Research On The Intelligent Monitoring For Thermal Effect KPI Of Cement Clinker Burning System

Cement clinker burning system is a huge energy consumption system whose heat consumption accounts for the most of those of cement production. While a number of devices constitute the complicated cement production process which is a complex thermal process with high nonlinear and high order characteristics. It is difficult to use a simple model to describe the relationship between the energy efficiency and energy transfer rule. At present, research on the heat and thermal efficiency of cement production process is only limited to the clinker burning system as well as off-line calculation and unable to monitor online real-timely, which has a big lag and no thermal effect KPI for online guiding the controlling of clinker burning process in real time, too.This paper is based on a cement plant of 5000t/d clinker production line in Shandong as the background. We studied the thermal process and thermodynamic principle of cement production and defined thermal efficiency and total thermal efficiency(thermodynamics) of system and each link(preheater link, decomposing furnace link, rotary kiln link, grate cooler link) as KPI for monitoring status of energy utilization. We also realized intelligent monitoring of heat balance and KPI, which is an effective support for the operation of clinker burning process on site.The main work is as follows:First of all, we determined the influence factors and the ways of obtaining relevant parameters for the intelligent monitoring about thermal efficiency of cement clinker burning system. These parameters include online monitoring parameters collected from cement production(such as the temperature of kiln hood, the pressure of decomposition furnace,the speed of high temperature fan etc.), indefinite period laboratory parameters(e.g. the calorific value of coal, the ingredients of raw material, the ingredients of flue gas etc.), fixed parameters(e.g.the heat of system surface, the radiant heat of kiln head, the gas temperature, etc.) through the artificial setting, some key soft measurement data(the actual air flow of fan, the heat capacity, the amount of clinker) which are approached by soft measurement method. For soft measurement data, we focused on the amount of clinker by principle of LS_SVM and the actual air flow of fan by mechanism analysis.Secondly, we studied the online monitoring for the heat input and heat output of system, the preheater link, the decomposing furnace link, the rotary kiln, the grate cooler link and realized their online monitoring respectively. Based on field investigation and thermal analysis, we defined thermal efficiency and total thermal efficiency(thermodynamics) of system and each link as thermal effect KPI of cement clinker burning system. Through real-time access to relevant parameters above and thermodynamics theory, we achieved intelligent monitoring for thermal equilibrium and thermal effect KPI of burning system and other four links, then given the analysis of engineering example.Finally, we developed the intelligent monitoring software on thermal effect KPI of cement clinker burning system, including background computation that is used to collect data and calculate parameters, web page publishing whose main function is to release important data and browse on the web and so on, which is convenient for relevant personnel to understand the energy situation on site locally or remotely. The practical application of this software proves that it is reliable and its results is relatively accurate. The software also can provide real-time effective support for the operating personnel to control the clinker burning process reasonably.