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Christer Haugland, Modeling and Control of fertilizer granulation process

Controllability of a Granulation Process. Christer Haugland Supervisors: Sigurd Skogestad Vidar Alstad ( Yara Technology Center). Christer Haugland, Modeling and Control of fertilizer granulation process. Outline. Summary process description

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Christer Haugland, Modeling and Control of fertilizer granulation process

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  1. Controllability of a Granulation Process Christer Haugland Supervisors: Sigurd Skogestad Vidar Alstad (YaraTechnology Center) Christer Haugland, Modeling and Control of fertilizer granulation process

  2. Outline • Summaryprocessdescription • Obtaining limit cyclebehaviour as seen at theYara plant • Fitting model to plant data • Simulinkmodel • Furtherwork

  3. Process description • Feed: • Slurry melt • Spherodizer: • Drying • Granulation • Screens • Separation • basedonsize • Crusher • Crushoversize • particles

  4. Recycle mass flow controller • Split range controller

  5. Model • Modeldeveloped in MATLAB • First looked at discretizations in particle sizes • Increased particle classes (no. of discretizations) until the effect on the model was no longer seen. • Limit cycles occurred!

  6. Stable system. Crushed particle sizes = 2.55 mm

  7. Unstable system. Crushedparticlesizes = 1.55 mm

  8. Bifurcation plots d50_mill = 1.95 mm

  9. Plant data compared to model • Too large particle sizes in the system! • Only closed loop data available • Recycle mass flow controller output should also be in the same range as plant data. • Unknown controller tunings. Many unknown parameters

  10. Model fitted to plant data • Trial and error approach • Based on average values of plant data d50 and controller output values • Not able to get the same amplitude in d50 oscillations • Controller output and d50 in the same region as plant data.

  11. Model fitted to plant data Screen 2 Screen 1 New parameters Old parameters

  12. Simulink Model • Particle balance. Recycle controller off. • Particles inn-> Crusher , Particles out -> Product

  13. Simulink Model • Particle balance. Recycle controller on. • Keeping recycled particles constant -> Stable particle balance

  14. Further work • Bifurcation plots with the new model fitted to plant data • Controllability analysis • Look at control structure

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