Mathematical modeling of the rotary furnace operations for the production of clinker

Abstract

This paper presents a comprehensive system of mathematical models to describe, simulate, and optimize the operational and energetic aspects of rotary furnaces within the cement industry. To achieve this, we delve into the interaction between the furnace and other aggregates within the plant. We define the key variables governing the furnace’s operation through a meticulous analysis. Leveraging the power of genetic algorithms, we successfully validate the model’s performance under static and dynamic operational conditions. A pivotal aspect of our approach involves considering the behavior of combustion gases as analogous to a piston flow system. This consideration enhances our understanding of the complex processes occurring within the furnace. Furthermore, we establish shutdown criteria based on predetermined values obtained from the Case study facility: TR (Total Runtime) of 47 minutes, GT (Gas Temperature) at 97 percent, and ℵ (Agitation Speed) at 35 percent. These predefined values align with the desired outcomes of our objective function (Z). Through integrating and implementing our findings, a promising avenue emerges for improving the final product’s fuel consumption rate and quality. By concurrently addressing the plants and furnaces efficiency indicators, we set the stage for a more sustainable and productive operation in the cement industry.