TDCC Kiln N Cooler Process Expert Report

.1 Introduction
The Process Expert Report gives an overview of basic
control schemes and strategies involved in TDCC Kiln N Cooler.

.2 Process Expert Control Group For Kiln

The Process Expert is provided with different control groups to have
control over the Kiln circuit. The diversified Process Expert control
gives individual set points to the process unit depending on various
control schemes. The basic control groups and their functionalities
were discussed below.

2.1 Kiln Feed Control

Parameters for Controlling:

Kiln Load (Torque), PH NOx, Kiln Hood Temperature, Kiln Inlet NOx
and Quality Parameters (Free Lime & Litre Weight)

Fuzzy Set points:

Fuzzy gives the total Feed Set Point to the PLC depending on the Kiln
Load (Torque), PH NOx, Kiln Hood Temperature, Kiln Inlet NOx and
Quality Parameters (Free Lime & Litre Weight).

Fuzzy Indexes:

BZTI – Burning Zone Temperature Index – Kiln Load (Torque), PH

NOx, Kiln Hood Temperature, Kiln Inlet NOx and Quality Parameters
(Free Lime & Litre Weight).

KOSI – Kiln Operating Stability Index – Depending on the trend

increase/decrease of Kiln Load (Torque), PH NOx, Kiln Hood
Temperature, Kiln Inlet NOx.

KPRI – Kiln Production Index – It calculates the deviation of Kiln Feed

from Target Value.
 KDRI – Kiln Draft Index – It calculates the deviation of Kiln and Pre
Heater Oxygen from Target Value.

Control Loops:

The Total Feed Set Point is given as a result of two separate control
loops. One taking account of the Level/Load with respect to index
BZTI, the other taking care of the Stability with respect to Index KOSI.
The control decision is finally made with BZTI, KOSI, KPRI and KDRI.

2.2 Kiln Coal Control

Parameters for Controlling:

Kiln Load (Torque), PH NOx, Kiln Hood Temperature, Kiln Inlet NOx
and Quality Parameters (Free Lime & Litre Weight)

Fuzzy Set points:

Fuzzy gives the Kiln Coal Set Point for the kiln firing depending on the
Kiln Load (Torque), PH NOx, Kiln Hood Temperature, Kiln Inlet NOx
and Quality Parameters (Free Lime & Litre Weight)

Fuzzy Indexes:

BZTI – Burning Zone Temperature Index – Kiln Load (Torque), PH

NOx, Kiln Hood Temperature, Kiln Inlet NOx and Quality Parameters
(Free Lime & Litre Weight)

KOSI – Kiln Operating Stability Index – Depending on the trend

increase/decrease of Kiln Load (Torque), PH NOx, Kiln Hood
Temperature, Kiln Inlet NOx.

KPRI – Kiln Production Index – It calculates the deviation of Kiln Feed

from Target Value.

KHCI – Kiln Heat Consumption Index – It calculates the deviation of

Coal consumption of the kiln from the normal Value.

KDRI – Kiln Draft Index – It calculates the deviation of Kiln and Pre
Heater Oxygen from Target Value.

Control Loops:
 The Kiln Coal Set point is given as a result of two separate indexes.
One taking account of the Level/Load with respect to BZTI and the
other taking care of the Stability with respect to KOSI. The control
decision is finally made with BZTI, KOSI, KPRI, KCHI and KDRI along
with Heat action needed.

2.3 Kiln Speed Control

Parameters for Controlling:

Synchronisation Factor (Kiln Feed Vs Kiln Speed), Kiln Load (Torque),

PH NOx, Kiln Hood Temperature, Kiln Inlet NOx and Quality
Parameters (Free Lime & Litre Weight).

Fuzzy Set points:

Fuzzy Expert gives the Kiln Speed Set Point by considering the Total
Feed SP.

Fuzzy Indexes:

KSLI – Kiln Speed Level Index – deviation of Calculated Kiln speed and
actual kiln speed.

BZTI – Burning Zone Temperature Index – Kiln Load (Torque), PH

NOx, Kiln Hood Temperature, Kiln Inlet NOx and Quality Parameters
(Free Lime & Litre Weight)

KOSI – Kiln Operating Stability Index – Depending on the trend

increase/decrease of Kiln Load (Torque), PH NOx, Kiln Hood
Temperature, Kiln Inlet NOx.

Control Loops:

The Kiln Speed Set point is given as a result of two separate indexes.
One taking account of the KSLI based on calculated kiln speed and the
other based on the control decision made with BZTI and KOSI.

2.4 Kiln ID Fan Control

Parameters for Controlling:

Kiln Inlet CO, Kiln Inlet O2, PreHeater Exit CO and PreHeater Exit O2.

Fuzzy Set points:

 Fuzzy Expert gives the Kiln ID Fan Speed Set Point by considering all
above parameters.

