First-principle modeling and simulation of cement rotary kiln

Chongjian SUN1, Jianyu ZHAO, Shi LI*, Ping JIANG

1. School of Engineering, University of Jinan, Jinan, 250022, Shandong, China
E-mail: 1395554776@qq.com

Abstract: Cement rotary kiln is the core equipment of clinker firing system. The system model is very important for
understanding the process of cement calcination and optimizing the operating conditions. In this paper, a detailed
first-principle model is proposed, which can describe the change of temperature field and material density field in kiln.
By studying the production process of cement rotary kiln, a dynamic model is established for each section according to
the first principle mechanism. The unknown key parameters can be inferred from the known parameters in the model.
The model is simulated and analyzed dynamically according to the relevant data collected in the actual cement
production process. The simulation results of the model match with the actual conditions.
Key Words: Cement rotary kiln, first-principle model, temperature field, material density field, simulation

and carried out simulation study. The results showed that

1 INTRODUCTION
Cement industry is a typical process industry and an
important pillar industry of China's national economy and
social development [1]. China produced more than 2.4
billion tons of cement in 2016, accounting for nearly 60
percent of global output [2]. However, energy consumption,
which accounts for 65 percent of the cost of cement clinker,
has become a key factor hindering the development of
China's cement industry [3]. Optimizing and controlling
cement production process, improving energy efficiency
and reducing pollutant emission are the top priorities for the
green and healthy development of cement production
industry. The accurate system model is the basis of
optimizing control [4].
In the production process of new dry cement, the physical
and chemical reaction of cement clinker calcination is
complex, involving many variables, and the coupling,
hysteresis and strong nonlinearity among variables exist, so
the modeling is difficult [5]. In view of these problems,
domestic and foreign experts have conducted a large
number of relevant studies. Mechanism modeling is a
mathematical relationship between system variables based
on the first principle, which lays a foundation for optimal
control and parameter estimation of cement firing
system[6]. Liu et al. measured and analyzed the
temperature distribution of different reaction areas in the
cement rotary kiln, the movement of raw materials and the
heat transfer of high-temperature gas, and made an in-depth
study on the relationship between the movement of raw
materials in the rotary kiln with the rotary kiln body moving
towards the kiln head, which laid a foundation for
establishing the relationship among various variables in the
cement rotary kiln [7-9]. Mellman et al. analyzed the
factors that mainly affected the temperature change of
rotary kiln, established the mathematical model of
temperature control of rotary kiln with analytical method,
the model had certain reliability [10-12]. Hanein et al.
constructed a rotary kiln model based on the laws of
material balance and energy conservation, which could
predict the axial temperature change curve in the kiln [13].
Wang et al. constructed a dynamic model of cement rotary
kiln based on the material and energy balance and nonlinear
partial differential equation in the rotary kiln [14]. Shahin
and Liu established a one-dimensional calcination
mechanism model of cement clinker firing system based on
the energy conservation law and chemical reaction
mechanism, and analyzed the system thermal energy based
on the established model [15,16]. Zhao and Chen
established the static model of material and energy balance
by analyzing the relevant variables of rotary kiln, and this
kind of mathematical modeling has certain limitations [17].
Therefore, through comprehensive analysis and research,
combined with the production process of cement rotary kiln,
this paper segmented the inside of the rotary kiln, and put
forward a new method to model the segmented mechanism
of the rotary kiln. The modeling method fully reflects the
variation of temperature field and material density field in
rotary kiln. The model is simulated and analyzed
dynamically according to the relevant data collected in the
actual cement production process.
2 PLANT DESCRIPTION
The cement firing system consists of four parts: suspension
preheater, decomposition furnace, rotary kiln and grate
cooler. Raw material enters each link in turn. Complete the
process of raw material preheating, raw material
decomposition, raw material calcination and clinker
cooling. In the system, the raw material and the high
temperature gas move in the opposite direction, forming a
kind of suspension countercurrent heat exchange and
carrying out complex physical and chemical reactions. As
shown in Figure 1.

