PID-Fuzzy Controller for Grate Cooler in Cement Plant

Awang N.I. Wardana*

* Control Department
Indonesia Cement and Concrete Institute
Jalan Raya Ciangsana, Bogor, 16969, Indonesia.
Phone: +62-21-82403650 Fax: +62-21-82403654
e-mail: awang.wardana@telkom.net

Abstract solve these problems because PID-Fuzzy controller has

some advantages:
This paper studied about application of PID-Fuzzy
controller for grate cooler in cement plant. The
proportional, integral and derivative constant adjusted by Conventional
new rule of fuzzy to adapt with the extreme condition of rk
setpoint
6 ek PID-Control
uk
grate
PLANT yk
under grate
process. The new algorithm performs in every condition speed pressure #1

and already tested in every extreme condition. The result of

this new algorithm is very good; changes of under grate
pressure #1 were reduced and temperature of output clinker
was reduced.

1 Introduction Figure 1: Grate Cooler Conventional PID Control

Scheme
The efficiency problem is well known in the cement
industry and a standard process control response has 1) It has the same linear structure as the conventional PID
evolved to solving the problem [2]. Cooling air is blown controller, but has adjusted coefficient, self-tuned control
into the chambers below the clinker grate. This is the means gains: the proportional, integral, and derivative gains are
by which the clinker is cooled and the thermal energy is nonlinear functions of the input signals [7].
recovered from the clinker. The pressure under the grate of 2) The controller is designed based on the classical discrete
the cooler is monitored and is taken to be directly PID controller [6] [7].
proportional to the thickness of the bed of clinker on the
grate. 3) Membership functions are simple triangular with fuzzy
logic rules [6] [7].
When extreme condition come for example, the load of
clinker entering the cooler increases the bed thickens and 4) Stability of these fuzzy PID controllers is guaranteed [3].
the pressure under the grate rises. The control response is to In next section we will explain about design of PID-Fuzzy
increase the speed of the grate to transport the additional control that used in this process. After that we will explain
clinker away from the kiln [4]. about the fuzzification, rule and defuzzification of fuzzy
The reverse process takes place when the amount of clinker algorithm. And the last section we will explain about
entering the cooler lessens. The clinker bed thins out and application of this controller in the real plant.
the pressure under the grate falls, with the control response
being to slow the grate down and retain the clinker on the 2 Controller Design
grate for longer in order to build up the bed depth. All these
control procedure are described in figure 1. In this paper we used two type controllers to detect
This apparently straight forward conventional process performance of these controllers in the real plant. These
control solution is often extremely unpopular with kiln controllers are:
operators, and sometimes creates more problems than it 2.1 PID Controller
solves. The root of the problem is the conventional PID The theoretical PID-controller,
controller cannot adapt to the dynamics of the process. So
we need some algorithm to adjust PID controller according § ·
1
to the dynamics of the process. In grate cooler, the dynamic U (s) K p ¨¨ 1   T d s ¸¸ E ( s ) (1)
of the process is nonlinear. So we need algorithm that can © Ti s ¹
adapt with nonlinear behavior. Fuzzy logic matches to
where Kp, Ti and Td are the proportional gain, integral time ek
and derivative time, respectively, E(s) and U(s)are Laplace ek Fuzzy
transforms of the control signal and the error between the 6

reference signal and the plant output. ek-1

dek

rk 6 PID uk yk
In this paper, we used a PID-controller proposed by Clarke
Controller
PLANT
[1] is used because of its better derivative part. The
controller is of the form

§ 1 · K pTd s
U (s) K ¨¨ 1  s ¸¸ E ( s )  Y (s)
p
© T i ¹ 1  aT d s (2)
Figure 2: PID-Fuzzy Control Scheme
These fuzzy algorithms that adjust the PID controller are
where a is the filtering constant at the interval (0,1), and
discussed in the next section.
U(s) is Laplace transform of the plant output. The
implementation of the derivative part is more realistic than
in (1). The low pass filter reduces the effect of the 3 Fuzzification, Rule Base Establishment and
measurement noise, and only the plant output, which is Defuzzification
continuous, is differentiated. This controller can be
discretized with an approximation s | 1  d / h , where h is The fuzzy PID controller was designed by following the
the sampling interval, and d is the delay operator. Thus, the standard procedure of fuzzy controller design, which
discretized controller is of the form: consists of fuzzification, control rule base establishment,
and defuzzification as shown by figure 3.
H
u pi ( k ) u pi ( k  1)  K p ( de ( k )  e( k )),
Ti Linguistic

