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ISSN 0040-5795, Theoretical Foundations of Chemical Engineering, 2019, Vol. 53, No. 4, pp. 463–471. © Pleiades Publishing, Ltd.

, 2019.
Russian Text © The Author(s), 2019, published in Teoreticheskie Osnovy Khimicheskoi Tekhnologii, 2019, Vol. 53, No. 4, pp. 363–371.

Generalized Model for Engineering and Controlling a Complex


Multistage Chemical Energotechnological System for Processing
Apatite-Nepheline Ore Wastes
V. P. Meshalkina, A. Yu. Puchkovb, M. I. Dlib, and V. I. Bobkovb, *
aMendeleev
University of Chemical Technology of Russia, Moscow, 125047 Russia
b
Moscow Power Engineering Institute, Smolensk Branch, Smolensk, 214013 Russia
*e-mail: vovabobkoff@mail.ru
Received February 4, 2019; revised March 4, 2019; accepted March 6, 2019

Abstract—A comprehensive formulation for the problem of engineering applied to a multistage chemical
energotechnological system for the production of phosphorus from the technogenic wastes of apatite-nephe-
line ores is presented. The main objective of the studies performed within the procedure of engineering is to
determine the phosphorus-production technology parameters decreasing energy and resource efficiency due
to the optimization of energy-consumption values for all considered multistage chemical energotechnological
processes instead of individual stages. A generalized model of engineering is developed for the chemical ener-
gotechnological system of phosphorus production in compliance with the IDEF0 International Standard of
Function Modeling, and parameters suitable for further use in the procedure of minimizing the energy and
resource efficiency of this production are concretized for multistage chemical energotechnological processes.
A conceptual foundation based on the methods of automatic control theory, i.e., the state-space description
of control objects, is proposed for the creation of a universal program-optimization model for a chemical
energotechnological system. Some results of a simulation experiment in the Simulink environment for the
modeling of dynamic systems are presented to demonstrate the applicability of the proposed approaches to
the optimization of multistage chemical energotechnological processes.

Keywords: chemical energotechnological system, heat and mass transfer, control, pellets, optimization,
energy and resource efficiency, technogenic wastes, functional simulation, systems analysis
DOI: 10.1134/S0040579519040237

INTRODUCTION furnaces (EOSFs) [1]. It is obvious that the formation


The environmental safety of technological pro- and efficient operation of such a production chain
cesses planned for application becomes the primary must be based on the methods of system analysis and
factor affecting the decision to begin designing and provided with the methodology of engineering energy-
further developing new production plants. The prob- and resource-efficient environmentally safe plants for
lem of engineering technological processes with the processing apatite-nepheline ore wastes at mining and
purpose of revealing their most environmentally haz- refining enterprises with the immediate implementa-
ardous stages becomes relevant for plants which have tion of the interdisciplinary approach [2, 3].
been already put in operation. The submitted work is aimed at solving the urgent
This problem is especially urgent for large plants fundamental problem of creating scientific founda-
such as metallurgical, chemical, and mining and tions for engineering energy- and resource-efficient
refining enterprises. The exhaustion of the resource environmentally safe multistage systems for process-
base of mineral raw materials and the environmental ing apatite-nepheline ore wastes at mining and refin-
problems of storing the technogenic wastes of apatite- ing enterprises in calcining conveyors for the forma-
nepheline ores from mining enterprises necessitate the tion of pellets with their further use in EOSFs [4]. This
creation of a complex system for their processing and problem is directly associated with the development of
utilization. fundamental methods for controlling the energy and
The phosphorus production process is a multistage resource efficiency of multistage chemical energo-
and energy-consuming technological operation technological processes (CETPs) on the basis of hier-
involving, from the technical equipment viewpoint, archical heat-and-mass-transfer models in the imple-
granulators, calcining conveyor machines (hereinaf- mentation of individual subprocesses with consider-
ter, calcining conveyors), and electric ore-smelting ation for the properties of processed raw materials and

463
464 MESHALKIN et al.

