolfi, Giacomo
Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title_full Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title_fullStr Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title_full_unstemmed Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title_short Advanced Process Control for Clinker Rotary Kiln and Grate Cooler †
title_sort advanced process control for clinker rotary kiln and grate cooler †
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10007288/
https://www.ncbi.nlm.nih.gov/pubmed/36905011
http://dx.doi.org/10.3390/s23052805
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