Presets
Playback
Process settings
Gas flows from the burner end to the exhaust end while the solid moves the other way. Conversion only starts once the solid passes about 810 C, so a short warmup gives rejects.
Controller
Inject faults
Model checks
The science
What is modelled
A chain of twelve zones. Each zone has a gas, a solid and a shell temperature that relax towards each other with fixed time constants; gas is transported from the burner end towards the exhaust, solids the other way at a rate set by the rotation speed. Conversion of the solid follows a first-order rate that switches on between 810 C and 1250 C. A sequence controller steps OFF, PRECHECK, PURGE, IGNITE, WARMUP, RUN, COOLDOWN and latches TRIPPED when a permissive is lost.
Equations
dTgas,i/dt = f (Tgas,i+1 - Tgas,i)/τg - (Tgas,i - Tsolid,i)/τx - (Tgas,i - Tamb)/τlosswith fan factor f.dXi/dt = ri(1 - Xi) / 2100 s,ri = clamp((Tsolid,i - 810)/440, 0, 1).- Fuel energy:
E = ∫ (fuel%/100) · 1.8 MW dt.
Checks run in the page
- The start sequence time equals precheck + purge + flame proving.
- Interlocks refuse a start with the door open or low airflow.
- Product plus rejects equals the fed mass, and the fuel energy matches an independent sum.
- An idle kiln stays at ambient; a firing kiln is hotter at the burner end.
Honest simplifications
A lumped educational model with illustrative time constants and a fixed 1.8 MW firing rate. It is not a calibrated kiln model, not certified burner-management software and not a safety design.
What to try
- Let the start sequence run, then tick Flame detector lost and watch the fuel isolate.
- Pick Weak draft: the start is denied because airflow is below the 60 % permissive.
- Raise the process time scale to see warmup and cooldown in a few seconds.