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© F L Smidth
Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation
TABLE OF CONTENTS
© F L Smidth Page 2
Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation
8.1 INTRODUCTION
The FLS CEMulator (Cement Process Simulator) is a training tool, which provides
hands-on kiln and mill operation experience for cement process operators and cement
process engineers. The FLS CEMulator System simulates not only the process behav-
iour but also the process information/operator manipulations with control variables
which resemble the real control situation.
The operators are trained at the PC work station under the supervision of an instructor.
The instructor sets up the simulation model prior to the training session by choosing
among the available kiln or mill models already loaded in the database. A set of opera-
tional parameters simulating an actual state of operation is specified by the instructor
and loaded onto the trainee PC work station from which the training session is per-
formed.
Throughout the session, by means of the instructor console, the instructor can introduce
process disturbances to observe and train an operator's ability to react correctly in both
normal and abnormal situations. It is possible for the instructor to control the timing of
the situation - e.g. speeding it up to get through process paths of minor interest or set-
ting time back to rehearse and discuss a difficult operating situation.
Besides operator training, the FLS CEMulator System can be used to perform specific
process studies to elevate and optimise process performance.
The following included appendices to this module describe the instructor/trainee opera-
tion of the FLS CEMulator system :
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Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation
concerning cement kiln systems. The model is specifically adapted to the characteristics
of the following kiln type, including start-up and shut-down:
Example:
To regulate the gas flow in a kiln you have to regulate the position of a damper.
The controller calculates the necessary damper position and sends this value to the posi-
tioner.
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Package P3: Kiln – Operation and Optimisation
Module 8: Simulation of Kiln and Cooler Operation
A measuring-device (e.g. a potentiometer) tells the positioner the present position of the
damper and, depending on the output value, the positioner makes the damper motor ei-
ther increase or decrease the opening.
The pressure-measurement device reports the result to the controller and the loop con-
tinues until the process value is equal to the set-point value.
Below is a list of the controllers available for a kiln type ILC with grate cooler:
1. The coal feeding to the calciner is controlled by the temperature in the 5th cy-
clone.
2. The speed of the 1st grate in a grate cooler is controlled by the pressure under
the 1st grate.
3. The speed of the 2nd and 3rd grate in a grate cooler is controlled by the speed
of the 1st grate.
4. The exhaust air fan is controlled by the pressure in the kiln hood.
5. The cooler fans speed are normally controlled by the air flow. Alternatively
the air flow can be controlled by the damper position.
6. The raw meal feed can be controlled by the kiln speed.
7. The injection of water into the conditioning tower is controlled by the gas
temperature.
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