Mathematical model for the rotary furnace predictive control

Rotary furnaces belongs to the principal thermal apparatuses for material processing in many industries branches. Because of their slow dynamics, the model based predictive control is the most suitable control approach. Developed control system is of three level hierarchies. At the optimization level optimal control trajectory and its responding controls are determined at the period of material charging. At the discharging time period the model is calibrated, and real process trajectory is determined. The difference of optimal and real control trajectory used for the control correction at the stabilization level. At the basic level process monitoring and control of individual loops is executed. Control interval is determined according the difference of optimal and actual process trajectory. The simulation model is based of the first principles and enables real time application. Optimal set point can be determined according selected criteria, which includes technological, economical and environmental indexes. Control system is visual based. Visual support is enabling internal view to the furnace and is oriented on the extraction of critical process and equipments parameters. Developed model based predictive control system was applied on the rotary furnace of magnesia sintering at SMZ Jelsava, Slovakia.