Burning Zone Temperature Research Articles

Development of Conventional Controller Based on Image Processing for Monitoring and Controlling Burning Zone Temperature in a Cement Plant in Rotary Kiln Process Through IOT

In the cement factories, a rotary kiln is a pyro-processing device that is used to raise the temperature of the materials in a continuous process. Temperature monitoring is an essential process in the rotary kiln to yield high quality clinker and it has been implemented using various image processing techniques. In this paper we are measuring and controlling the temperature of rotational kiln in cement industry to get proper clinker ouput. Burning zone flame images are captured using CCD(Charge Coupled Device) camera and are processed using image processing with PID(Proportion Integration and Derivative) controller and which are programmed on raspberry pi card with the help of python language, also the captured images and attributes are transferred to authorized mobile/pc through Raspberry PI by selecting the IP address of mobile or PC. All the attributes received in the mobile in the form of web page the according to the object following data temperature controlled and object is ceaselessly followed to get the proper clinker output. Picture handling calculation with Open cv, as indicated by the calculation the edge estimation of the camera is settled. The frame value of the camera is set. Conversion from RGB color space to HSV color space is achieved and the reference color threshold value is determined. The range esteem estimated by the camera is contrasted and the reference esteem. In this study temp of rotational kiln is measured effectively using PID controller, this controller continuously control the temperature of revolving kiln by varying the i/p images of burning zone at finally fix one flame which is giving 1400degc.

Integration of genetic algorithm tuned adaptive fading memory Kalman filter with model predictive controller for active fault-tolerant control of cement kiln under sensor faults with inaccurate noise covariance

Reliable control of cement kiln under sensor faults is vital to ensure cement clinker quality. To accomplish this objective, an active fault-tolerant control (FTC) scheme is proposed for burning zone temperature control of cement kiln even under inaccurate measurements. FTC is achieved by integrating adaptive fading memory Kalman filter (AFMKF) in an already existing model predictive controller (MPC) framework. Residue from the Kalman filter is used to detect faults, and the model prediction replaces sensor measurements. Hence, there is a need for an accurate model and its associated noise covariance. Model accuracy is ensured by the online estimation of sensor noise covariance using the proposed AFMKF. Hyperparameters governing the AFMKF are tuned using the multi-objective genetic algorithm (GA), aiming to minimise the modelling and tracking error. Sensor measurement failure, bias, and stuck are considered for performance validation of the proposed FTC. Percentage recovery from fault is evaluated in terms of Integral square error (ISE) and energy utilisation compared with a conventional MPC. Experimental results illustrate the significant improvement in model accuracy and fault-tolerant behaviour using the proposed GA tuned AFMKF.

Design and Real Time Implementation of Anfis Controller for Optimizing the Burning Zone Temperature in Rotary Kiln in Cement Industry

Design and Real Time Implementation of Anfis Controller for Optimizing the Burning Zone Temperature in Rotary Kiln in Cement Industry

Design of a Robust Fractional Order Controller for Burning Zone Temperature Control in an Industrial Cement Rotary Kiln

The control of the temperature of the burning zone of an industrial cement rotary kiln is addressed in this paper. An experimental identification of the process was carried out, which yielded a second order transfer function with no zeros but with a very large time delay. Moreover, it was detected that this time delay could change between ±8% of its nominal value. Then a robust controller had to be designed for this process. A standard PI controller, a PI controller embedded in a Smith Predictor scheme, and a fractional-order controller embedded in a Smith Predictor have been studied. A method to design the fractional-order controller is developed in this paper that yields better results than the other studied controllers. Simulated results are presented.

Development and Evaluation of Mathematical Model based Region of Interest for Rotary kiln Burning Zone Temperature in Cement Industry by Digital Image Processing

