Controllynx
Advanced Process Control Projects
Cement Kiln Optimization
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Cement Kiln Optimization
Client Challenge
A major cement manufacturer struggled with excessive fuel consumption in their rotary kiln. Operators controlled combustion manually, leading to frequent temperature fluctuations and high clinker variability. This resulted in both quality issues and rising energy costs.
Our Proposal
We proposed implementing a model predictive control (MPC) system, which would optimize fuel feed and combustion air dynamically. Our proposal demonstrated clear ROI through projected fuel savings of 6–10% annually. After reviewing bids, the client awarded us the project because of our prior track record in energy-intensive industries.
Solution Delivered
* Installed kiln temperature and pressure sensors with advanced calibration.
* Developed an MPC algorithm for real-time kiln stabilization.
* Integrated predictive alarms for early detection of unstable combustion.
* Provided continuous performance monitoring dashboards.
Result
Fuel consumption dropped by 8%, refractory life increased by 20%, and clinker quality stabilized. The savings paid back the project cost within 18 months.