This work was supported by the National Natural Science Foundation

(NNSF) of China under Grant 61601197 and the Research Fund for the
Taishan Scholar Project of Shandong Province of China.
*˖Corresponding author

978-1-7281-5855-6/20/$31.00 2020
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 ܳ௚଴ : Air output rate, N݉ଷ /h.
H3: Suppose the carbon content of coal is 100%, the
reaction is instantaneous, and carbon dioxide is completely
generated.
H4: Assuming that the primary air volume is ignored, the
primary wind and secondary wind are actually regarded as
the air input rate.
H5: Since the combustion of pulverized coal is
instantaneous, which is equivalent to changing the oxygen
part into carbon dioxide part, the volume flow of air input
rate is equal to the volume flow of tail gas.
3.2 Mathematical modeling
Fig1. Cement rotary kiln Material mass conservation equation:
ௗ௠
As shown in Figure 2. According to the mechanism, the ‫ܮ‬௜ ೞǡ೔ ൌ ܳ௦ǡ௜ିଵ െ ܳ௦ǡ௜ ൌ ݉௦ǡ௜ିଵ ‫ݑ‬௦ െ ݉௦ǡ௜ ‫ݑ‬௦ ń
ௗ௧
rotary kiln is divided into four sections: decomposition L: Length, m.
zone, transitional zone, firing zone and cooling zone. Each i: Number of segments.
region can be regarded as a first-order model, that is, ݉௦ : The density of material, t/m.
material temperature, gas temperature and material mass ‫ݑ‬௦ : Velocity of material flow, m/h.
density in each region are uniform. According to the Write the detailed equation in four parts:
principle of mass conservation and energy conservation, the ௗ௠
‫ܮ‬ଵ ೞǡభ ൌ ܳ௦௜௡ െ ݉௦ǡଵ ‫ݑ‬௦ Ņ
mass conservation equation of material, energy ௗ௧
ௗ௠ೞǡమ
conservation equation of material, energy conservation ‫ܮ‬ଶ ൌ ݉௦ǡଵ ‫ݑ‬௦ െ ݉௦ǡଶ ‫ݑ‬௦ ņ
ௗ௧
equation of gas and oxygen concentration conservation ௗ௠ೞǡయ
‫ܮ‬ଷ ൌ ݉௦ǡଶ ‫ݑ‬௦ െ ݉௦ǡଷ ‫ݑ‬௦ Ň
equation are established. ௗ௧
ௗ௠ೞǡర
‫ܮ‬ସ ൌ ݉௦ǡଷ ‫ݑ‬௦ െ ݉௦ǡସ ‫ݑ‬௦ ň
ௗ௧
Material energy conservation equation:
݀൫ܿ௣௦ ݉௦ǡ௜ ‫ܮ‬௜ ܶ௦ǡ௜ ൯
ൌ ܿ௣௦ ܳ௦ǡ௜ିଵ ܶ௦ǡ௜ିଵ െ ܿ௣௦ ܳ௦ǡ௜ ܶ௦ǡ௜ ൅
݀‫ݐ‬