Formulation of the CETS Mathematical Selection


energy consumption formulation of the CETS of the optimization
optimization energy consumption
problem solution concept
problem optimization problem

Interpretation of modeling Selection of a numerical


Estimation of the precision
results with the correction optimization problem
and reliability of preliminary
of the mathematical solution algorithm
solution results
model

Refinement of the CETS Correction of the precision


optimization problem and computational efficiency
formulation on the basis of CETS optimization
of results of applying problem solution
a mathematical model algorithms

Fig. 1. Scheme of interrelation between the problems of the multiscale mathematical modeling and optimization of the energy
and resource efficiency of a chemical energotechnological system.

the need for the rational use of secondary energy ary character of scientific studies on the creation of
resources in the closure and redistribution of energy scientific foundations for the complex energy- and
flows in a complex chemical energotechnological sys- resource-efficient environmentally safe processing of
tem (CETS) [5, 6]. apatite-nepheline ore wastes is due to the need to
apply the fundamental methods of the system analysis
of physicochemical transformations and heat-and-
MATERIALS AND METHODS mass transfer and complex multistage chemical ener-
The adaption of equipment to operational regime gotechnological processes.
fluctuations at varied chemical and technological One inextricable part of engineering in the consid-
properties of raw materials belongs to the class of ered plants is the development and application of mul-
resource saving and environmental problems, as unex- tiscale mathematical models of chemical engineering
pected changes in the operational conditions of appa- processes (CEPs) and the methods of optimal control
ratuses in energy-consuming plants generally lead to over the energy and resource efficiency of multistage
an increase in the energy expenditures per unit of the chemical, metallurgical, and mining plants as complex
product and the variation of emissions. Much impor- CETSs [11].
tance is attached to the problems of energy and resource The comprehensive formulation for the problem of
conservation and ecology in metallurgy, the chemical improving the energy and resource efficiency of a
industry, and ore mining and refining [7–10]. chemical energotechnological system and its multi-
Improving the tool used for the engineering of scale mathematical model (MM) are in interaction
complex technological equipment for processing solid with each other in the process of engineering and pro-
technogenic wastes from mining and refining enter- vide a dynamic character of the modeling and deci-
prises and which provides an integrated approach to sion-making procedure itself (Fig. 1).
the algorithms of optimal control over the interrelated The initial problem formulation and mathematical
processes implemented in calcining conveyors and model sustain appreciable transformations in the pro-
EOSFs is an urgent problem in the process of increas- cess of study, thus leading to the iterative character of
ing the energy efficiency of plants. The interdisciplin- the entire modeling procedure and the further use of