Industrial processes particularly cement manufacturing unit consumes about 7% of total fuel used in the industry and hence there are strenuous efforts to reduce the fuels and lower the production costs by applying Optimal Control Algorithms. In order to achieve these parameters in the Rotary Kiln Plant, we need to continuously monitor the temperatures of the burning zone inside the rotary kiln at Regions of Interest (ROI) in real-time. In this image processing setup a thermal camera samples the temperatures inside the kiln at a rate of 5 frames per 2 seconds. The images which are highly sensitive to red and green wavelengths provide sufficient resolution to differentiate between various burning temperatures. The present burning zone temperature measurement obtained from the radiation pyrometer is not reliable on the one hand and indicates temperature information about particular point in the burning zone on the other hand. This is inadequate for optimizing the operation the kiln where a kiln furnace camera has been already installed at the plant for watching the burning status the inside the kiln. Software will be developed to determine the temperature T, for the video captured from the camera. Presently real time video from the camera is displayed in a computer monitor at kiln control room. We will tap the video signal from the setup and the calculate the burning zone temperature at the Region of Interest utilizing real time Image Processing Technologies. The temperature signal so estimated will be validated using the radiation pyrometer signal obtained from the field. The graphical tool developed in MATLAB automatically converts the receiving color images to temperature measure by proposed algorithms and also interactively analyzes the temperatures in a neat graphical user interface, in less than 2 seconds duration. ROI can be selected by a movable and re-sizable window which acts like a probe on the kiln temperatures at this instant, then displays the summary statistics of the temperatures. The tool is extended to provide a real-time graph of average temperature in the ROI over a long time when the probe is fixed at a particular region. However, the developed temperature tool and the point burning zone temperature measured by a proposed mathematical model as like thermocouple in the plant. The results are carried out by MATLAB software and benefits will be quantified in terms of enhancement in the Production efficiency, Energy efficiency, Pollution Control and clean environment.

Single-step prediction method of burning zone temperature based on real-time wavelet filtering and KELM

The single-step prediction of burning zone temperature plays an important role in the safety and stability control of cement rotary kiln. This is because, the abnormal temperature events can be found as early as possible and the operator can take effective emergency measures in time. In this paper, the burning zone temperature single-step prediction method based on real-time wavelet filtering and kernel extreme learning machine is studied. Firstly, the visual inspection device is used to detect the burning zone temperature. And then, the amplitude limited filtering method is used to weaken the effects of temperature anomalies. On this basis, the real-time filtering of the burning zone temperature is realized by combining the sliding time window and wavelet filtering method. After that, the single-step prediction of burning zone temperature is realized by combining the sliding time window and kernel extreme learning machine method. At last, the burning zone temperature prediction method is validated. The minimum root mean squared error of the 5 consecutive days is 0.4259°C. The single average running time of model training and prediction of kernel extreme learning machine is much less than support vector regression, which is very helpful for the online prediction of burning zone temperature. The result shows that the burning zone temperature single-step prediction method proposed in this paper is feasible and effective.

Research on the numerical simulation of secondary air diffusion angle to the swirl burners combustion process

In this paper, the combustion process of swirl burners during 660 MW unit power plant is simulated. The influence of secondary air diffusion angle on the furnace temperature and furnace slagging is studied. In detail the temperature field and the carbon concentration field and velocity field inside the furnace are analysed when the secondary air diffusion angle is set as 30 °, 45 ° and 60 ° respectively. The simulation results show that when the secondary air diffusion angle is set as 30°, the center temperature of the furnace is highest, and at this time the pulverized coal combustion is sufficient, the carbon concentration near the water wall is the lowest, moreover, it is not easy to slag in the furnace. With the increase of secondary air diffusion angle, the center temperature of boiler burning zone gradually decline, carbon concentration near the water wall increase, it is the more prone to coking inside the furnace. The numerical simulation results not only provide a reference basis for the boiler operation, but also provide an important reference value for exquisite combustion research of the boiler.

Trend extraction and identification method of cement burning zone flame temperature based on EMD and least square

The trend analysis of the temperature change of burning zone is very important for the normal production of cement clinker. In this paper, empirical mode decomposition (EMD) combined with the least square method is researched to realize the trend extraction and identification of cement burning zone flame temperature. Firstly, the temperature data is decomposed by EMD to obtain every intrinsic mode function (IMF) and the remainder. Then, the least square method is used to fit every IMF and the remainder. With the fitting error as the judgment criterion, the trend of the signal is extracted as the combination of the IMF components with less fitting error and the remainder. Further, the first derivative of the fitting function is used to determine the fundamental change in the trend of the signal, and the trend identification result is obtained. At last, the trend extraction and identification method is validated on the burning zone temperature data obtained from a cement company. The results show that the trend extraction and identification of the burning zone temperature based on EMD and least square is effective. More importantly, the method proposed in this paper can automatically determine the number of EMD decomposition layers. It does not have the problem of artificial selection of basis function and decomposition layers, and does not require empirical knowledge and complex experimental procedures for extracting trend item of burning zone temperature. This paper provides a feasible method for the extraction and identification of the burning zone temperature.

