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2 authors:
Kyarash Shahriari
Stanislaw Tarasiewicz
Laval University
15 PUBLICATIONS 27 CITATIONS
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Modelling and parameter identication of complex dynamic systems/processes is one of the main challenging problems in control engineering.
An example of such a process is clinker rotary kiln (CRK) in cement industry. In the prevailing models independently of which structure is used
to describe the kilns dynamics and the identication algorithm, parameters are assumed to be centralised and constant while the CRK is well
known as a distributed parameter system with a strongly varying dynamic through time. In this work, the kilns dynamic is described in the
form of a state-space representation with three state variables using a system of partial differential equations (PDE). The structure is chosen so
that it can easily be embedded in classical state-space control algorithms. The parameters of the PDE system are called operating functions
since their numerical values vary with respect to different operating conditions of the kiln, to their position in the kiln, and through time. A
phenomenological approach is also proposed in this paper to identify the operating functions for a given steady-state operation of the kiln. The
model is then used to perform a semi-dynamic simulation of the process through manipulating main process variables.
La modelisation et lidentication des param`etres de syst`emes/procedes dynamiques complexes constituent lun des principaux probl`emes en
genie des contr
oles automatiques. Un exemple dun tel procede est le four rotatif clinker dans lindustrie du ciment. Dans les mod`eles actuels
independamment de la structure utilisee pour decrire la dynamique du four et lalgorithme didentication, on presume que les param`etres sont
centralises et constants, alors que le FRC est bien connu comme syst`eme de param`etres distribue avec une dynamique qui varie beaucoup avec
le temps. Dans ce travail, la dynamique du four est decrite sous forme de representation despace detats avec trois variables detats faisant usage
dun syst`eme dequations differentielles partielles. La structure est choisie pour e tre facilement integree en algorithmes de commande despace
detats traditionnels. Les param`etres du syst`eme dE DP sont nommes fonctions doperation, puisque leurs valeurs numeriques varient concernant
les differentes conditions de fonctionnement du four, leur position dans le four et dans le temps. Une approche phenomenologique est e galement
proposee dans le present document pour determiner les fonctions doperation pour un fonctionnement en e tat stationnaire donne du four. Le
mod`ele est ensuite utilise pour realiser une simulation semi-dynamique du procede par la manipulation des principales variables du procede.
Keywords: phenomenological modelling, systems identication, cement industry, clinker rotary kiln, operating function
INTRODUCTION
Researcher.
of the Laboratory of Complex Automation and Mechatronics.
Author to whom correspondence may be addressed.
E-mail address: kyarash.shahriari@ieee.org
Can. J. Chem. Eng. 89:345359, 2011
2010 Canadian Society for Chemical Engineering
DOI 10.1002/cjce.20398
Published online 9 November 2010 in Wiley Online Library
(wileyonlinelibrary.com).
Head
345
346
MODEL STRUCTURE
Investigations on the CRK reveals strongly coupled physical and
chemical phenomena within the kiln (Bogue, 1947; Tarasiewicz
and Shahriari, 2008a). Applying classical modelling procedures
leads to a system of complex mathematical equations with different time scales for freeboard and bed materials dynamics. To
reduce model structure complexity while persisting on model
accuracy, we adopt in this work the phenomenological modelling
approach; main phenomena are identied and described individually with the aid of an appropriate process variable and the
respective operating functions as its coefcient. Three key process variables are chosen as state variables that are bed materials
temperature TC(x ,t) , freeboard gas temperature TG(x ,t) , and bed
materials mass distribution MC(x ,t) . The evolution of the state
variables in the tempo-spatial state-space representation is then
expressed using a system of partial differential equations derived
from phenomena affecting any state variable and MEB equations
in a mobile control volume.