Defuzzification
u min d u pi ( k ) d u max (3)
Fuzzification Rule Set
Td

Output
u d (k ) ( au d ( k  1)  K p dy ( k ))
Input

h  Td IF….
u (k ) u pi ( k )  u d ( k ), u min d u ( k ) d u max
THEN….

where k is a sampling time, e(k)=r(k)-y(k) is the error

signal, de(k)=e(k)-e(k-1) and dy(k)=y(k)-y(k-1) are the
differences. The control signal is restricted to the interval Figure 3: Structure of Fuzzy Logic
||umin,umax|. To optimized PID controller we used Ziegler-
Nichols formula [8]: 3.1 Fuzzification
Fuzzification is mapping from the crisp domain into the
Kp 0 .5 K c , Ti 0 .5T c , T d 0 .125 T c (4) fuzzy domain. Fuzzification also means the assigning of
linguistic value, defined by relative small number of
membership functions to variable. In this research, we have
where Tc is ultimate period and the process gain Kc two input with three output. For all this input and output,
approximately given by: we choice symmetrical triangular membership function that
shown in figure 4. The triangular curve is a function of a
4p vector, x, and depends on three scalar parameters a, b, and
K c
Sa m (5) c, as given by:

§ §xa c x· · (6)
where am is amplitude of limit cycle and p is the relay P ( x : a, b, c) max ¨¨ min ¨ , ¸ , 0 ¸¸
© ©ba cb¹ ¹
amplitude

2.2 PID-Fuzzy Controller
The PID controller that described by equation (3) is
adjusted with fuzzy controller that described in figure 2.
where the parameters a and c locate the "feet" of the
triangle and the parameter c locates the peak. Inputs for
fuzzy algorithms are set point and output of process and the
outputs for these fuzzy algorithms are proportional, integral
and derivative constant.
 4 Application of PID-Fuzzy Controller in Grate
1
NB NM NS ZO PS PM PB
Cooler

0.8
These fuzzy rules that shown by figure 5 applied to control
grate cooler in cement plants with specification:
0.6 x Rotary kiln
x Clinker cooler with grate hydraulic drive
0.4
x Preheater two strings 4 stage with precalciner
0.2
x Total capacity 4,600 M Ton per day

0
4.1 PID Controller
In first time, we used conventional PID controller to control
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
under grate pressure #1. Using Ziegler-Nichols formula in
Figure 4: Symmetrical Membership Function equation (3) at normal condition we get Kp= 150% Ti = 80
s and Td= 20 s. This calculation used to control grate
3.2 Rule cooler and the result as shown in figure 6.
In this research, classic interpretation of Mamdani [5]
logic operations are applied, for ‘and’ minimum is used,
for ‘or’ also with ‘maximum’. So with IF-THEN rule, we
can describe the rule of fuzzy algorithm with the following
two dimensional table rules.

ek
dek NB NM NS ZO PS PM PB
PB ZO PS PM PB PB PB PB
PM NS ZO PS PM PB PB PB
PS NM NS ZO PS PM PB PB
ZO NB NM NS ZO PS PM PB
NS NB NB NM NS ZO PS PM
Figure 6: PID Controller Result
NM NB NB NB NM NS ZO PS
NB NB NB NB NB NM NS ZO From figure 6 we can calculate that approximation normal
probability density function under grate pressure # 1.
Figure 5: Used Rule Base for Kp, Ti and Td Figure 7 show this calculation. From experiment we can
get some data:
3.3 Defuzzification x Standard deviation of under grate pressure is 50
In this paper we used centre of area method for mmH2O
defuzzification. This method determines the centre of the x Clinker temperature output 1500
area of the combined membership functions. This method is 200

referred to the centre of gravity method because its 180

computes the center of the composite area representing the

160
output fuzzy term. Assuming that a control action with a
140
point wise membership function P(zj) has been produced,
with centre of area method crisp output z calculates: 120