Fuzzy Indexes:

KDRIk – Kiln Draft Index for Kiln – Kiln Inlet CO, Kiln Inlet O2, Kiln Exit
CO and Kiln Exit O2.

Upsets:

1. An upset has been configured which increases the Kiln ID Fan

Speed SP when Kiln Inlet CO / PreHeater CO is High.

2.5 Tertiary Air Damper Control:

Same as Kiln ID fan Control, but used only during start up or if there
are any fan limitations. It will come under control based on selection.

2.6 Calciner Coal Control

Parameters for Controlling:

Average 5/15 Cyclone Temperatures and PreHeater O2 & CO.

Fuzzy Set points:

Fuzzy Expert gives the Calciner Coal Set Point by considering Average
5/15 Cyclone Temperatures and PreHeater O2 & CO.

Fuzzy Indexes:

CATI – Cyclone/ Calciner Temperature Index – Average 5/15 Cyclone

Temperatures.

PDRI – PreHeater Draft Index – It calculates the deviation of Pre

Heater Oxygen & CO from Target Value.

Upsets:

1. An upset has been configured which decreases the Calciner Coal

whenever Cyclone Temperature is very high and similarly another
upset which increases Calciner Coal whenever Cyclone Temperature
is very Low.
 2. An upset has been configured which decreases the calciner coal
when the PreHeater CO is High.

.3 Indexes
There are calculated some process status (Indexes) that tells us how
the kiln status is, there are for an example: BZTI (Burning Zone
Temperature Index), KOSI (Kiln Operation Stability Index), KDRI (Kiln
DRaught Index).

This indexes shows always in values between (-1) to (+1), for an

example; BZTI = (+1) the kiln is hot, BZTI = (-1) the kiln is cold, BZTI =
(0) the kiln is in steady/stable temperature.

All Indexes are calculated in the Process Expert and saved into points
in the database; the indexes are used as operator information and for
controlling the kiln.

-BZTI (Burning Zone Temperature Index)

Purpose: show if the kiln is hot or cold, Burning Zone Control.

Analyse values of the Clinker are used to calibrate the temperature

profile for the kiln, this means that the BZTI is calibrated every time a
new analyse value is received (adaptive control). We can use up to 8 of
the latest samples correlated to the temperatures, torque, NO x in the
kiln. The inputs for the correlation are delayed to fit with the Free
Lime/Litre Weight value when the sample was in the kiln. This for
calculates what we call, “Good Values” for each measurement. They
are put together with weight factors and compared with the actual
process values to make the BZTI(1).

In cases where it is hard to find a reliable measurement to base the

BZTI on, the BZTI is calculated (model based) out from actual free
lime/ Litre weight analyse values, NO X, Torque, Temperatures and the
predicted next free lime/Litre weight sample, based on the last analyse
value and corrected by changes in fuel, NO X, Torque and feed. Al this
are weighted together to the Index; BZTI(2).

For TDCC the BZTI 1 is used:

Litre Weight Lab Value (BZTI(1))

Free Lime Lab Value (BZTI(1))

Kiln Torque (Burning Zone Indicator (1)) (BZTI(1))

Preheater NOX (Burning zone Indicator (2)) (BZTI(1))

Kiln Hood Temp (Burning Zone Indicator (3)) (BZTI(1))

Kiln NOX (Burning Zone Indicator (4)) (BZTI(1))

-KOSI (Kiln Operation Stability Index)

Purpose: show if the kiln heating up or cooling down, Burning Zone

Control.

KOSI is using the scaled tendencies of Kiln Torque, Kiln temperatures

and kiln inlet NOX. Each indicator has three tendencies (slopes): Long
Term, Medium term and Short term. The slopes are put together with
weight factors to one Index; KOSI. KOSI shows if the kiln is heating up
or cooling down. The weight factors have to be set up and scaled so
they show when the kiln is heating up, or cooling down.

TDCC Inputs are:

Kiln Torque (Burning Zone Indicator (1))

Preheater NOX (Burning zone Indicator (2))

Kiln Hood Temp (Burning Zone Indicator (3))

Kiln NOX (Burning Zone Indicator (4))

-HACT Kiln (Heat ACTion Kiln)

Purpose: show needed action on Kiln fuel.

HACT Kiln is the needed heat action for the kiln; it is a combination
between BZTI and KOSI.

-KDRI (Kiln DRaft Index)

Purpose: show actual oxygen level for combustion, ID-Fan Control.

KDRI is using the Oxygen in Kiln Inlet, CO in Kiln Inlet, Oxygen after
Preheater and CO after Preheater compared with the Oxygen set
points and the CO limits for detecting if the combustion is OK. If CO
exceeds the high limit the Index shows (-1). Internal there are two
indexes calculated one for Preheater and one for Kiln Inlet.

KDRI shows normally the scaled value of Preheater Outlet, but if the
Preheater Outlet analyser is faulty the KDRI will show the scaled value
of the kiln Inlet.

