SUNConferences, Southern African Institute of Industrial Engineering 2013

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Designing Of An Intelligent Fuzzy Logic System For Accretion Prevention In Sponge Iron SL/RN Rotary Kiln Based 100TPD DRI Process
Talon Garikayi, Nyanga Lungile, Pardon Kuipa, Samson Mhlanga, Tawanda Mushiri

Last modified: 2013-06-26


Sponge iron is an intermediate product of steel formed during direct reduction of iron ore with aid of regulated temperatures and pressures within a rotary kiln. The greatest challenge is the direct measurement of kiln shell temperatures due to the catastrophic accumulation of sintered particles of solid bed which form rings at places along the length of the kiln thus hindering material flow. The accretion reduces productivity, damage kiln lining and reduces the production period as well as reduction in product quality. This process requires a controller which will be able to control with imprecise and partial data input; and be able to achieve the desired product quality under dynamic process conditions thus a Fuzzy Controller was used for the proposed design. The main goal of the research was to predict the rate of accretion build up within the kiln and minimize it with aid of a Fuzzy Control System cascaded to an already existing Programmable Logic Controller. A 16.2% build up rate was achieved as compared to the most appreciated 27% thus nearly a 10% decrease, a result which can improve the campaign period by approximately 48 hoursĀ  which will be a 200 tons of sponge iron.

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