100

q 80

¦
j 1
z jP (z j ) (7) 60

z q 40

¦ j 1
P (z j )
20

0
600 650 700 750 800 850 900 950

where, zj is the amount of control output at the quantization mmH2O

level j, P(zj) is membership value in zj and q is number of Figure 7: Probability Density Function Under-Grate
quantization levels of the output Pressure (#1) with Conventional PID Controller with
Ziegler- Nichols Formula
4.2 PID-Fuzzy Controller x With PID-Fuzzy, under grate pressure # 1 as
To build PID-Fuzzy controller, first we examine three output variable of process was not deviate more
extreme conditions and calculated with equation (3) the than 5 mmH2O. This is means that reduced more
optimal PID controller. This three extreme condition yield that 90 % than controlled with conventional PID
result as shown in figure 8: controller. This condition described by
approximated normal probability density function
condition start up snowman kiln upset of under grate pressure # 1 that shown in figure 7
proportional 80 % 120 % 200 % and 10.
constant x Because under grate pressure #1 stable so the bed
integral 40 s 12.5 s 20 s depth of clinker on grate cooler relative constant.
constant Due to that temperature of secondary air that
derivative 0s 40 s 90 s increases more than 1500C after using PID-Fuzzy
constant controller. Its means increase efficiency of
calcinations in precalciner.
Figure 8: Calculation Result of Kp, Ti and Td in extreme x Also temperature of clinker output is reduce from
condition around 150oC to around 90oC, its means that with
PID-Fuzzy burn out material can be reduced.
From this calculation we build rule for PID-Fuzzy
controller as shown in figure 9.
5 Conclusions

With PID-Fuzzy controller, efficiency problem that become

well known problem in cement plant can be solved.
Because used PID-Fuzzy controller we have some
advantages:
x Under-grate pressure deviations were reduced
x Clinker output temperature were reduced so the
frequency of grate burnout was reduced
x Changes in secondary air temperature were
reduced and increase secondary air temperature.
x Increase calcinations efficiency in preheater.

References

Figure 9: PID-Fuzzy Controller Result [1] Clarke D., Automatic tuning of PID regulators, Expert
400
Systems and Optimization in Process Control,
Technical Press, Aldershot, England, 1986.
350

[2] Clark M.C, Whitehopleman, Efficiency and

300
Reliability, Resolving the Efficiency: Reliability
250
Cooler Conflict, Cooler Justification, http://
www.istimaging.com, 1998.
200

[3] Chen, G and Ying, H, BIBO Stability of Nonlinear

150
Fuzzy PI Control Systems, Int. J. Intell. Control Syst.,
100 vol. 5, pp. 3–21, 1997.
50 [4] Duda, W. H, Cement Data Book 2: Automation,
0
Storage, Transportation, Dispatch, Bouverlag
740 745 750 755 760 765 770 775 780

mmH O
GmbH,1990
2

Figure 10: Probability Density Function Under-Grate
Pressure #1 with PID-Fuzzy Controller
After PID-Fuzzy controller was applied in operation with
full 2 strings suspension preheater, we can observe the
result that:
[5] Mamdani, M, Application of Fuzzy Algorithm for
Control of Simple Dynamic Plant, Proc. IEE, v. 121,
no.12, pp. 1585-1588, 1974.
[6] Tang K. S., Man K.F., Chen G. and Kwong S, An
Optimal Fuzzy PID Controller, IEEE Transactions on
Industrial Electronics, Vol. 48, No. 4, pp.757-765,
2001.
[7] Viljamaa P. and Koivo H.N., Fuzzy Logic in PID Gain
Scheduling, Third European Congress on Fuzzy and
Intelligent Technologies EUFIT’95, Aachen,
Germany, August 28í31, 1995.
[8] Ziegler, J.B. and N.B Nichols, Optimum Setting for
Automatic Controllers, Trans. ASME, vol.64, pp.759-
768, 1942.