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


GENERALIZED MODEL FOR ENGINEERING 465

its results. Both the general problem formulation itself the desired goals. The so-called context diagram
and the mathematical model are refined during the reflecting the uppermost level in the hierarchy of stud-
development of an adequate model. The same prob- ied procedures, which may be considered from differ-
lem may have different mathematical models depend- ent viewpoints, e.g., organizational and functional
ing on the selected concept. For this reason, it is nec- ones, in regard to the processed data and the structure
essary to search for such an MM variant for which the of engineering processes, products, and services, is
solution of problem of studies would be simplest and, formed when beginning the development of a model.
nevertheless, provide the required depth of analysis. Each of these viewpoints is divided into three more
The general structure of a multistage complex sublevels, such as the description of requirements, the
CETS implies the systematization and application of description of specifications, and the description of
the fundamental models of physicochemical, chemi- introduction. The most informative presentation for
cal engineering, and thermophysical processes for the the further study of trends in improving the energy and
processing of wastes from the disposal fields of mining resource efficiency is provided by the functional view-
and refining enterprises into commercially competi- point, so the IDEF0 model will be developed just for
tive products and takes into account the four aggre- it. The first decomposition level for the IDEF0 con-
gated levels of phenomena and processes: text diagram in shown in Fig. 2.
The first level describes CETPs in an individual The mathematical models, which describe a chem-
pellet; ical energotechnological process at the presented lev-
The second level reflects the interactions in the els and were implemented in computer-aided simula-
vertical multilayered bed of pellets; tors, are complex systems of partial differential equa-
tions closed by various boundary conditions [12]. The
The third level embraces CETPs in the moving ver- results of their solution for one CETP will serve as ini-
tical multilayer bed of pellets; tial data for the differential equations describing the
The fourth level is based on the models of the first following CETP. Such a sequential transmission of
three levels for the solution to the problem of describ- information flows (signals) enables the application of
ing the chemical energotechnological process of the methods of automatic control theory to the calcula-
melting of pellets in energy-consuming EOSFs. tion of the entire multistage CETS. From the view-
CETP models take into account a variety of control point of automatic control theory, CETS represents a
variables and factors for both the EOSF and every vac- complex of objects with a specified set of control sig-
uum chamber of the calcining conveyor (characteris- nals, interferences, and input parameters (see Fig. 3).
tics of the initial raw materials and intermediate and Further analysis requires the detalization of the
resulting products for EOSF, functional dependences input and output parameters of phosphorus produc-
of the parameters of resulting products in the consid- tion CETS objects shown in Fig. 3.
ered CETP on these characteristics, etc.). Moreover, it Raw materials (technogenic wastes from the flota-
is necessary to take into consideration the possibility tion of apatite-nepheline ores in the form of a finely
of the rational utilization of secondary energy dispersed fraction) with a specified chemical compo-
resources in the closure and redistribution of energy sition varied depending on the ore-deposit field are fed
flows in a system. to the granulator inlet.
For the comprehensive consideration of the proce- In the granulator, roundish pellets are grained by
dure of reengineering providing the energy and wetting the finely dispersed fraction with water and
resource efficiency of the phosphorus production clumped on rotary platelike disks inclined at a certain
CETS, it is reasonable to construct a hierarchical angle. The input parameters for control object no. 1
structure of its models which would make it possible to
focus attention on different conceptual features. (granulator) is the mass flow rates of water GH 2O and
raw materials Grm, the inclination angle of plates α,
The upper level of developed models is presented
by the models of IDEF International Standards (Icam and the power-supply voltage of the electric driving
DEFination, Integrated Computer-Aided Manufac- motor of plates Up. The output parameters are the
turing (ICAM)), in particular, IDEF0 (function mod- mass flow rate of pellets Gk, the humidity content in a
eling methodology, IDEF subclass of standards pellet u0, and their diameter d. In addition to the listed
indexed with zero), which reflects the aggregated engi- output parameters, it is necessary to emphasize the
neering functions and their interrelations imple- energy consumption of the first CETS object when
mented to attain the mentioned aims of increasing conserving energy; let us demote this parameter as E1.
energy efficiency. After the granulator, the raw pellets are fed to the
The development of IDEF0 models implies the calcining conveyor, which represents 44 consecutively
sequential decomposition of the general problem into connected vacuum chambers with an overall length of
individual functions until the composition and meth- 130 m. In each chamber, the multilayer bed of pellets
ods of their implementation will become entirely clear moving on the conveyor is purged with the heating
for all parties concerned in the procedure of attaining exchange gas from the hearth, where the high tem-

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


466 MESHALKIN et al.

Production technology Mathematical models


of technological objects Russian Federation
Energy-efficiency and processes Environmental law
audit results
Analysis of audit
results with the formation
of an energy-efficiency register Energy-efficiency
of technological processes
register
0p. 1
Experience in the application Positive experience
to improve energy efficiency Determination of a positive experience of application
Complex of measures
in the application of measures
to improve
to improve energy
efficiency energy efficiency
0p. 3
Analytic center

0p. 5
State of economics Estimation of the state of external Economic-
economic conjuncture conjuncture
for an enterprise estimate

0p. 2

Application of CETP
and CETS models
0p. 4

Organization
management
Decision support system
Research institutes
and organizations

