Method and system of predicting safe time of operation for a rotary kiln

A system, comprising:

• a memory storing instructions;
• one or more communication interfaces;
• and
• one or more hardware processors coupled to the memory via the one or more communication interfaces, wherein the one or more hardware processors are configured by the instructions to:
• receive a plurality of operational parameters and a plurality of design parameters of the rotary kiln;
• obtain a plurality of derived parameters by processing one or more operational and design parameters using, a set of models, the set of models executed by the one or more hardware processors comprising
• a solid bed height variation model to estimate a height parameters of the solid bed along the kiln length,
• a gas stream model to estimate a gaseous phase parameters associated with a plurality of gaseous components in the gas stream introduced through the discharge end of the rotary kiln,
• a solid stream model to simultaneously estimate (i) reaction kinetics of the solid bed associated with a plurality of components formed in the rotary kiln as a result of plurality of reactions occurring within various components of the solid bed and a molten phase formed within the rotary kiln, and (ii) temperature parameters of the solid bed and the kiln walls by aggregating the obtained reaction kinetics and heat balance in the rotary kiln,
• a melt model to estimate rate of formation of molten phase by calculating energy parameter associated with the total available solid material along the length of the kiln,
• an aggregation model to calculate rate of interaction among particles of the solid bed and molten phase forming an aggregate by obtaining interaction parameters,
• a volatile model to simultaneously estimate, the flow rate of volatile compounds circulating in the rotary kiln, and the deposition rate of the volatile compounds at the inner walls of the rotary kiln forming a ring, wherein the volatile compounds iteratively experience change in state parameters along the length of the rotary kiln causing deposition and re-circulation;
• and
• aggregate by a ring model the set of height parameters, the gaseous phase parameters, the temperature parameter, the energy parameter, the interaction parameters and the state parameters to estimate ring thickness, net ring growth and strength of the deposited material in the rotary kiln to predict safe time of operation of the rotary kiln.

One or more non-transitory machine-readable information storage mediums comprising one or more instructions which when executed by one or more hardware processors cause:

• receiving a plurality of operational parameters and a plurality of design parameters of the rotary kiln,
• obtaining a plurality of derived parameters by processing one or more operational and design parameters using, a set of models executed by the one or more hardware processors, the set of models comprising
• a solid bed height variation model to estimate a height parameters of the solid bed along the kiln length,
• a gas stream model to estimate a gaseous phase parameters associated with a plurality of gaseous components in the gas stream introduced through the discharge end of the rotary kiln,
• a solid stream model to simultaneously estimate (i) reaction kinetics of the solid bed associated with a plurality of components formed in the rotary kiln as a result of plurality of reactions occurring within various components of the solid bed and a molten phase formed within the rotary kiln, and (ii) temperature parameters of the solid bed and the kiln walls by aggregating the obtained reaction kinetics and heat balance in the rotary kiln,
• a melt model to estimate rate of formation of molten phase by calculating energy parameter associated with the total available solid material along the length of the kiln,
• an aggregation model to calculate rate of interaction among particles of the solid bed and molten phase forming an aggregate by obtaining interaction parameters, and
• a volatile model by simultaneously estimating the flow rate of volatile compounds circulating in the rotary kiln;
• and the deposition rate of the volatile compounds at the inner walls of the rotary kiln forming a ring, wherein the volatile compounds iteratively experience change in state parameters along the length of the rotary kiln causing deposition and re-circulation;
• and
• aggregating, via the one or more hardware processors, by a ring model executed by the one or more hardware processors, the set of height parameters, the gaseous phase parameters, the temperature parameter, the energy parameter, the interaction parameters, and the state parameters to estimate ring thickness, net ring growth and strength of the deposited material in the rotary kiln to predict safe time of operation of the rotary kiln.