Optimal control of accretion growth and quality of sponge iron in a coal-fired rotary kiln at Tata Sponge, India

Abstract

Conventional and AI techniques are used for prediction of temperature along the length of kiln and also quality of sponge iron produced. Actual measured temperature and other operational data such as feed rate of ore and coal, primary and secondary air blowing rate, kiln pressure is used to tune and update the model continuously. The model equations are suitably constrained to restrict accretion growth. A graphic user interface is used by the operator to control the process. Results of plant trials are described. Minimum response time of a large coal fired rotary kiln (80 m in length) is approximately 3-4 hours. � 2018 by AIST.