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An Expert System Application for Lime Kiln Automation

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An Expert System Application for Lime Kiln Automation AN EXPERT SYSTEM APPLICATION FOR LIME KILN AUTOMATION STEPHEN W. HAGEMOEN, P.E. SENIOR MEMBER, IEEE Universal Dynamics Limited 100-13700 International Place Richmond, Canada V6V 2X8 Abstract - The complex nature of the lime lime at optimum efficiency have not calcining process with its long time delays, been developed, variable feed characteristics, changing • kiln operators have varying and operating conditions, non-linear chemical sometimes conflicting operating methods and thermal reaction rates makes the rotary that prevent efficient and stable kiln lime kiln difficult to operate. The time operation from one shift to the next, dependent and complex interaction between • long process time delays, particularly kiln parameters makes the successful with respect to product temperature automation of kiln operation a daunting task control, make operation of the kiln that has eluded many kiln operators. difficult because operators must remember their past actions for several This paper describes a kiln automation hours in order to correctly interpret system that combines an expert system with current kiln conditions. adaptive loop controllers to automate kiln operation and provide significant kiln Many of the problems facing kiln automation performance improvements. can be corrected by using present technology and by maintaining process sensors and equipment in good working order. However, INTRODUCTION there are certain kiln control loops such as the firing hood draft whose characteristics The goals of lime kiln automation are: are beyond the capability of conventional process controllers. Kiln operators generally • improve lime quality turn such loop controllers to the manual • increase kiln production mode and close the loop themselves. Most • improve fuel efficiency operators have difficulty handling the long • increase refractory life time delays inherent with lime kiln • improve kiln information gathering and operation. In addition, they often use processing. unsuitable control tactics. The net result is less than optimal kiln operation and lime In most lime kilns these goals are not being quality, and production efficiency suffers. met because: The lack of kiln automation can significantly • process sensors are unreliable and limit kiln performance. inaccurate, • the instrument loop controllers used This paper describes a new approach to lime cannot maintain the process variables at kiln automation that combines the experience the set points, of lime kiln operators in an expert system • accurate, dynamic kiln process models program with a unique adaptive process loop that can automatically calculate and controller to achieve the long sought goals of adjust kiln set points to produce quality kiln automation. www.andritz.com 1 of 7 CO 2 VS DUST COLLECTOR I D FAN SECONDARY MUD MUD AI R FILTER FLOW METER 950 deg. C 1250 deg. C 750 deg. C 230 deg. C CaCO3 NCG LI ME MUD VS PRI MARY AI R AND FUEL VS O 2 ANALYZER DRIVE 250 deg. C HOT LI ME CaO Figure 1. Typical Pulp Mill Lime Kiln DESCRIPTION OF KILN OPERATION calcium oxide. Some kilns have a third section where the quick lime is cooled and The rotary lime kiln is a major component of the secondary combustion air is preheated. In the kraft pulp mill recausticizing operation. most cases, the cooler consists of a number Sodium hydroxide, which is mixed with the of tubes arranged around the circumference wood chips and cooked in the digester, is of the kiln at the firing end of the kiln. The recovered in the recovery boiler and calcining process is endothermic and regenerated in the recausticizing plant. This requires 3.0 kJ/kg of lime at a temperature in is done by exchanging the sodium ion in the excess of 900°C. Most kilns use natural gas green liquor (sodium carbonate stream) from or oil as a fuel source. Some installations use the recovery boiler with a calcium ion from coal as a fuel but there is concern that the ash calcium hydroxide. After the exchange, residue will cause an undesirable build-up of sodium hydroxide is mixed with wood chips contaminates in the lime, which could in the digester and the calcium carbonate is adversely affect the quality of caustic calcined to form CaO in the rotary kiln. The produced by the recausticizing plant. calcium oxide is then slaked to form calcium hydroxide. The calcium hydroxide is mixed The transit time of the feed through the kiln with the sodium carbonate from the recovery varies with the production rate but is boiler and the whole cycle is repeated. typically between three to four hours. The lime calcining process used by most In many kilns secondary burners are used to kraft pulp mills uses a rotary lime kiln to destroy the non-condensable gases (NCG) convert the calcium carbonate mud from the that are generated in other parts of the pulp clarifiers to quick lime or calcium oxide. A mill. These gases are collected and burned in typical kiln installation is