݇௚௦ǡ௜ ‫ܮ‬௜ ൫ܶ௚ǡ௜ െ ܶ௦ǡ௜ ൯ െ ܳ௦ǡ௜ ο‫ܪ‬௦ǡ௜ െ ݇௟ǡ௜ ‫ܮ‬௜ ܶ௦ǡ௜ ʼn
ܿ௣௦ : Specific heat capacity of material mass.
݇௚௦ : Heat transfer coefficient, gas-solid.
ο‫ܪ‬௦ : Material reaction enthalpy.
݇௟ : Heat loss coefficient.
Put the above equation into order˖
Fig2. Rotary kiln section
݀ܶ௦ǡ௜
ܿ௣௦ ൫݉௦ǡ௜ ‫ܮ‬௜ ൯ ൌ ܿ௣௦ ൫݉௦ǡ௜ିଵ ‫ݑ‬௦ ൯൫ܶ௦ǡ௜ିଵ െ ܶ௦ǡ௜ ൯ ൅
3 FIRST-PRINCIPLE MODELLING ݀‫ݐ‬
݇௚௦ǡ௜ ‫ܮ‬௜ ൫ܶ௚ǡ௜ െ ܶ௦ǡ௜ ൯ െ ൫݉௦ǡ௜ ‫ݑ‬௦ ൯ο‫ܪ‬௦ǡ௜ െ ݇௟ ‫ܮ‬௜ ܶ௦ǡ௜ Ŋ
3.1 Modeling hypothesis
Write the detailed equation in four parts˖
The calcining process of rotary kiln is a complicated and ݀ܶ௦ǡଵ
changeable process. Some minor factors need to be ignored ܿ௣௦ ൫݉௦ǡଵ ‫ܮ‬ଵ ൯ ൌ ܿ௣௦ ܳ௦ǡ௜௡ ൫ܶ௦ǡ௜௡ െ ܶ௦ǡଵ ൯ ൅
݀‫ݐ‬
in the modeling process so that the simulation of the model ݇௚௦ǡଵ ‫ܮ‬ଵ ൫ܶ௚ǡଵ െ ܶ௦ǡଵ ൯ െ ݉௦ǡଵ ‫ݑ‬௦ ο‫ܪ‬௦ǡଵ െ ݇௟ ‫ܮ‬ଵ ܶ௦ǡଵ ŋ
can be closer to the actual production conditions. ݀ܶ௦ǡଶ
H1: Assuming that the input raw material flow is equal to ܿ௣௦ ൫݉௦ǡଶ ‫ܮ‬ଶ ൯ ൌ ܿ௣௦ ݉௦ǡଵ ‫ݑ‬௦ ൫ܶ௦ǡଵ െ ܶ௦ǡଶ ൯ ൅
݀‫ݐ‬
the output clinker material flow, which accounts for 5 ݇௚௦ǡଶ ‫ܮ‬ଶ ൫ܶ௚ǡଶ െ ܶ௦ǡଶ ൯ െ ݉௦ǡଶ ‫ݑ‬௦ ο‫ܪ‬௦ǡଶ െ ݇௟ ‫ܮ‬ଶ ܶ௦ǡଶ Ō
percent of the raw material flow is decomposed into gas, ݀ܶ௦ǡଷ
this part is neglected. ܿ௣௦ ൫݉௦ǡଷ ‫ܮ‬ଷ ൯ ൌ ܿ௣௦ ݉௦ǡଶ ‫ݑ‬௦ ൫ܶ௦ǡଶ െ ܶ௦ǡଷ ൯ ൅
݀‫ݐ‬
ܳ௦ ൌ ܳ௦ǡ௢௨௧ ൌ ܳ௦ǡ௜௡ Ł ݇௚௦ǡଷ ‫ܮ‬ଷ ൫ܶ௚ǡଷ െ ܶ௦ǡଷ ൯ െ ݉௦ǡଷ ‫ݑ‬௦ ο‫ܪ‬௦ǡଷ െ ݇௟ ‫ܮ‬ଷ ܶ௦ǡଷ ō
ܳ௦ : Material flow rate, t/h. ݀ܶ௦ǡସ
ܳ௦ǡ௢௨௧ : Output material flow rate, t/h. ܿ௣௦ ൫݉௦ǡସ ‫ܮ‬ସ ൯ ൌ ܿ௣௦ ݉௦ǡଷ ‫ݑ‬௦ ൫ܶ௦ǡଷ െ ܶ௦ǡସ ൯ ൅
݀‫ݐ‬
ܳ௦ǡ௜௡ : Input material flow rate, t/h. ݇௚௦ǡସ ‫ܮ‬ସ ൫ܶ௚ǡସ െ ܶ௦ǡସ ൯ െ ݉௦ǡସ ‫ݑ‬௦ ο‫ܪ‬௦ǡସ െ ݇௟ ‫ܮ‬ସ ܶ௦ǡସ Ŏ
H2: Assume perfect gas: Gas energy conservation equation˖
ߩ௔଴ ܳ௔଴ ൌ ߩ௔ǡ் ܳ௔ǡ் ł ݀ܶ௚ǡ௜
ߩ௚଴ ܳ௚଴ ൌ ߩ௚ǡ் ܳ௚ǡ் Ń ܿ௣௚ ݉௚ ‫ܮ‬௜ ൌ ܿ௣௚ ߩ௚଴ǡ௜ାଵ ܳ௚଴ǡ௜ାଵ ܶ௚ǡ௜ାଵ െ
݀‫ݐ‬
ߩ௔଴ : Air input density. ܿ௣௚ ߩ௚଴ǡ௜ ܳ௚଴ǡ௜ାଵ ܶ௚ǡ௜ െ ݇௚௦ǡ௜ ‫ܮ‬௜ ൫ܶ௚ǡ௜ െ ܶ௦ǡ௜ ൯ െ ܳ௙ǡ௜ ο‫ܪ‬௙ ŏ
ܳ௔଴ : Air input rate, N݉ଷ /h. ܿ௣௚ : Specific heat capacity of gas.
T: Standard case,0ćand one standard atmosphere. ݉௚ : Gas unit mass.
ߩ௚଴ : Air output density. ܳ௙ : Coal flow, t/h.