Fig. 2. Structure of the IDEF0 engineering model for the procedure of providing energy and resource efficiency to the phosphorus
production CETS.

perature of the heat-transfer gas is provided by the energy value E2 = λEt + Eel, where Et is the thermal
combustion of fuel. It is distributed between the vac- energy with the weight coefficeint λ, which takes into
uum chambers due to forced draft created by the consideration the nonequivalence of expenditures on
exhaust blowers over the technological zones of dry- the generation of electrical Eel and thermal energies.
ing, preheating, high-temperature calcination, heat The specific energy consumption in CETS object
recovery, and cooling. The presence of a great number no. 2 is 615 MJ per ton of final calcined pellets. It is of
of vacuum chambers is explained by the technological interest to study the phosphorus-production CETS
features of heat-and-mass transfer and chemical ener- from the viewpoint of improving its energy efficiency.
gotechnological processes occurring in the calcining
conveyor machine. On the other hand, this leads to an Control object no. 3 is an electric-arc ore-reducing
increase in the number of parameters to be controlled furnace in which the pellets are heated (reaction zone
(according to the number of vacuum chambers): the temperature, 1500–2000°C). The phosphorus flow
input signals for each vacuum chamber are the rate GP is an input EOSF parameter. The energy and
resource efficiency of EOSF operation is affected by
exchange-gas temperature at its inlet Tgi0 , i = 1, …, nk, the parameters of calcined pellets fed from the calcin-
where nk is the number of chambers, and the output ing conveyor machine, such as their strength and
parameters are the output air temperature Tgi and the degree of reaction, alongside the depth of immersion
air flow rate Wgi. of the electrodes deep into the furnace hel, which gov-
erns the reaction-zone temperature. Let the electric
The output parameters of the entire calcining con- energy expenditures providing the technological pro-
veyor are the mass flow rate Gko of pellets and their cess of the smelting of pellets in EOSF be denoted as
finite strength σk and degree of reaction ηk for the dis- E3. In this case, it is necessary to take into account that
sociation reactions of carbonates MgCO3 → MgO + the thermal energy is partially turned back into CETS
CO2 and СаCO3→ СаO + CO2. As a result of the heat- due to the redistribution of heat flows and the recovery
ing of pellets, the process of decarbonization with the of heat. The specific electrical energy consumption in
release of carbon dioxide is activated. This process EOSF is 14.6 MW h per ton of final product.
consumes the energy, which is taken into account in The total specific energy consumption of the entire
the overall balance of the plant. CETS is 52755 MJ per ton of final product—yellow
The operation of the calcining machine is provided phosphorus.
by the expenditure of both thermal energy and electric The analysis of heat-and-mass transfer and chemi-
energy (consumed by the exhaust blowers), which can cal energotechnological processes and their parame-
be taken into account as the generalized consumed ters in the three CETS decomposition objects makes it

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


GENERALIZED MODEL FOR ENGINEERING 467

Control object no. 2


Chemical energotechnological system
for the calcination of phosphorite pellets
Control
object no. 1
Raw materials Pellets Calcination
(apatite-- Calcined
with a high CETP pellets
nepheline content
ores) Drying
Granulator CETP
Sintering
CETP

Control object no. 3

Phosphorus
Electric ore-smelting
furnace

Consumed energy Heat energy recovery

Fig. 3. Generalized flowsheet of a chemical energotechnological system as a control object.

