Abstract
The recycling of zinc in the Waelz process is an important part of the efficient use of resources in the steel processing cycle. The pyro-metallurgical processing of zinc-containing wastes takes place in a Waelz rotary kiln. Various measured variables are available to monitor the process. The temperature of the kiln-shell is analyzed by an infrared kiln-shell-scanner. In this paper, methods are presented which eliminate external weather-related disturbances on the temperature measured by the kiln-shell-scanner using a weather model and which extend the monitoring of the regularly necessary melting process to remove accretions. For this purpose, an adapted sigmoid estimation is introduced for the melting process, which provides new information about the current process status and a forecast of the further development of the melting process. As an assistance system for the plant operator, this enables an efficient execution of the melting process and reduces downtimes.
Highlights
Melting Process for Reduction of AccretionsThe Waelz process is negatively influenced by large grown accretions. Once they get too thick, the accretions are treated by melting them down
The kiln-shell-scanner temperature is an important source of information for the plant operator for evaluating accretions, for example, during a melting process
A linear weather model consisting of outside temperature and air humidity is introduced that can eliminate the disturbance of external weather-related influences and enable a correct representation of the temperature profile
Summary
The Waelz process is negatively influenced by large grown accretions. Once they get too thick, the accretions are treated by melting them down. The progress of the melting process is monitored by observing the temperature profile along the rotary kiln using a kiln-shell-scanner. The plant operator controls the melting process based on experience, supported by the temperature profile of the kiln-shell-scanner. During an optimal melting process, the accretions on the kiln brickwork are systematically removed from kiln feeding to the end. Depending on kiln-shell temperature development, the negative pressure can be gradually reduced, and the melting process can be controlled from kiln feeding to the end. The end of the melting process is difficult to estimate for the plant operator It is melted until no changes in the temperature profile of the rotary kiln can be recognized. The consideration of this effect and the presentation of an appropriate information is part of this paper
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