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The flow direction of gas is opposite to that of material. input rate, material entry temperature, air entry temperature
ߩ௚ǡଵ ൌ ߩ௚ǡଶ ൌ ߩ௚ǡଷ ൌ ߩ௚଴ Ő and kiln rotation speed. Among the 13 state variables,
ߩ௚ǡସ ൌ ߩ௚ǡହ ൌ ߩ௔଴ ő oxygen concentration is an algebraic equation, which can
ܳ௚ǡହ ൌ ܳ௚ǡସ ൌ ܳ௚ǡଷ ൌ ܳ௚ǡଶ ൌ ܳ௚ǡଵ ൌ ܳ௔଴ Œ be calculated directly from the input of the model without
considering its dynamic analysis. Under the initial
ܶ௚ǡହ ൌ ܶ௔ǡ௜௡ œ conditions, the material density, material temperature and
Write the detailed equation in four parts˖ gas temperature are assumed to be uniform in the four
݀ܶ௚ǡଵ sections, so the twelve state variables are simplified into the
ܿ௣௚ ݉௚ ‫ܮ‬ଵ ൌ ܿ௣௚ ߩ௚଴ ܳ௔଴ ൫ܶ௚ǡଶ െ ܶ௚ǡଵ ൯ െ
݀‫ݐ‬ initial points of three variables in table 1.
݇௚௦ ‫ܮ‬ଵ ൫ܶ௚ǡଵ െ ܶ௦ǡଵ ൯ (20) As shown in Figure 3, about 0.8h reaches the steady state,
݀ܶ௚ǡଶ and it can be seen from ݉‫ ݏ‬that with the movement of
ܿ௣௚ ݉௚ ‫ܮ‬ଶ ൌ ܿ௣௚ ߩ௚଴ ܳ௔଴ ൫ܶ௚ǡଷ െ ܶ௚ǡଶ ൯ െ
݀‫ݐ‬ material, the mass of material from decomposition to the
݇௚௦ ‫ܮ‬ଶ ൫ܶ௚ǡଶ െ ܶ௦ǡଶ ൯ (21)
cooling zone gradually increases. Both material
݀ܶ௚ǡଷ temperature and gas temperature increased from the initial
ܿ௣௚ ݉௚ ‫ܮ‬ଷ ൌ ܿ௣௚ ܳ௔଴ ൫ߩ௔଴ ܶ௚ǡସ െ ߩ௚଴ ܶ௚ǡଷ ൯ െ
݀‫ݐ‬ point of 850ɗ, but the firing zone increased the fastest,
݇௚௦ ‫ܮ‬ଷ ൫ܶ௚ǡଷ െ ܶ௦ǡଷ ൯ െ ܳ௙ ο‫ܪ‬௙ (22) because the coal injection rate in the firing zone was
݀ܶ௚ǡସ assumed to be instantaneous combustion, releasing heat to
ܿ௣௚ ݉௚ ‫ܮ‬ସ ൌ ܿ௣௚ ߩ௔଴ ܳ௔଴ ൫ܶ௔ǡ௜௡ െ ܶ௚ǡସ ൯ െ
݀‫ݐ‬ heat the gas. Therefore, temperature increases the fastest.
݇௚௦ ‫ܮ‬ସ ൫ܶ௚ǡସ െ ܶ௦ǡସ ൯ (23) At the same time, gas flows into the transition zone and
Oxygen concentration conservation equation˖ decomposition zone to heat material, while when material
Since the pulverized coal is completely burned in the firing flows into the cooling zone, gas is heated. Therefore, it can
section, oxygen is consumed instantly in the firing section, be seen from the figure that for the material temperature,
and the oxygen content in the cooling section is consistent the temperature of the firing zone changes the fastest,
with the oxygen content in the air input rate. The other three followed by the cooling zone, and finally, the transition
areas have the same amount of oxygen. zone and decomposition zone. The gas temperature changes
݂௢௜௡ ߩ ܳ െ ݂௢మ ߩ௚଴ ܳ௔଴ െ ߛ௖ି௢మ ܳ௙ ൌ Ͳ (24)
relatively quickly.
మ ௔଴ ௔଴
1.12 1400
݂௢మ : Percent oxygen content. 1.1 1300