TG (x, t)
x
where:
pa (x, t)cpa (Tpa (x, t)) + m
sa (x, t)csa (Tsa (x, t))
fG (x, t) = m
f (x, t)cf (Tf (x, t))
+m
() (x, t) represents the distributed
In the above expression, m
mass and c() (T() (x, t)) the specic heat of primary air, secondary
air, and fuel at temperature T() (x, t). Moreover, the heat generated
by fuel combustion is calculated from:
Qfuel (x, t) = hf (x, t)
Mf (x, t)
Mf (x, t) TG (x, t)
= hf (x, t)
x
TG (x, t)
x
Qtotal (x, t) =
Mf (x, t)
fG (x, t) + hf (x, t)
TG (x, t)
TG (x, t)
x
(1)
Calculating Qtotal (x,t) from Equation (1) requires accurate mea () (x, t), Mf (x,t), and T() (x, t) and
surement of process variables m
identication of coefcients c() (T() (x, t)) which can hardly be
TG (x, t)
x
where the so-called operating function FQ (x,t) embeds the mentioned process variables and coefcients. Calculating FQ (x,t)
directly through an identication procedure will bypass the
() (x, t), Mf (x,t), T() (x, t), and
measuring and identifying of m
c() (T() (x, t)) to compute Qtotal(x ,t) .
Generally speaking, operating functions replace complex mathematical descriptions of phenomena in a process. Any operating
function includes a number of inaccessible process variables as
well as unknown physical/chemical coefcients. To employ operating functions in modelling a process, we decompose it in the
rst place into its basis phenomena. The key process variable is
then determined for any phenomenon, and the evolution of the
phenomenon is described in terms of its respective key process
variable with the aid of an operating function as coefcient. The
resulting expression should be in such a way that the operating
function can directly be identied using available observations on
the process. As for the example of the energy supplied to the CRK,
transferred heat Qtotal (x,t) is expressed in terms of the evolution of
freeboard gas temperature along the kilns length and operating
function FQ (x,t) as its coefcient. Using this approach, modelling
and identication procedures are simplied by introducing a phenomenological description of the process that brings the problem
to a higher and more user-friendly level than detailed mathematical equations. Moreover, down-to-up accumulation of parameters
uncertainty in identication procedure from physical/chemical to
phenomenological representation is excluded which results in a
more accurate model of the process under study.
Operating function approach is not the only method to take into
account tempo-spatial variation of model parameters. An alternative solution is to consider the data as separate time series
correlated in space or extending traditional spatial methods such
as kriging to the spatio-temporal domain by adding an extra
dimension (Sampson and Guttorp, 1992; Oehlert, 1993). Some
researchers have also proposed to use Kalman lters. In Wikle and
Cressie (1999) a statistical model that is temporally dynamic and
spatially descriptive has been applied to a data set of near surface
winds in atmospheric science. However, the main drawback of
these models is that the parameters are derived statistically and
a reach data set is required to mitigate measuring uncertainties
while this set is generally not available for a CRK due to measuring technical problems. Moreover, a priori knowledge cannot
explicitly be integrated in statistical models that are a major source
of information for CRK modelling.
where hf (x,t) is the heat released per fuel mass unit and Mf (x,t)
is the injected fuel mass rate. Therefore, total heat transferred to
the kiln is expressed as:
performed due to technical constraints. On the other hand, Equation (1) can be reformulated as:
347
(b) Diffusion of the materials into the gas and vice versa.
It is described as the absolute temperature times by the
respective operating function, that is, F1,1 (x, t)TC (x, t) and
F2,1 (x, t)TG (x, t) for diffusion of materials into gas and gas
into materials, respectively.
(c) The freeboard gas and bed materials displacement along
the length of the kiln. It is dened with the aid of the
derivative of the temperature with respect to x and the
operating function resulting in F1,2 (x, t)(TG (x, t)/x) and
F2,2 (x, t)(TC (x, t)/x) for freeboard gas and bed materials
displacements. It is worth to state that velocities vG (x,t) and
vC (x,t) are embedded into the operating functions.
