Background:The leading carbon emitting unit of the zinc smelting industry is the zinc oxide rotary kiln, which preserves a trade-off between carbothermic reduction and the zinc recovery rate. To scale up a substantial zinc restoration rate during the hydrometallurgical process, a substantial amount of coke is combusted, which leads to significant greenhouse gas emissions. It is imperative to mitigate the emission of carbon as reduced as possible. Since the kiln operates in three different regions — gas, solid, and wall — several highly non-uniform paths are typically linked to one another to yield complex looping processes. In industrial settings, solid maldistribution and gas refluxing pose prevalent challenges in the gas–solid flow mechanism. Consequently, control over processes and observation of the internal states/concomitant parameters become critical for ensuring safe and reliable operation. Therefore, it is imperative to devise effective control layouts to optimize the functioning of the kiln system. Method:(i) The usual form of model-predictive control rule is paired with an economic stage cost (using the CasADi optimization method) to offer optimal consumption of the coal and the rotation speed, thereby effectively alleviating the adverse effects of the unmeasured perturbations, actuator faults, or multi-sensor failures. (ii) With the aid of accessible state sensors, a cubature Kalman filter infused with a singular-value-decomposition strategy reliably predicts uncertainties/faults of the actuators or the unmeasured states of the kiln. (iii) cubature Kalman filter and event-triggered scheduling are utilized together, to consume less communication resources. Significant findings:A variety of indicators, such as zinc recovery rate (1.35% improvement), carbon emissivity (11.54% improvement), residence time (6% shorter), accuracy of the controllers/observers were well assessed and compared with standard form of the non-linear model predictive control law to figure out the efficiency and acceptability of the economic model predictive controller, demonstrating on an industrial rotary kiln. An in-depth study of the proposed control method satisfying Lyapunov inequality has been addressed.
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