ߛ௖ି௢మ : Oxygen demand per unit of carbon. 1.08 1200

m s (t/m)

T (C)
zone1
In this paper, a rotary kiln model as shown above is 1.06
zone2
1100

s
established by studying the production process of cement 1.04 zone3
zone4
1000

1.02 900
rotary kiln. The model is simulated according to the data of
1 800
rotary kiln in some references, and the simulation results 0 0.2 0.4 0.6
time (h)
0.8 1 0 0.5
time (h)
1

are shown in the fourth section. 1800

4 DYNAMIC AND STATIC SIMULATION 1600

AND ANALYSIS 1400

Tg (C)

1200

4.1 Dynamic simulation from initial value to steady 1000

state value 800

0 0.5 1
time (h)
Table1. Simulation Parameters
Fig3. Dynamic description from initial point to steady point
Initial point As shown in Figure 4, in steady state, material temperature
݉‫ݏ‬
ܶ‫ ݏ‬and gas temperature ܶ݃ in the four regions.
1t/h
1800
ܶ௦ 850ɗ 1700
Ts
Tg
ܶ௚ 850ɗ 1600

Input value 1500

ܳ௦ 300t/h
Temperature (C)

1400

ܳ௙ 12t/h 1300

Calculated by the excess 1200

ܳ௔଴
oxygen ratio
1100
ܶ‫Ͳݏ‬ 850ɗ
1000
ܶ݃Ͳ 1150ɗ 900

N 4r/min 800
1 1.5 2 2.5 3 3.5 4
The state variables of the model include four material Length

densities, four material temperatures, four gas temperatures Fig4. Steady state temperature distribution of furnace gas and solid
and one oxygen concentration. There are six input of the The temperature distribution is match with the actual
model, including material flow rate, coal injection rate, air conditions. As shown in Table 2.

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 Table2. Simulation Temperature zone1
140 1.096
zone2
2 3 4

Qa0 v ariation (% )
i 1 120 1.096 zone3
zone4

m s (t/m )
ܶ௚ (ć) 1050 1242 1755 1226 100 1.096

ܶ௦ (ć) 900 1050 1349 1298 80 1.096

60 1.096
0 1 2 3 4 0 1 2 3 4
4.2 Step input dynamic analysis time (h) time (h)

Step through the six input states of the model in turn. The 1400 1800

dynamic characteristics of the six inputs are analyzed. The 1200

1600

magnitude, speed and sensitivity of step change are

Tg (C)
Ts (C)
1400
analyzed. 1000
1200
1) The step response characteristics of the model to the
800 1000
material flow rate 0 1 2 3 4 0 1 2 3 4
time (h) time (h)

140 1.6 Fig7. Step response characteristics of the model to air input rate
zone1
Air input rate increased by 10%. On the whole, cooling gas
Qs variation (% )

120 1.4 zone2

m s (t/m )

100 1.2
zone3 is added to cool the temperature in the kiln, and the
zone4
temperature of the cooling zone and the firing zone is
80 1
decreased by increasing the air input rate locally, but the
60 0.8
0 1 2 3 4 0 1 2 3 4 temperature of the transition zone and the decomposition
time (h) time (h)
zone is increased. Because the change in enthalpy is small,
1600 2000
the temperature doesn't change much. Air input rate
1400 decreased by 10%, resulting in the opposite result.
Tg (C)
Ts (C)

