Mathematical Modeling and Optimal Control of Sintering Processes in Rotary Tubular Kilns

We consider methods for modeling the temperature fields inside a rotary tubular kiln and in the lining
of the oven.
These models are used for creating a control system that supports the necessary technological
parameters and reduces the heat loss through the kiln body to the environment. Two-dimensional
modeling of the processes inside the kiln confirms the applicability of a unidimensional model to these
processes. A simulation method for selecting a new design for the thermal-insulation elements,
ensuring the reduction of the heat loss to the environment and performing the required thermal
processing is implemented using the ANSYS Fluent software package. A new type of insulation
element is proposed, which reduces the heat loss from the kiln to the environment and reduces the
temperature of the outer surface of the kiln. A system for monitoring the state of the lining using a
thermal imager and a control system that ensures the consistency of the lining without stopping the
kiln operation are developed. The developed mathematical model of petroleum coke calcination for
improved coke production describes chemical transformations through weight loss of the charge in the
chosen rotary tubular kiln with an appropriate adequacy. It can be used for optimization of an
industrial process with the use of nonlinear programming mathematical methods.