(d) Heat transferred from combustion of fuel to freeboard gas.
It is described as F1,3 (x, t)Mf (x, t) by the fuel feed mass rate
Mf (x,t). Thermal properties of the fuel are considered by the
operating function.
(e) Gas and materials heat exchange due to physical/chemical
reactions. Any reaction results in mass evolution and
hence, the latter is expressed as F1,4 (x, t)(MC (x, t)/x) and
F2,3 (x, t)(MG (x, t)/x) for bed materials and freeboard gas,
respectively.
(f) Gas and materials mass exchanges due to physical/chemical reactions. Identical to the previous case,
F3,1 (x, t)(MC (x, t)/x) and F3,2 (x, t)(MG (x, t)/x) describe
mass exchanges between freeboard and solid phases. For two
last cases, reaction coefcients and rates are included in the
operating functions.
It should be mentioned that the identied phenomena and their
respective mathematical descriptions are subject to further modications if additional accuracy would be required or a priori
knowledge and observations on the kiln would be available.
Description
Proposed structure
(3)
TC (x, t)
= f2,1 (x, t) + f2,2 (x, t) + f2,3 (x, t) + f2,4 (x, t) + f2,5 (x, t)
x
(4)
for bed materials temperature, and
C (x, t)
M
= f3,1 (x, t) + f3,2 (x, t) + f3,3 (x, t) + f3,4 (x, t) + f3,5 (x, t)
x
(5)
(2a)
(2b)
348
(8a)
C (L, t)
M
= f6,1 (L, t)
x
(8b)
where x = 0 is the lower end and x = L is the upper end of the kiln.
For freeboard gas, x = 0 is the xed and x = L is the free boundary
whilst for bed temperature and mass distribution x = L is the xed
and x = 0 is the free boundary. Detailed description of functions
fi ,j (x,t) in Equations (6)(8) is given in Table 3. As soon as the
model structure is established, we tackle with the identication
of the operating functions.
(6a)
TG (L, t)
=0
x
(6b)
(7a)
TC (L, t)
= f5,1 (L, t) + f5,2 (L, t)
x
(7b)
Description
Proposed structure
f1,1 (x,t)
f1,2 (x,t)
f1,3 (x,t)
f1,4 (x,t)
f1,5 (x,t)
f1,6 (x,t)
f2,1 (x,t)
f2,2 (x,t)
f2,3 (x,t)
f2,4 (x,t)
f2,5 (x,t)
f3,1 (x,t)
f3,2 (x,t)
f3,3 (x,t)
f3,4 (x,t)
f3,5 (x,t)
349
Description
Proposed structure
f4,1 (x,t)
f4,2 (x,t)
f5,1 (x,t)
f5,2 (x,t)
f6,1 (x,t)
ln(r2 /r1 )
ln(r3 /r2 )
= 0.0462 K/W, R5 =
= 0.0005 K/W
2kref x
2kshell x
1
= 0.1721 K/W
2hr3 x
TSur TS (x)
Req (x)
(9)
350
Description
Value (m)
1.625
1.825
1.85
120
q1 (x) =
TG (x)TBin (x)
R1 (x)
(10a)
q2 (x) =
TC (x)TBin (x)
R2 (x)
(10b)
(10c)
0<(x)1
(11)
1
(x)(x)
(TG (x)TB (x)) +
(TC (x)TB (x))
qloss (x)
((x))qloss (x)
(12a)
R2 (x) =
(x)
1
(TG (x)TB (x)) +
(TC (x)TB (x))
(x)(x)qloss (x)
qloss (x)
(12b)
Again for simplicity, we chose (x) = 1.0 in this work. Thermal resistances R1 (x) and R2 (x) are then calculated by solving
the system of Equations (10) and (12). The respective operating
functions are consequently computed as follows:
F0,1 (x) =
R1 (R4 + R5 )
R1 R2 + (R1 + R2 )(R4 + R5 )
F0,2 (x) =
R2 (R4 + R5 )
R1 R2 + (R1 + R2 )(R4 + R5 )
F0,3 (x) =
R 1 R2
R1 R2 + (R1 + R2 )(R4 + R5 )
F0,4 (x) =
Req
Req + R4 + R5
F0,5 (x) =
R4 + R5
Req + R4 + R5
351
(13)
where Cp,G (x) is the specic heat and MG (x) is the mass distribution of freeboard gas. As for the latter, following data are available:
vG (x)|x=0 [14.76, 36.3] m/s
in Equation (13) and F1,5 (x) is identied from a similar expression as in Equation (14). The only unknown term is qC (x) which
consists of two parts. The rst part is associated with the drying
zone to evaporate moisture from raw materials and the second
part elsewhere in the kiln to heat up bed materials. Dried mass
distribution prole including the mass coated in the chains and
diffused in the gas has already been dened as MC (x). The initial concentration of water in raw materials is known to be 30%.