1200 1500 The effect of material entry temperature on the temperature

1000 of each part is close to that of the material. The air entry
800 1000
temperature has a great influence on the cooling zone,
0 1 2 3 4 0 1 2 3 4
time (h) time (h)
followed by the firing zone. The other two areas were
largely unaffected. With the increase of kiln rotating speed,
Fig5. The step response characteristics of the model to the material flow
rate the material moving speed is improved and the material
The material density field and temperature field in the kiln density is decreased, which has little influence on the
will be affected if the material flow rate increases and temperature. However, the increase of rotating speed will
decreases by 20% respectively. The material density reduce the temperature of each section, especially the
increases with the increase of material flow rate. Material temperature of firing zone. Due to the space, the dynamic
and gas temperature decreases with the increase of material step simulation graphs of the remaining three input items
flow rate. are no longer given.
2) The step response characteristics of the model to coal 4.3 Static analysis of input and output
injection rate
1˅ The model varies with the amount of material flow rate
zone1
140 1.096
zone2
40 300
zone3
Qf v ariation (% )

120 1.096 zone1

zone4 200 zone2
m s (t/m )

20
zone3
100 1.096
var ms (% )

var T (C)

100 zone4
s

0
80 1.096 0

-20
-100
60 1.096
0 1 2 3 4 0 1 2 3 4
-40 -200
time (h) time (h) 70 80 90 100 110 120 130 70 80 90 100 110 120 130
varQs (% ) varQs (% )
1600 2000
200
1400
100
Tg (C)
Ts (C)

1200 1500
var Tg(C)

0
1000
-100
800 1000
0 1 2 3 4 0 1 2 3 4
time (h) time (h) -200
70 80 90 100 110 120 130
varQs (% )
Fig6. The step response characteristics of the model to coal injection rate
The coal injection rate increases and decreases by 10% Fig8. The model varies with the amount of material flow rate
respectively. The temperature field in the kiln is affected, The material flow rate changes from 70% to 130%, and
but the material density is not affected. The oxygen content simulation is conducted every 5% to obtain the steady-state
in the kiln will change. value, record the steady-state value, and draw the static
3) Step response characteristics of the model to air input analysis diagram. It can be regarded as the sensitivity
rate analysis of 12 state variables to the input in each segment of
݉௦ , ܶ௦ and ܶ௚ . With the increase of material flow rate, the
material density increases, and the temperature of both

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material and gas decreases. Material flow rate decreases,
40 60
material density decreases, and temperature rises. The
temperature of firing zone is the most sensitive, followed by 20 40

var ms (% )

var Ts (C)
transition zone and cooling zone, and the range of 0 20

decomposition zone is the least. In general, the change of -20 0

material flow rate makes all state variables in the model
-40 -20
fluctuate greatly. 850 860 870 880 890 900 850 860 870 880 890 900
Ts0 (C) Ts0 (C)
2˅ The model varies with the amount of coal injected rate 60
zone1
40 200 z one1 40 zone2
z one2

var Tg (C)
zone3
z one3
20 100 20 zone4
z one4
var m (% )

var T (C)
s

s
0 0 0

-20 -100 -20

850 860 870 880 890 900
-40 -200 Ts0 (C)
70 80 90 100 110 120 130 70 80 90 100 110 120 130
varQf (% ) varQf (% )
Fig11. The model changes with the material entry temperature
300
The material entry temperature rises from 850ć to 900ć,
200

100
and a steady state value is obtained every 10ć. With the
v ar T (C)

increase of material entry temperature, the material mass

g

-100
density remain unchanged, the temperature of material and
-200

-300
gas rises linearly, and the temperature change from kiln tail
70 80 90 100 110
varQf (% )
120 130
to kiln head decreases.
Fig9. The model varies with the amount of coal injected rate 5˅ The model changes with the air entry temperature
The linear degree was better when the coal injection rate 40 20

increased, the temperature increased, the coal injection rate

20 0
decreased and the temperature decreased. The sensitivity of
v ar ms (% )

v ar Ts (C)
the firing zone is the highest, followed by the cooling zone 0 -20

and the transition zone, and the mass density of the material -20 -40

is not affected. -40 -60

1000 1050 1100 1150 1200 1000 1050 1100 1150 1200

3˅ The model varies with the amount of air input rate Tg0 (C) Tg0 (C)

