Package P3: Kiln – Operation and Optimisation

Module 8: Simulation of Kiln and Cooler Operation

TEXTBOOK

Course name : Kiln operation and optimization

Course number : P3
Module number : 8
Module title : Simulation of kiln and cooler operation
Module objectives : The participants will be able to:

Identify disturbances in kiln operation.

Choose actions required to obtain optimal
operation.

Duration : 1,5 day

Necessary facilities : Classroom. Access to computer facilities.
Necessary instruments : -

© F L Smidth
Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation

TABLE OF CONTENTS

SIMULATION OF KILN AND COOLER OPERATION .............................................. 3

8.1 INTRODUCTION ...................................................................................................... 3
8.2 SIMULATION OF KILN SYSTEMS........................................................................ 3
8.2.1 Controllers and control loops .............................................................................. 4
APPENDIX A
User manual for CEMulator
APPENDIX B
User manual for ECS OpStation
APPENDIX C
User manual for SDR Alaram Header

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Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation

SIMULATION OF KILN AND COOLER OPERATION

8.1 INTRODUCTION
The FLS CEMulator (Cement Process Simulator) is a training tool, which provides
hands-on kiln and mill operation experience for cement process operators and cement
process engineers. The FLS CEMulator System simulates not only the process behav-
iour but also the process information/operator manipulations with control variables
which resemble the real control situation.

The operators are trained at the PC work station under the supervision of an instructor.
The instructor sets up the simulation model prior to the training session by choosing
among the available kiln or mill models already loaded in the database. A set of opera-
tional parameters simulating an actual state of operation is specified by the instructor
and loaded onto the trainee PC work station from which the training session is per-
formed.

Throughout the session, by means of the instructor console, the instructor can introduce
process disturbances to observe and train an operator's ability to react correctly in both
normal and abnormal situations. It is possible for the instructor to control the timing of
the situation - e.g. speeding it up to get through process paths of minor interest or set-
ting time back to rehearse and discuss a difficult operating situation.

Besides operator training, the FLS CEMulator System can be used to perform specific
process studies to elevate and optimise process performance.

The following included appendices to this module describe the instructor/trainee opera-
tion of the FLS CEMulator system :

• The CEMulator, User Manual (appendix A)

• The ECS OpStation, User Manual (appendix B)
• The SDR Alarm Header, User Manual (appendix C)

8.2 SIMULATION OF KILN SYSTEMS

The simulation of the processes in the kiln, preheater and cooler is performed by a com-
plex mathematical model based on physical, chemical and thermodynamic relations

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Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation

concerning cement kiln systems. The model is specifically adapted to the characteristics
of the following kiln type, including start-up and shut-down:

In-Line Calciner Kiln system (ILC)

5 stages preheater
1 string
Grate cooler
5500 TPD

8.2.1 Controllers and control loops

The simulator offers a number of automatic controllers. For instance, a controller regu-
lates a motor or other electrical device in order to maintain a process value (flow, tem-
perature, pressure etc.) steady at a predefined value.

A controller is defined by 4 points as shown in Figure 8.1 and Figure 8.2.

Set-point The desired process value set by the operator

Process Value Feedback from process, i.e. the actual process value
Controller output Output to motor or other devices to regulate a process factor in
order to increase or decrease the process value.
THE CONTROLLER OUTPUT IS NORMALLY A CONTINU-
OUS SIGNAL USED AS A SET-POINT FOR THE FINAL
CONTROL ELEMENT. (SUCH AS A DAMPER A WATER
VALVE OR A WEIGH-FEEDER).
If the final control element is operated by increase/decrease pulses
(as a damper is), a positioner is inserted between the controller
and the final control element. (See the example in Figure 8.2).
Mode point The status of the controller. Tells if the controller is in automatic,
manual or some other mode.
Figure 8.1 Controller Components

Example:
To regulate the gas flow in a kiln you have to regulate the position of a damper.

The controller calculates the necessary damper position and sends this value to the posi-
tioner.

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Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation

A measuring-device (e.g. a potentiometer) tells the positioner the present position of the
damper and, depending on the output value, the positioner makes the damper motor ei-
ther increase or decrease the opening.

The pressure-measurement device reports the result to the controller and the loop con-
tinues until the process value is equal to the set-point value.

Figure 8.2 Example of control loop

Below is a list of the controllers available for a kiln type ILC with grate cooler:

1. The coal feeding to the calciner is controlled by the temperature in the 5th cy-
clone.
2. The speed of the 1st grate in a grate cooler is controlled by the pressure under
the 1st grate.
3. The speed of the 2nd and 3rd grate in a grate cooler is controlled by the speed
of the 1st grate.
4. The exhaust air fan is controlled by the pressure in the kiln hood.
5. The cooler fans speed are normally controlled by the air flow. Alternatively
the air flow can be controlled by the damper position.
6. The raw meal feed can be controlled by the kiln speed.
7. The injection of water into the conditioning tower is controlled by the gas
temperature.

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