possible to specify the vectors of their input (these particular, the regime providing the required quality of
parameters are denoted with the symbol V) and output the final product, the conservation of energy
(denoted with the symbol Y) parameters and formulate resources, and the reduction in recycling were
the optimization criterion from the viewpoint of the obtained for an OK-520/536F calcining machine).
energy and resource efficiency of the entire CETS as Optimal energy consumption regimes were deter-
mined for EOSFs in [12]. At the same time, it is of
V1 = (GH2O, Gc , α, U Т ) ,
Т
interest for economics to optimize the energy con-
(1) sumption for the entire multistage phosphorus pro-
Y1 = (Gk , u0, d ) ,
Т
duction process and determine not the local energy
( )
Т consumption minima for each of the considered
V 2 = Tg , Gk , d, u0
0
, objects as much as the global extremum, possibly with
(2)
some deviation from optimality for an individual
Y 2 = (Tg , Gko, σk , ηk ) ,
Т
object.
V3 = (Gko, σk , ηk , hel ) , A great number of factors, which are grouped into
Т
(3) vectors (1)–(3) and have an effect on the considered
Y 3 = (G p, σk , ηk ) .
Т
technological processes, make it more probable that
the surface of the response function of the objective
In Eq. (2), the inlet and outlet temperatures of each optimization function will be polyextremal [18]. This
vacuum chamber are denoted with the vectors circumstance actualizes the problem of the complex
( )
0 Т study of the considered CETS for the development of
Tg = Tg 1 Tg 2 ... Tg n
0 0 0
, methods and algorithms of determining the parame-
ters optimal from the viewpoint of energy efficiency
Tg = (Tg1 Tg 2 ... Tgn ) .
Т
for the phosphorus production CETS objects. The
The known mathematical models for optimizing objective function for the optimization of the energy
the energy expenditures in every control object con- and resource efficiency of the multistage phosphorus
sider them apart from the entire technological chain of production CETS must take into account the energy
phosphorus production [12–17]. Thus, the optimal consumption Ei, i = 1… 3, of each control CETS
regimes for the calcination of clumped raw materials object, but partial minima Ei does not have to be pro-
on calcining conveyor machines were found in [15] (in vided.

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


468 MESHALKIN et al.

The general energy- and resource-efficiency crite- from them to the space-state description. Introducing
rion is presented as a linear combination of the partial the vector of state variables X(t), it is possible to
criteria Ei of control objects describe the control system by the vector-matrix first-
order differential equation
Е = λ1Е1 + λ 2Е2 + λ3Е3, (4)
X (t ) = AX(t ) + BV(t ), (5)
where λi is the weight coefficients specified to provide
the possibility to adjust the optimization procedure. supplemented with the output equation
The constraints of the optimization problem are
formed with consideration for the technical features Y(t ) = CT X(t ) + DV(t ), (6)
and operational regimes of CETS units and the specif- where А is the matrix of a system; B, D are the transfer
ics of heat-and-mass transfer and chemical energo- vectors; V is the input signal in a given channel; Y is the
technological processes [15, 17]. vector of input variables; and C is the observation
Extremum search problem (4) requires the vector matrix.
(E1, E2, E3) to be calculated with the further selection The extension of the stated approach to all control
of the vector providing the minimization of the crite- channels makes it possible to calculate the energy-
rion Е. This problem is divided into several subprob- consumption parameters at different combinations of
lems, such as input data and take into account the cross coupling of
(1) The mathematical description of individual CETP variables.
CETPs from the viewpoint of calculating their energy
efficiency; PROGRAM IMPLEMENTATION
(2) The development and testing of program CETP AND RESULTS
models on the basis of their mathematical description;
Applying the proposed approach to the space-state
(3) The aggregation of individual models into the description of control objects, an integrated program
integrated program model (IPM) of multistage model of the phosphorus production CETS was devel-
CETPs and its testing; oped in the Simulink environment. The consecutive
(4) The use of an integrated program model for cal- connection of the program models of the granulator,
culation vectors (E1, E2, E3); the calcining conveyor machine, and the EOSF
(5) The application of the optimization procedure reflects the multistage character of this CETS and the
for revealing the optimal parameters of the generalized order of its operation, thus maintaining the adequacy
CETS. of the entire program model. The general structure of
Points 1 and 2 in this list already have a solution the computer program model is shown in Fig. 4.
and are described in [1, 15–17]. Points 3–5 require The scheme shown in Fig. 4 enables modeling at
study and development. Let us consider the method- different combinations of initial data, parameters, and
ological aspects of their implementation in more control signals due to the application of structural ele-
detail. ments such as input and output ports (denoted as 1, 2,
To aggregate the developed program models of 3, and 4 in Fig. 4 with arrows corresponding to the
individual CETPs in point 3, it is necessary to have an direction of their assignment).
environment for their deployment. The Simulink A simulation experiment in Simulink was per-
dynamic-system modeling package incorporated into formed on an IPM fragment with the purpose of
the MatLAB software [19] may be selected as such an studying the effect of two factors (the radius and mois-
environment. To use this package, it is reasonable to ture content of a pellet) on the CETP energy-con-
recast the individual mathematical models in a form sumption value. Modeling was performed for these
suitable for calculations in Simulink, e.g., in the parameters lying within the following ranges: pellet
space-state description of control systems as applied to radius, 0.09–1.1 cm; moisture content, 12.6–13.4%.
both continuous- and discrete-time estimation prob- The experimental results are shown in Fig. 5 as a map
lems [20, 21]. of level lines on the CETP energy-consumption sur-
The local models of control objects represent sys- face (MJ) depending on the radius and moisture con-
tems of partial differential equations of different tent of a pellet.
orders, and the transition from these models to the The region corresponding to the admissible tech-
space-state description is very problematic. For this nological deviations of the radius and moisture con-
reason, it was decided to use these models to obtain tent of a pellet in Fig. 5 is outlined with a rectangle.
the runout characteristics of objects by different chan- The study of its topology makes it possible to find
nels (1)–(3) and with their further approximation combinations of affecting parameters which provide a
[22]. The set of such runout characteristics has pro- minimum CETS energy consumption within the tech-
vided the possibility to obtain linearized (near steady- nological norms for the parameters of pellets.
state regime points) models of control objects in the A visual analysis of the technological zone shows
form of transfer functions and perform the transition that it has energy consumption minima (level lines