40
40 40 zone1
20
zone2
20 0 zone3
20
var Tg (C)

zone4
var ms (% )

-20
var Ts (C)

0
0
-40
-20
-60
-20
-40
-80
1000 1050 1100 1150 1200
-40 -60
70 80 90 100 110 120 130 70 80 90 100 110 120 130 Tg0 (C)
varQa0 (% ) varQa0 (% )

Fig12. The model changes with the air entry temperature

100
zone1
zone2
The air entry temperature changes from 1000ć to 1200ć.
50
zone3 As the temperature rises, the material density is not affected.
var Tg(C)

zone4
0
The temperature in the cooling zone varies the most, but the
-50 other three regions have little influence.
-100
70 80 90 100 110 120 130
6˅ The model varies with the kiln rotational speed
varQa0 (% )
40 20
Fig10. The model varies with the amount of air input rate
20 10
The increase or decrease of air input rate has no effect on
var ms (%)

var Ts (C)

mass density, but has little effect on material and gas 0 0

temperature. The firing zone and cooling zone decrease -20 -10

with the increase of air input rate, while the decomposition -40 -20
70 80 90 100 110 120 130 70 80 90 100 110 120 130
zone and transition zone rise with the increase of air input varN (% ) varN (% )

rate. The reason is that the air input temperature is lower 20 zone1
than the cooling zone, so the cooling zone temperature zone2
zone3
10
drops. The temperature of the cooling zone is lower than zone4
var Tg (C)

that of the firing zone. The temperature of the firing zone is 0

higher than that of the transition zone. Similarly, the -10

temperature goes up. -20

70 80 90 100 110 120 130
4˅ The model changes with the material entry temperature varN (% )

Fig13. The model varies with the kiln rotational speed

2020 Chinese Control And Decision Conference (CCDC 2020) 3271

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 With the increase of kiln rotational speed, the mass density
decreases, and the temperature is not affected in the steady
state.
The actual production data of cement rotary kiln need to be
collected in person. The data provided in the simulation
process are from the actual production data of rotary kiln in
the references. The results are shown in section 4.This
paper has not done the field actual cement rotary kiln
verification.
4.4 Conclusion of dynamic and static analysis of model
on input
a) Material flow rate
The material density, material temperature and air
temperature are all affected. Material flow rate is negatively
correlated with temperature. There is a positive linear
correlation between material flow rate and material density.
b) Coal injection rate
It has the greatest influence on temperature, good linearity
and high sensitivity. Oxygen concentration is negatively
correlated with coal injection rate. If the amount of coal
injection rate increases, the amount of air supply should be
correspondingly increased.
c) Air input rate
It has little effect on temperature and is weakly nonlinear.
Oxygen concentration is positively correlated with air input
rate.
d) Material entry temperature
The material entry temperature is linearly correlated with
material temperature and gas temperature.
e) Air entry temperature
It has little influence on the temperature, and the air entry
temperature is linearly correlated with the temperature of
the material.
f) Kiln rotational speed
The material density is affected, and the kiln rotation speed
is negatively correlated with the material density. In the
dynamic condition, the temperature field in the kiln varies
slightly, but the influence is small. In the static condition,
the temperature field is not affected.
5 Conclusion
In this paper, a method of zone modeling for cement rotary
kiln based on the first-principle is established. It can
describe the change of temperature field and material
density field in kiln. This modeling method has strong
applicability and versatility. After parameter correction, it
can meet the demand of fine modeling for rotary kilns of
cement factories of different sizes. The model can be used
for global optimization, local optimization, advanced
control and high precision simulation platform. Through
dynamic and static simulation of the model, it can be seen
that the model has high accuracy and good stability under
3272 2020 Chinese Control And Decision Conference (CCDC 2020)
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the condition of step input, which provides theoretical
support for optimization of cement production.
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