T-S fuzzy neural network predictive control for burning zone temperature in rotary kiln with improved hierarchical genetic algorithm

How to control burning zone temperature of the lime rotary kiln is an important problem. In order to improve the control performance of burning zone temperature in lime rotary kiln, a predictive control method based on improved hierarchical genetic algorithm and T-S fuzzy neural network was proposed. This control method utilised T-S fuzzy neural network to build a nonlinear predictive model of burning zone temperature in rotary kiln. The predictive error is corrected through predictive output burning temperature, output feedback error and error correction. A fitness function is established by deviation and control variable. An improved hierarchical genetic algorithm was used for rolling optimisation of the optimal control variable. Simulation results show that the proposed predictive method has good control effect.

MODELING OF PROCESS PARAMETERS AND ANALYSIS OF EFFECT OF VARIABLES IN THE DEAD BURNING OF MAGNESITE IN ROTARY KILN

The challenges of improving sintered MgO raw materials with special high temperature properties demand higher temperature calcination. In the process of dead burning of magnesite (DBM) in rotary kiln, the heat expenditures were found to be mainly due to dead burning of magnesite, loss through exhaust gases, loss through kiln shell by radiation & convection, clinker exit etc. The calcination process is highly energy intensive and involves various interdependent variable factors. An attempt was made to build a model and a screening design of experiment was performed with few process variables to identify the greatest effect of variables on the response quality. The design variables chosen were raw magnesite (RM) feed rate, kiln rotation (RPM), fuel consumption and burning zone temperature (BZT). The response variables were exit gas temperature and density of dead burnt magnesite (DBM). A fractional factorial design was used to keep the number of experimental runs to a minimum. ANOVA and normal plots were used to evaluate the effects of different variable factors on the sensory/response properties. The Experimental Design, ANNOVA, Response surface etc. given an insight of dead burning of magnesite in rotary kiln. This work had enabled us to correlate the BZT, RPM, RM feed with the exit gas temp and density of magnesite produced. The result opens up an avenue to look into the optimum region of operations within the ranges of variables considered in order to minimize the exhaust gas temp. and to maximize the density of the DBM produced.

Application of Flame Image Recognition-Based Information Fusion Technology to Roller Kiln Temperature Detection

Roller kiln is a kind of advanced fast sintering kiln. In production process of roller kiln, materials sintering of burning zone is the key working procedure which affects product quality directly. Hence, the temperature detection process of burning zone became the key link in roller kiln control system. This paper proposed a kind of fusion method of both temperature point detection and flame image recognition of imitating ‘artificial-look-fire’. Flame image processing-based temperature detection scheme was also given. In the scheme, expert system fuses temperature data detected by the thermocouple with flame image data of burning zone detected by CCD so as to obtain the actual temperature of burning zone. The method proposed greatly improves the temperature detection precision of burning zone working conditions. The experimental results show that the proposed method is feasible and effective.

Analysis and Depiction of the Dynamical Characteristic of Burning Zone Temperature in Rotary Kiln of Cement Material Production

The cement is one of the most important building materials, and the rotary kiln is a key equipment or process in the cement production industry. During the operating of the cement rotary kiln, the burning zone temperature (BZT) is an important production index and has a significant role on the quality of the clinker. However, the BZT has complex dynamic characteristic and is difficult to be described online using the conventional approaches. Although the BZT can be detected by using the expensive infrared pyrometer which located at the kiln head hood, it generally loses veracity due to the complex dynamics of the cement rotary kiln. In this paper, a novel approach is proposed to analyze and depict the dynamical characteristics of the BZT. Industrial tests have been performed to demonstrate the effectiveness and validity of the proposed method.