Considering the operating zone limits, moisture concentration is
approximated by the empirical hyperbolic function Cmoisture (x) =
0.15 tanh(0.1(x90)) + 0.15 in drying zone and therefore, moisture mass distribution prole is:
Mmoisture (x) = Cmoisture (x)MC (x)
TG (x)|x=0 = 557 K
G (x)
m
vG (x)
1
qloss (x)
Cp,G (x)MG (x)
(14)
Rate(x) =
1
MC (x)
(E(x)vC (x))
x
352
which is due to the fact that radiation from the ame increases
considerably the heat exchange rate from gas to bed materials.
Thermal energy required to heat up the kiln is provided by
combustion of fuel. Considering energy balance equations in the
mobile control volume we have:
F1,3 (x)Mf (x) = qF (x)
1
Cp,G (x)MG (x)
where qF (x) is the heat rate produced by combustion. The operating function F1,3 (x) is then calculated and illustrated in Figure
7 for qF (x) = 16.75 106 J/s. The function is non-zero only in the
ame position where the fuel is injected into the kiln and zero
elsewhere.
As mentioned before, the observations have been performed
in steady-state operation of the kiln leading to TG (x)/t = 0 in
Equation (3). Therefore, operating function F1,2 (x) is computed
as the residual from:
F1,2 (x)
TG (x)
= F1,3 (x) + F1,5 (x)(TG (x)TC (x))
x
+ F1,6 (x)(TG (x)TB (x))
TC (x)
1
=
qC (x)
t
Cp,C (x)MC (x)
(15)
which implies:
F2,4 (x)(TG (x)TC (x)) =
1
qC (x)
Cp,C (x)MC (x)
(16)
TC (x)
= F2,4 (x)(TG (x)TC (x))F2,5 (x)(TC (x)TB )
x
353
66%
22%
5%
4%
2%
1%
Mreleased (x)
MC (x)
=
x
x
On the other hand and due to mass balance between solid and
gas phases in the control volume, we have:
F3,2 (x)
MG (x)
MC (x)
= F3,1 (x)
x
x
C (x)
(vC (x)MC (x))
M
=
x
x
354
C (x)
MC (x)
MG (x)
M
+ F3,2 (x)
+ F3,5 (x)
x
x
x
q1 (x)
Cp,G vG (x)MG (x)
from which F4,2 (x) is identied for x 0. It is void for x < 0 since
the gas is not in contact with the refractory layer in this region.
Accordingly, operating function F4,1 (x) is computed for x 0 from:
TG (x)
F4,1 (x)(TG (x)TC (x)) =
F4,2 (x)(TG (x)TB (x))
x
Being acquainted with the kilns feeding installation is mandatory to identify F4,1 (x) for x < 0.
