Abstract
The operation of granulation plants on an industrial scale is challenging. Periodic instability associated with the operation of the granulation loop causes the particle size distribution of the particles flowing out from the granulator to oscillate, thus making it difficult to maintain the desired product quality. To address this problem, two control strategies are proposed in this paper, including a novel approach, where product-sized particles are recycled back to maintain a stable granulation loop process. A dynamic model of the process that is based on a population balance equation is used to represent the process dynamics. Both of the control strategies utilize a double-loop control structure that is suitable for highly oscillatory systems. The simulation results show that both control strategies, including the novel approach, are able to remove the oscillating behaviour and stabilize the granulation plant loop.
Highlights
Granulation is a particle enlargement process during which fine particles and/or atomizable liquids are converted into granules via a series of complex physical processes [1]
A novelty of this paper is to show that product-to-recycle ratio can be used as a manipulated variable in order to stabilize the granulation plant
The dynamic model that was developed for the rotary drum granulation loop used in fertilizer production is able to capture the main dynamics of the granulation process
Summary
Granulation is a particle enlargement process during which fine particles and/or atomizable liquids are converted into granules via a series of complex physical processes [1]. CSs, the controlled variable is the granule PSD distribution, as measured by d50 , coming from the rotary drum (effluent from the granulator). In some industrial-scale rotary drum granulation loop plants, the crusher gap spacing can be manipulated by operators from the control room. In other rotary drum granulation loop plants, the crusher gap spacing can only be changed manually by operators on the plant itself, and, the crusher gap spacing can not be chosen as manipulatable variable. A novelty of this paper is to show that product-to-recycle ratio can be used as a manipulated variable in order to stabilize the granulation plant
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