Lateral propagation of the helium shell flash on an accreting neutron star

view Abstract Citations (31) References (9) Co-Reads Similar Papers Volume Content Graphics Metrics Export Citation NASA/ADS Lateral propagation of the helium shell flash on an accreting neutron star Nozakura, T. ; Ikeuchi, S. ; Fujimoto, M. Y. Abstract The propagation of a thermal wave caused by a helium flash on an accreting neutron star is investigated by a one-zone model. Our model consists of equations for the energy balance and the mass balance. The energy equation includes the nuclear reaction, the radial heat flux which is characterized by a parameter representing the temperature of the hydrogen burning zone, and the lateral heat flux. Another parameter of the model is the accretion rate in the mass equation. As for the lateral heat flux, two limiting cases are examined: one is the case that there is no convention, and the other is the case that the convection is effective for the lateral heat transport. The velocities of thermal waves are obtained in the above two cases for various parameters started from the local ignition of flashes. In the "convective case" the velocities are generally two orders of magnitude larger than those in the "conductive case," and the travel time across a large fraction of the surface of a neutron star is ∼ 0.1-10 s, depending upon the temperature of the hydrogen burning zone. Furthermore, if the initial surface density is inhomogeneous, there can be several interesting temperature profiles. The velocities of the waves are determined by the local pressure in these cases, and the waves never stop as long as the local pressure is beyond a certain critical value. Publication: The Astrophysical Journal Pub Date: November 1984 DOI: 10.1086/162590 Bibcode: 1984ApJ...286..221N Keywords: Computational Astrophysics; Helium; Neutron Stars; Stellar Mass Accretion; Stellar Structure; X Ray Sources; Computerized Simulation; Heat Balance; Heat Flux; Mass Balance; Propagation Velocity; Stellar Models; Thermal Radiation; Thermonuclear Reactions; Astrophysics full text sources ADS |

Process Analysis Techniques for Cement Kilns

Some useful techniques for the process analysis of cement kilns, related experience, and theoretical considerations are discussed in this paper. In the practical application of process analysis techniques?i.e., autocorrelation, spectral density analysis, crosscorrelation, scatter diagram, and estimation of impulse response by the use of the least-square method?the most important problem is how to treat the data prior to data analysis in order to minimize the effect of noise. The data gathered directly from a kiln contains, in many cases, two kinds of noises?trend and high-frequency noise?and the most useful information lies in the medium-frequency range. In our process analysis system, the high-frequency noise within the range 0.01-60 Hz is eliminated by the use of non-linear analog filters specially developed during the data acquisitions. Remaining high-frequency noise and trend are eliminated by digital filters, i.e., high-pass and low-pass filters, respectively. If these filters and process analysis techniques are applied properly, remarkably clear relationships are obtained among the kiln data, notably: clinker quality, burning-zone temperature, kiln drive torque, secondary air temperature, etc. In the technical theory it is proved that the application of filters does not alter the estimated process characteristics when the same filter is applied to both input and output data of the process to be analyzed. Concerning the estimation of the impulse response, very important considerations are the selection of the data sampling interval, the length of response to be estimated, and feedback loops contained in the process itself.

Dynamic computer regulation of a dry-process cement kiln

The paper describes the application of adigital computer to the dynamic regulation of a dry-process Humboldt cement kiln and its associated Fuller cooler. The background to the project and an outline of this particular process and its control problems are given. The control hardware is then briefly outlined, together with details of the kiln models and their method of derivation. Particular attention is paid to the problem of measuring the burning-zone temperature, and the close correlation of this measurement with kiln power, which can be used as an alternative indication of burning zone temperature in the short term. The control system and the discrete equations for control of the kiln are also given, together with a discussion of their functions. One feature of this application, which greatly reduced commissioning time, was the implementation of the linear and nonlinear control equations entirely by a standard conversational control package online via a control panel without programming in the conventional sense. The commissioning procedure and the results obtained under control are discussed.

Dynamic Control of the Cement Process with a Digital Computer System

A control study of the cement manufacturing process has culminated in the installation of a direct digital control (DDC) system which automatically controls both the ball-mill blending of raw materials for kiln feed and the kiln-cooler combination. In each case, the control schemes were developed by determination of the process dynamics, computer simulation and analysis, and field application at the plant. The blending control scheme finally developed is based on measurement of ball-mill output composition with an X-ray analyzer, and on a concept of noninteracting feedforward-feedback control. The kiln-cooler control scheme utilizes conventional and advanced control techniques such as nonlinear, feedforward and adaptive compensations, and optimization. This control scheme includes coordinated loops for control of burning zone temperature by manipulation of fuel rate and/or kiln speed, for control of kiln exit temperature and oxygen by ID fan speed, and for maximization of production rate by trim manipulation of kiln speed. The control schemes are being applied at the plant with a DDC system which provides maximum operating flexibility with extensive simplification of the operator-computer interface. The direct digital control operating experience has been very favorable.

Uneveness of Solids Flow through Cement Rotary Kiln and Burning Zone Temperature

Uneveness of Solids Flow through Cement Rotary Kiln and Burning Zone Temperature