Likewise for freeboard gas temperature, we have:
MC (x)|Llx<L
1
=
vC
MC (x)|x=Ll =
Ll
L
which implies:
and consequently:
q2 (x)
Cp,C vC (x)MC (x)
M0
dx
l
M0
vC
q2 (x)
TC (x)
=
x
Cp,C vC (x)MC (x)
TC (x)
F5,2 (x)(TB (x)TC (x))
x
355
F6,1 (x)|Llx<L =
M0
lMC (x)
F6,1 (x)|x=Ll = 0
The operating functions of lumped parameters zone are illustrated in Figure 12. Although they are not employed in this work
for process simulation, their identication paves the path to implement the proposed model in process control algorithms in future
works.
356
of the kiln. Evidences and experiences on the kiln justify qualitatively the simulation results while quantitative observations are
unfortunately not available at this stage to validate them.
The second semi-dynamic simulation is performed on mass
distribution prole while inlet raw materials mass rate is considered as the manipulated variables. Other process variables are
kept invariant. The simulation is performed for 90 min applying
M0 = MC (x = 120) shown in Figure 14. The evolution of the mass
distribution prole through time for t = 400 and 1800 s is also
illustrated in the same gure. The mass prole follows the raw
materials entry pattern which is in accord with the qualitative
evidences on the kiln. However, likewise the previous case, quantitative observations due to technical constraints are not available
in this stage to validate the results. Meanwhile, a preliminary conclusion is that the effect of manipulating the raw materials entry
will be seen approximately after 30 min at the other end of the
kiln which is quite reasonable for the kiln under study.
NOMENCLATURE
c() (T() (x, t))
Cm (x)
Cmoisture (x)
Cp,C (x)
Cp,G (x)
Crelease (x)
CW
Gf
h
hf (x,t)
HC
k()
l
L
() (x, t)
m
G (x)
m
MC (x,t)
Mf (x,t)
MG (x,t)
q() (x)
qF (x)
Qair (x,t)
Qfuel (x,t)
Qtotal (x,t)
Ri (x)
TB (x,t)
TC (x,t)
TG (x,t)
TS (x,)
TSur (x,t)
vC (x)
vG (x)
Greek Symbols
(x)
(x)
= 5.67 106 W/m2 K4
lling angle
a corrective coefcient
inclination angle
StefanBoltzmann constant
END NOTES
As soon as the missing information would be available, the model
can be updated, respectively. The fact that a phenomenon can be
eliminated/embedded easily from/into the modelconsidering the
availability of the corresponding informationshould be regarded as
an advantage of this structure that adapt itself to available measuring
system on the kiln.
Drying Zone
In a wet process, fed raw materials contain 2540% of moisture.
This water is evaporated while the following chemical reactions
take place:
CaO + H2 OCa(OH)2 + E
CaMgO + H2 OCa(OH)2 + MgO + E
Preheating Zone
This zone begins after the drying zone and ends before the temperature of clinker reaches 875 K. In this zone, materials are heated
up and the calcination begins. The following reactions take place
in this zone:
CaCO3 MgCO3 + ECaOMgO + 2CO2
CaCO3 + ECaO + CO2
CaO + SO2 +
1
O2 CaSO4
2
Calcination Zone
This zone begins where the bed temperature reaches 975 K and
ends as soon as the temperature achieves 1325 K. Calcination is
completed in this zone. Other reactions in this zone are as follows:
357
Clinkering Zone
In this zone, the bed materials are partially melted and the following reactions take place:
2CaO + SiO2 C2 Si + E
C2 Si + CaOC3 Si + E
4CaO + Al2 O3 + Fe2 O3 (CaO)4 Al2 O3 Fe2 O3
3CaO + Al2 O3 (CaO)3 Al2 O3
C + O2 CO2 + E
2H2 + O2 + N2 2H2 O + N2 + E
2H2 + 2O2 + S2H2 O + SO2
S + O2 SO2
ACKNOWLEDGEMENTS
The present work is made possible partly by grants from the
Natural Sciences and Engineering Research Council of Canada
(NSERC) and the Research Center on Concrete Infrastructures
(CRIB).
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359