Optimization of Rotary Kiln in Cement Industry Using Conventional Control Systems

Author Name(s): N. Merrin Prasanna, Polaiah Bojja
Author Email: nagadasari.merrin@gmail.com


The main aim of the work is used to develop the mathematical models which are used to design conventional control system for the real time cement plant to control several variables of a cement rotary kiln in the plant. A cement rotary kiln is a non linear distributed process which has a highly complex dynamic behavior due to chemical reaction, development of a system to understand the behavior of a kiln process as mathematical model based on control scheme for cement rotary kiln processes. However, the variables are back-end temperature, pre heater temperature, oxygen content and CO2 gas content of the kiln are used to develop the model of the processes by the most use of Automation. The proposed controller uses a PI controller and PID controller. Finally the designed of Controller scheme for cement rotary kiln process of results are carried out by MATLAB software for evaluation of the performance kiln process.


Control framework hypothesis is considered as one of the imperative and valuable territories in the field of engineering and innovation. With a specific end goal to plan successful controllers for a nonlinear framework, a precise numerical model is required to register the ideal control law. Endeavors to utilize finish numerical models have made the traditional methods burdensomely confused. The diminished request models give an appealing option handy advantage. This casing work is adequate from powerful plan points of view in light of the fact that the mistake limits can be found and the confused flow can be utilized as a part of the amalgamation of strong control laws. The presence and elaboration of exact models is a subject of concern in light of the fact that an extensive variety of marvels can’t be incorporated and mapped by the subsequent differential conditions created. Indeed, some of the time basic presumptions are thought to be substantial. What’s more, parameters of dynamic frame- works are shifting, and depiction of genuine frameworks by utilizing ostensible models is a doubtful suspicion. Thus the architect can’t hope to accomplish a correct streamlining. Robust control is arranged towards the decreased request plan point of view, binds together various wanted goals from heartiness angles, and increases one towards attainable viewpoints in amalgamation, execution, and strength investigation of dynamic frame- works within the sight of limited vulnerabilities. Distinctive methods have been connected to assault the model diminishment issue. As of late, real improvements in demonstrate lessening have been accomplished, and solid strategies have been distributed. Hence the substitute technique for managing high- arrange frameworks is to diminish them to a lower ar- range with fitting attributes of the first frameworks .This is done routinely by each control build with occupation to achieve control framework plans, in view of the second request estimate to whatever request the procedure to be and these controls frameworks work, typically calm well. There are different circumstances, anyway for which a second request show isn’t sufficient and where an orderly, expository way to deal with advancement of an estimate would be attractive. Along these lines by lessening the request of the frame- work we accomplish the accompanying:

1. Ease in physical development of the model,
2. Less computational many-sided quality
3. Models of less size and at lower cost and
4. Lower dimensional “control law” (K).


The stable operation of kiln precalciner is one of the critical issues in a cement plant and the automatic operation is highly preferred. Due to the complexity of the processes involved, an analytical modeling is extremely difficult as well as to utilize such model for control purposes. In this study a simplified dynamic model between the temperature in precalciner outlet and feed rate of the primary fuel is presented using a series of equal connected tanks. The model with the optimum number of tanks providing the minimal residual errors is used to tune a PID controller between process and control variables. In parallel, several loop properties, like Peak-overshoot, Rise time, Settling time, Error have been computed. The uncertainty of their values is computed based on the uncertainty of the dynamic parameters. The control of temperature in cement rotary kiln for the quality product will be obtained by controller successfully. Due to its simplicity, the tuning results could be used at least as initial PID values in real process. A more precise parameterization needs a more detailed and accurate modeling. . Hence, its concluded PID controller has small overshoot, and fast response comparing with PI controller based on the implementation of controller for kiln processes


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