Modeling and Control of Rotary Kiln in a Cement Manufacturing Unit

Abstract

Kiln systems are used in industry for processes such as pyrotechnics, cement making, combustion, thermal desorption, organic combustion, sintering, thermal curing and many other processes. This system models built on the principle of mass/heat transfer and knowledge of the kinetics of the reactions taking place in the kiln are used to simulate the process with the MATLAB SIMULINK tool. The data used in the system model was obtained from an Indian cement company. This work aims at carrying out the mathematical modeling of the rotary kiln in the process and to improve the efficiency of the kiln control system. This modeling can be used in the control system of the cement rotary kiln. The mathematical modeling gave the better performance for burning zone temperature control of the rotary kiln using PID controller due to its low overshoot as compared to Cohen Coon and Fuzzy PID controller. The PID controller was observed to give an overshoot of 7.04% and a settling time of 260 seconds.

Keywords: kiln, burning zone, temperature control, modeling, Simulink, PID controller