초록 ▼

A system and method of determining clinker composition and optimizing raw material and fuel feed rates for a cement kiln plant is provided. Raw material data, fuel data, clinker kiln dust data, and emissions data are received. At least one of a raw material feed rate, a fuel feed rate, and an expect

A system and method of determining clinker composition and optimizing raw material and fuel feed rates for a cement kiln plant is provided. Raw material data, fuel data, clinker kiln dust data, and emissions data are received. At least one of a raw material feed rate, a fuel feed rate, and an expected clinker composition are calculated based on the raw material data, the fuel data, the clinker kiln dust data, and the emission data. At least one of the raw material feed rate, the fuel feed rate, and the expected clinker composition are outputted.

대표청구항 ▼

What is claimed is: 1. A method of optimizing feed rates for a cement kiln plant comprising: receiving raw material data associated with raw material for said cement kiln plant, fuel data associated with fuel for said cement kiln plant, clinker kiln dust data associated with clinker kiln dust from

What is claimed is: 1. A method of optimizing feed rates for a cement kiln plant comprising: receiving raw material data associated with raw material for said cement kiln plant, fuel data associated with fuel for said cement kiln plant, clinker kiln dust data associated with clinker kiln dust from said cement kiln plant, and emissions data associated with emissions from said cement kiln plant; receiving a user inputted clinker composition constraint indicating a composition of clinker resulting from said cement kiln plant; receiving a user inputted solution target parameter and a user inputted selection to minimize said solution target parameter, to maximize said solution target parameter, or to match said solution target parameter to an inputted value; calculating at least one of a raw material feed rate and a fuel feed rate with a processor, based on said raw material data, said fuel data, said clinker kiln dust data, and said emissions data, such that said raw material feed rate and said fuel feed rate result in a clinker composition meeting said clinker composition constraint and in said solution target parameter being minimized, maximized, or matched to said inputted value, according to said user inputted selection; and setting a cement kiln feeder based on at least one of said calculated raw material feed rate and said calculated fuel feed rate. 2. The method of claim 1 wherein said received solution target parameter is a total cost. 3. The method of claim 1 wherein said received solution target parameter is a total raw material cost. 4. The method of claim 1 wherein said received raw material data comprises at least one of raw material composition data, raw material loss factor data, raw material moisture data, and raw material cost data. 5. The method of claim 1 wherein said received fuel data comprises at least one of fuel composition data, fuel moisture data, fuel cost data, fuel ash factor data, and fuel heat value data. 6. The method of claim 1 wherein said received clinker kiln dust data comprises at least one of clinker kiln dust composition data, clinker kiln dust loss factor data, and clinker kiln dust rate data. 7. The method of claim 1 wherein said received emissions data comprises at least one of emissions composition data and emissions rate data. 8. The method of claim 1 further comprising receiving kiln feed heat consumption factor data wherein said calculated fuel feed rate is based on said kiln feed heat consumption factor data. 9. The method of claim 1 further comprising selecting at least one of a dicalcium silicate formula, a liquid phase formula, a coating tendency formula, and a lime saturation factor formula wherein at least one of said calculated raw material feed rate and said calculated fuel feed rate are based on at least one of said selected dicalcium silicate formula, said selected liquid phase formula, said selected coating tendency formula, and said selected saturation factor formula. 10. The method of claim 1 further comprising receiving at least one of a raw material composition constraint, a fuel composition constraint, and a raw mix composition constraint wherein at least one of said calculated raw material feed rate and said calculated fuel feed rate are based on at least one of said raw material composition constraint, said fuel composition constraint, and said raw mix composition constraint. 11. The method of claim 1 wherein said received solution target parameter is an amount of a raw material. 12. A feeder control system for a cement kiln plant comprising: a feed rate optimizer that receives raw material data, fuel data, clinker kiln dust data, emissions data, a clinker composition constraint, a solution target parameter, and a selection to minimize said solution target parameter, to maximize said solution target parameter, or to match said solution target parameter to an inputted value, and that calculates, based on said raw material data, said fuel data, said clinker kiln dust data, and said emissions data, at least one of a raw material feed rate and a fuel feed rate that minimizes said solution target parameter, maximizes said solution target parameter, or matches said solution target parameter to said inputted value, according to said selection, and that results in a clinker composition meeting said clinker composition constraint; and a kiln feeder control module that sets at least one cement kiln plant feeder according to at least one of said calculated raw material feed rate and said calculated fuel feed rate. 13. The feeder control system of claim 12 wherein said solution target parameter is a total cost. 14. The feeder control system of claim 12 wherein said solution target parameter is a total raw material cost. 15. The feeder control system of claim 12 wherein said raw material data comprises at least one of raw material composition data, raw material loss factor data, raw material moisture data, and raw material cost data. 16. The feeder control system of claim 12 wherein said fuel data comprises at least one of fuel composition data, fuel moisture data, fuel cost data, fuel ash factor data, and fuel heat value data. 17. The feeder control system of claim 12 wherein said clinker kiln dust data comprises at least one of clinker kiln dust composition data, clinker kiln dust loss factor data, and clinker kiln dust rate data. 18. The feeder control system of claim 12 wherein said received emissions data comprises at least one of emissions composition data and emissions rate data. 19. The feeder control system claim 12 wherein said feed rate optimizer receives kiln feed heat consumption factor data and calculates said fuel feed rate based on said kiln feed heat consumption factor data. 20. The feeder control system of claim 12 wherein: said feed rate optimizer receives at least one of a selected dicalcium silicate formula, a selected liquid phase formula, a selected coating tendency formula, and a selected lime saturation factor formula; and calculates said raw material feed rate based on at least one of said selected dicalcium silicate formula, said selected liquid phase formula, said selected coating tendency formula, and said selected saturation factor formula. 