shown in Figure 1. the lime kiln along with the main fuel. The variable heating value of the NCGs causes It consists of a mud filter where the moisture additional disturbances to kiln operation. content is reduced to about 30 to 35%, a rotary kiln and dust collector. The kiln itself Lime kilns are subject to a number of is generally thought to consist of three disturbances and variations, some of which sections. The first section is a preheater or can be measured and some not. Common chain section where the calcium carbonate problems that adversely affect kiln operation mud is dried and nodulized. The second are: section is a calcining zone where the feed is heated to about 1150°C and converted to www.andritz.com 2 of 7 • variable mud feed rates due to changing analysis to be carried out and further filter action and periodic recoating of the enhancements in kiln operation to be filter cloth, implemented. • varying mud moisture content, • excessive sodium carbonate (NaCO3) in Process Sensors the mud feed, • varying flow and heat content in the All the required process sensors have been NCGs burned in the kiln, available on most kilns for a number of • non-linear combustion and lime years. However, most mills do not have calcination characteristics, sensors that are accurate and available on a • manual operation of instrument control continuous basis. There are several reasons loops, for this situation: • unreliable operation of kiln instrumentation, • instruments have not been properly • operator propensity to run kilns in a installed to give reliable operation, "comfortable" mode rather than the most • instruments have not been maintained in efficient mode, good working order, • differing kiln control tactics between one • instrument signals that have a high noise shift and the next, which can cause kiln component which most controllers are upsets at each shift change. unable to effectively filter out, • instruments whose failure mode is not recognized by many lime kiln controllers KILN AUTOMATION SYSTEM or operators. The kiln automation system was developed No kiln automation system can function to address many of the problems that hinder unless all the required sensors are kept in proper kiln operation. Four elements were good working order. It is pointless to proceed identified as being essential for the with a kiln automation project unless there is successful automation of a lime kiln. They a commitment to upgrade and maintain the are the need for: kiln process sensors. • accurate and reliable process sensors for Instrument Loop Controls all key kiln parameters, • instrument loop controllers that will An adaptive controller (AC) was developed automatically and continuously maintain [1] specifically for use in controlling kiln variables at their set point under all complex instrument loops on rotary kilns operating conditions. The controllers where conventional loop controllers are must be able to handle non-linear process inadequate. The AC has the unique ability to characteristics that change over time and learn the process characteristics while it is have long time lags, controlling the process. The AC is an • a supervisory control system that will adaptive controller that predicts the correct adjust the instrument controller set control action to handle process changes. It points to maximize production of quality never needs re-tuning once it has been lime using the least possible amount of installed because it continuously adapts to fuel, the process characteristic changes. The AC's • a production database to analyze kiln ability to handle non-linear processes makes performance. it possible to stabilize all the kiln control loops and to leave the controller in the The ability to accurately measure and report "automatic" mode of operation. kiln performance makes management information readily available and the The AC uses a Laguerre function series evaluation of kiln performance possible. It representation for modeling plant dynamics. also permits on-line kiln quality control www.andritz.com 3 of 7 As such, it could also be described as a The expert system was designed and tested neural network based controller [2]. over a period of 1-1/2 years. It was designed to handle normal quasi steady state operation Expert System (i.e., able to handle small perturbations) of the kiln with some "rate" features to The purpose of the supervisory control accommodate some of the larger changes to system is to generate optimal set points for kiln operating conditions. The "rate" features the kiln control loops. At the beginning of of the program look at the rate of change to the development of the kiln automation kiln variables in the preceding couple of system, it was intended to use a linear steady hours and adjust the size of the calculated set state thermodynamic model of the kiln to point change accordingly. calculate the various instrument loop set points. Statistical analysis of the kiln Two expert system modules were devised to operating data would be used to adjust the operate independently of the other.
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