Kiln Control System for the Cement Industry

Share on facebook
Share on google
Share on twitter
Share on linkedin
The Cement Institute
Kiln burner firing

Kiln Control System for the Cement Industry

To produce a consistent product at the desired output, quality, and cost.

 

What do we mean by Kiln Control

Why is good kiln control important

Review current strategy

Sensors

High-Level Control

How can we improve kiln control

 

What do we mean by Kiln Control

  • Basic kiln control
  • Quality control
  • Optimization

Components of Good Kiln Control

 

Factors which affect Steady Operation

 

Basic Control – Signals Used

  • Burning Zone condition
    • Nox
    • Amps
    • Pyrometer
  • Combustion conditions
    • O2
    • CO
  • Material preparation
    • kiln inlet temp
    • preheater exit temp

Setting of Control Levels

Control Setpoints

Why is Kiln Control Difficult

  • Not a precise science
  • Multiple dependencies/constraints
  • Non-linear response necessary
  • Not always possible to achieve all targets
  • Process time lags / system inertia
  • Requires constant adjustment for optimum performance

Optimization of Kiln System

  • Good control of the process
  • Decide on overall strategy

Max output

Min fuel consumption

minimum dust loss

  • Strategy for optimizing BZT, O2, BET

Other Sensors

  • CO – safety, O2 optimization
  • SO2 – early indication of reducing conditions
  • Pyrometers
  • Shell scanners
  • Online free lime analyzer

Free Lime Correlation

 

Free Lime vs Kiln Amps

Targets for Kiln Control

Clinker Quality

Clinker Tph

Fuel Consumption

NOx

Oxygen

BET

Potential Benefits

  • Consistent operation
  • Management control
  • Improved understanding
  • Environmental control
  • Reduced costs

Leave a Replay

About Us

The Cement Institute provides powerful tools to drive success through knowledge and productivity delivered. Focus on plant assessment, plant personnel and plant methodology.

Recent Posts

Sign up for our Newsletter

Click edit button to change this text. Lorem ipsum dolor sit amet, consectetur adipiscing elit