-KPRI (Kiln PRoduction Index)

Purpose: show if production is lower or higher then target, Burning

Zone Control.

KPRI shows the difference between the actual Production set point and
the inserted Max Production (Operated inserted PXP SP).

-KHCI (Kiln Heat Consumption Index)

Purpose: show if we are using more or less fuel then last 1-3 hour
average, Burning Zone Control.

KHCI shows the difference between the actual heat consumption and
the long-term average (3 hours) heat consumption.

-KSPI (Kiln SPeed Index)

Purpose: show if kiln speed fits to production level, Burning zone

Control.

KSPI is calculated out from the actual filling degree compared with
target (set point) filling degree in the kiln. Filling degree calculates from
Kiln rpm and Production. The index creates a linear function between
Kiln Feed and Kiln Speed.

-CATI (CAlciner Temperature Index)

 Purpose: show if Calciner/cyclone temperature is to hot or to cold.

CATI is the difference between calciner/cyclone temperature set point

and actual process value.

.4 Process Expert Control Group For Cooler

The Process Expert is provided with different control groups to have
control over the entire Cooler Circuit. The diversified Process Expert
control gives individual set points to the process unit depending on
various control schemes. The basic control groups and their
functionalities were discussed below.

4.1 Grate Fans Control

For CIS Fan Flow Ratio:

Parameters for Controlling:

Grate Pressure, Kiln production and Kiln Hood Temperature.

Fuzzy Indexes:

CAFI – Cooler Air Flow Index – calculated based on the Grate

Pressure, Kiln production and hood temperature

Fuzzy Set Points:

Fuzzy gives individual Fan Flow Ratio SP by considering above

parameters. But stays at maximum during normal kiln operation.

For Grate1 Fan Flow Ratio:

Parameters for Controlling:

 Grate Pressure, Kiln production and Kiln Hood Temperature.

Fuzzy Indexes:

CAFI – Cooler Air Flow Index – calculated based on the Grate

Pressure, Kiln production and hood temperature

Fuzzy SetPoints:

Fuzzy gives individual Fan Flow Ratio SP by considering above

parameters.

For Grate 2 & 3 Fan Flow Ratio:

Parameters for Controlling:

Cooler Exit/Vent Gas Temperature, Kiln Production and Grate

Pressure.

Fuzzy Indexes:

CAFI – Cooler Air Flow Index – calculated based on the Cooler

Exit/Vent Gas Temperature, Kiln Production and Grate Pressure.

Fuzzy Set points:

Fuzzy gives individual Fan Flow Ratio SP by considering above

parameters.

.5 Grate Speed Control

Grate 1 Speed:

Parameters for Controlling:

Grate1 Pressure (Under Grate Pressure) and Grate Hydraulic Load.

Fuzzy Indexes:

CPRI – Cooler PRessure Index – calculated based on the deviation of

the Cooler Grate Pressure from the target.

COSI – Cooler Operation Stability Index – calculated based on the

tendency / trend of the Cooler Grate Pressure.
COLI– Cooler LOad Index – calculated based on the Cooler Hydraulic
Grate Load.

Fuzzy Set points:

Fuzzy gives Grate1 Speed Set Point by considering the above

parameters.

Upsets:

1. An upset has been configured which increases the Grate1 Speed SP

when UGP is high and similarly another upset which reduces the
Grate1 Speed SP whenever UGP is Low.

2. An upset, which reduces Grate1 Speed SP when Crusher Load is

high.

Grate 2 Speed Ratio:

Parameters for Controlling:

Grate1 Pressure (Under Grate Pressure) and Grate Hydraulic Load.

Fuzzy Indexes:

CPRI – Cooler PRessure Index – calculated based on the deviation of

the Cooler Grate Pressure from the target.

COSI – Cooler Operation Stability Index – calculated based on the

tendency / trend of the Cooler Grate Pressure.

COLI– Cooler LOad Index – calculated based on the Cooler Hydraulic

Grate Load.

Fuzzy Set points:

Fuzzy gives Grate2 Speed ratio Set Point by considering the above
parameters.

Upsets:

1. An upset has been configured which increases the Grate2 Speed

ratio SP when UGP is high and similarly another upset which reduces
the Grate2 Speed ratio SP whenever UGP is Low.
Grate 3 Speed Ratio:

Parameters for Controlling:

Grate1 Pressure (Under Grate Pressure), Cooler Crusher Load.

Fuzzy Indexes:

CPRI – Cooler PRessure Index – calculated based on the deviation of

the Cooler Grate Pressure from the target.

COSI – Cooler Operation Stability Index – calculated based on the

tendency / trend of the Cooler Grate Pressure.

Fuzzy Set points:

Fuzzy gives Grate3 Speed ratio Set Point by considering the above
parameters.

Upsets:

1. An upset, which reduces Grate3 Speed ratio SP when Crusher Load

is high.