Advanced Methods for Kiln-Shell Monitoring to Optimize the Waelz Process for Zinc Recycling

The recycling of zinc in the Waelz process is an important part of the efficient use of resources in the steel processing cycle. The pyro-metallurgical processing of zinc-containing wastes takes place in a Waelz rotary kiln. Various measured variables are available to monitor the process. The temperature of the kiln-shell is analyzed by an infrared kiln-shell-scanner. In this paper, methods are presented which eliminate external weather-related disturbances on the temperature measured by the kiln-shell-scanner using a weather model and which extend the monitoring of the regularly necessary melting process to remove accretions. For this purpose, an adapted sigmoid estimation is introduced for the melting process, which provides new information about the current process status and a forecast of the further development of the melting process. As an assistance system for the plant operator, this enables an efficient execution of the melting process and reduces downtimes.