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


GENERALIZED MODEL FOR ENGINEERING 469

2 3 4
Control signal 1 Control signal 2 Control signal 3

.
. x = Ax + Bu
x = Ax + Bu
y = Cx + Du
1 y = Cx + Du
Input port
Granulator
CETS for the calcination
of phosphorite pellets

.
x = Ax + Bu
1
y = Cx + Du
Output port

Electric ore-smelting
furnace

Fig. 4. Structure of the computer-aided CETS control model.

Pellet radius, cm
1.20

1.15
4.02e+04

1.10

1.05 5.34e+04
9.3e+04 6.66e+04

7.98e+04 6.66e+04
1.00 5.34e+04

0.95

0.90

0.85

12.8 12.9 13.0 13.1 13.2


Moisture content, %

Fig. 5. Level lines on the specific CETS energy-consumption surface.

THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019


470 MESHALKIN et al.

with an energy consumption of 53400 MJ per ton of pared with the results obtained in the optimization of
final product). Let us note that the isolated optimiza- every CETS apart. In this experiment, the energy con-
tion of every object of an integrated CETS apart from sumption minimum of 53.4 GJ per ton of final product
each other and the further summation of the energy was attained in the region of technological tolerances
consumption of these objects has given a level of only for the parameters of pellets, whereas the isolated opti-
54900 MJ per ton of final product. mization of the energy consumption of every object in
Hence, it is possible to adjust the parameters of an integrated CETS apart enabled the attainment of
individual CETPs to provide minimum energy con- this parameter only at a level of 54.9 GJ per ton of final
sumption for the entire generalized CETS instead of product.
its isolated objects.
Further works in the selected direction of studies FUNDING
will be aimed at the development of program modules
calculating the complex effect of all CETS parameters This study was financially supported by the Russian
on the energy consumption for the integrated program Foundation for Basic Research within scientific proj-
model of CETPs for other fragments of the aggregated ect no. 18-29-24094 MK.
model [23, 24].
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THEORETICAL FOUNDATIONS OF CHEMICAL ENGINEERING Vol. 53 No. 4 2019

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