21. The feeder control system of claim 12 wherein: said feed rate optimizer receives at least one of a selected dicalcium silicate formula, a selected liquid phase formula, a selected coating tendency formula, and a selected lime saturation factor formula; and calculates said fuel feed rate based on at least one of said selected dicalcium silicate formula, said selected liquid phase formula, said selected coating tendency formula, and said selected saturation factor formula. 22. The feeder control system of claim 12 wherein: said feed rate optimizer receives at least one of a raw material composition constraint, a fuel composition constraint, and a raw mix composition constraint; and calculates said raw material feed rate based on at least one of said raw material composition constraint, said fuel composition constraint, and said raw mix composition constraint. 23. The feeder control system of claim 12 wherein: said feed rate optimizer receives at least one of a raw material composition constraint, a fuel composition constraint, and a raw mix composition constraint; and calculates said fuel feed rate based on at least one of said raw material composition constraint, said fuel composition constraint, and said raw mix composition constraint. 24. The feeder control system of claim 12 wherein said solution target parameter is an amount of a raw material. 25. A method of evaluating the cost of a prospective raw material for a cement kiln plant comprising: receiving current raw material data, prospective raw material data, fuel data, clinker kiln dust data, and emissions data; calculating a current total cost based on said current raw material data, said fuel data, said clinker kiln dust data, and said emissions data; calculating a prospective total cost based on said prospective raw material data, said fuel data, said clinker kiln dust data, and said emissions data; comparing said current total cost per clinker ton with said prospective total cost per clinker ton; and acquiring said prospective raw material based on said comparing. 26. The method of claim 25 wherein said received current raw material data comprises at least one of current raw material composition data, current raw material loss factor data, current raw material moisture data, and current raw material cost data. 27. The method of claim 25 wherein said received prospective raw material data comprises at least one of prospective raw material composition data, prospective raw material loss factor data, prospective raw material moisture data, and prospective raw material cost data. 28. The method of claim 25 wherein said received fuel data comprises at least one of fuel composition data, fuel moisture data, fuel cost data, fuel ash factor data, and fuel heat value data. 29. The method of claim 25 wherein said received clinker kiln dust data comprises at least one of clinker kiln dust composition data, clinker kiln dust loss factor data, and clinker kiln dust rate data. 30. The method of claim 25 wherein said received emissions data comprises at least one of emissions composition data and emissions rate data. 31. The method of claim 25 further comprising selecting at least one of a dicalcium silicate formula, a liquid phase formula, a coating tendency formula, and a lime saturation factor formula wherein said current total cost and said prospective total cost are based on at least one of said selected dicalcium silicate formula, said liquid phase formula, said coating tendency formula, and said lime saturation factor formula. 32. A method of calculating cement kiln plant data comprising: receiving raw material data associated with raw material for a cement kiln plant, fuel data associated with fuel for said cement kiln plant, clinker kiln dust data associated with clinker kiln dust from said cement kiln plant, and emissions data associated with emissions from said cement kiln plant; receiving a user inputted calculation mode selection from a plurality of calculation modes including a first mode wherein both a raw material feed rate and a fuel feed rate are optimized, a second mode wherein said raw material feed rate is inputted and said fuel feed rate is optimized, a third mode wherein said raw material feed rate is optimized and said fuel feed rate is inputted, and a fourth mode wherein said raw material feed rate and said fuel feed rate are inputted; calculating said raw material feed rate and said fuel feed rate with a processor, based on said raw material data, said fuel data, said clinker kiln dust data, and said emissions data, when said first mode is selected; calculating said fuel feed rate with said processor, based on said raw material data, said fuel data, said clinker kiln dust data, and said emissions data, when said second mode is selected; calculating said raw material feed rate with said processor, based on said raw material data, said fuel data, said clinker kiln dust data, and said emissions data, when said third mode is selected; calculating an expected clinker composition with said processor, based on said raw material data, said fuel data, said clinker kiln dust data, said emissions data, said raw material feed rate and said fuel feed rate, when said fourth mode is selected; setting a raw material feeder based on said raw material feed rate and a fuel feeder based on said fuel feed rate when said first, second, and third modes are selected; generating an output indicating said calculated expected clinker composition when said fourth mode is selected. 33. The method of claim 32 further comprising: receiving a solution target parameter and a selection to minimize said solution target parameter, to maximize said solution target parameter, or to match said solution target parameter to an inputted value when said first, second, and third modes are selected; and calculating at least one of said raw material feed rate and said fuel feed rate by minimizing said solution target parameter, maximizing said solution target parameter, or matching said solution target parameter to said inputted value, according to said selection. 34. The method of claim 32 further comprising receiving a raw material composition constraint when said first, second, or third modes are selected, wherein at least one of said raw material feed rate and said fuel feed rate are based on said raw material composition constraint. 35. The method of claim 32 further comprising receiving a target kiln feed rate when said first, second, or third modes are selected wherein at least one of said raw material feed rate and said fuel feed rate are based on said target kiln feed rate. 36. The method of claim 32 further comprising receiving a fuel composition constraint when said first, second, or third modes are selected, wherein at least one of said raw material feed rate and said fuel feed rate are based on said fuel composition constraint.