I. INTRODUCTION
Rotary kiln is a kind of large scale sintering device widely
used in various process industries, such as metallurgical,
cement, refractory materials, chemical and environment
protection [1-3]. In the cement production industry, the
cement rotary kiln decomposition is the most important unit,
and its operating status serious affects the output, quality,
energy consumption, and environment pollution. The
automation problem of such complicated processes remains
unsolved because of the following inherent complexities. It is
a multivariable nonlinear system with strong coupling. The
complicated working mechanism includes physical change
and chemical reaction of material, procedure of combustion,
thermal transmission among gaseous fluid, solid material fluid
and the liner. Moreover, the key controlled variable of burning
zone temperature is difficult to be measured. In fact, most of
rotary kilns are still under manual control with human
operator observing the burning status; this is especially true in
This work is partially supported by NSF Grant #61104084, #61290323, #61333007, IAPI Fundamental Research Funds Grant #2013ZCX02-09, and the
Fundamental Research Funds for the Central Universities Grant #N130508002 to P. Zhou and M. Yuan.
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Raw
material
Coal
Powder
Headend
of kiln
Air
Reaction
exothermic
zone
Bunring
zone
Cooling
zone
Decomposite
zone
Preheating
zone
Drying
zone
Back
-end
of the
kiln
CBR
Soft-sensor
Estimated value
Model
Data Preprocessing
Learning Algorithm
Fig.2 The proposed intelligent soft-sensor modeling strategy for burning zone
temperature
x1 (t )
x2 (t )
x3 (t )
x4 (t )
z 1
z
z 1
z 1
z 1
x1 (t 1)
y (t )
x3 (t 1)
x4 (t 1)
y (t 1)
via the rotation of the kiln and its self weight, in counter
direction with the gas. Raw material is carried along the kiln a
very low speed. Near the middle of the kin is the firing zone,
where gas burners are placed to impose a given temperature
profile. In a kiln, the back-end is responsible for the
calcification of meal before the main baking, so if the
temperature of back-end is more than the acceptable range, the
baking will be done before entering the burning zone, and vice
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X (t ) [ x 1 (t ), x 2 (t ), x 3 (t ), x 4 (t ), x 1 (t 1),
soft-sensor technique to online estimate the BZT. Due to casebased reasoning (CBR) has good ability to identify and
control complex nonlinear systems [6-10], the CBR-based
soft-sensor dynamic modeling approach is therefore employed
to develop a BZT soft-sensor in this paper.
The CBR utilizes the specific case information available
as historical precedence for proposing solutions to current
problem. The most important aspects of the existing cases are
first stored and indexed. New problem situations are then
presented and similar, existing cases are identified from the
knowledge base. Finally, the previous problem solutions are
adapted and the revised solutions are proposed for the current
situation [7-10].
The proposed CBR based soft-sensor modeling approach
for dynamical estimating the BZT is shown in Fig.2. It mainly
consists of a process data pre-processing module and a
dynamic CBR soft-sensor system.
A. Data Pre-Processing
If the original secondary variables O {CF , AF ,
RF , K S } are used for soft-sensor modelling and calculating
directly, it will cause some adverse influences on estimation
precision. Therefore, digital filtering technique is employed to
pre-process these original data.
SIM
(
F
,
F
)
i simi ( f iT , fi , k )
k
k
1
i
T
sim ( f T , f ) 1 f i f i , k
i i i,k
max( fi T , fi , k )
O (t ) E (t 1)
Then E (t ) O (t ),
If E (t 1) O (t )
Then E (t ) E (t 1)
i 1
(1)
If O (t ) E (t 1)
Then E (t ) E (t 1)
where t denotes sampling time, E (t ) denotes the preproceed data by the noise peak filter, is the maximal
allowed variety value of O (t ) at successive sampling time.
SIM k ( F T , Fk ) yz
0.95, max (SIM k ( F T , Fk )) 0.95
k 1,, m
(2)
(t ) E (t N )
F (t ) F (t 1) E
N
, if r 3
3
ST
T
SIM r ( F , Fr )
r 1
M
s1 , if r 3
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(3)
TABLE I
CASE REPRESENTATION
f1
f2
f3
f4
CF (t )
AF (t )
RF (t )
K S (t )
CF (t 1)
AF (t 1)
f7
f8
f9
RF (t 1)
K S (t 1)
Bzt (t 1)
Bzt (t )
TABLE II
INITIAL CASE BASE OF CBR SOFT-SENSOR SYSTEM
CF (t )
AF (t )
RF (t )
K S (t )
167.42
166.64
168.76
167.83
28.82
28.23
27.42
27.62
9.02
9.07
8.46
8.71
3.633
3.834
3.656
3.728
27.852
28.21
27.82
28.22
1515
K S (t 1)
Bzt (t 1)
8.92
8.87
8.25
8.93
3.734
3.721
3.726
3.672
1451.7
1463.2
1510.2
1502.7
1471.1
1473.3
1500.1
1501.3
1510
1510
1505
1505
Sampled value
RF (t 1)
1500
1495
1490
1500
1495
1490
1485
Estimated value
Sampled value
1480
1475
10
20
30
1485
40
50
60
1480
1480
70
Sampled data
1485
1490
1495
1500
1505
1510
Estimated value
10
9
Estimated error
7
6
5
4
3
2
1
0
10
20
30
40
50
60
70
Sampled data
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