A new approach to expert kiln control

Expert system kiln control is proven technology. The expert system's smoother control provides significant operating cost reductions by: (1) lowering the specific consumption (i.e. MBTU/tons clinker or kcal/kg); (2) extending brick life; (3) lowering electrical energy costs; (4) lowering maintenance costs; (5) substantially reducing the use of high price auxiliary fuels such as gas; and (6) kiln NO/sub x/ levels are controlled, addressing stack emission and environmental regulation requirements. This paper describes the approach selected for kiln expert control for the Hercules cement pre-calciner kiln project, USA. The goals were full functionality expert control that focused on the issues of ease of use and the high costs of kiln expert control. This paper is divided into four sections. The first section provides an overview of kiln expert control system functionality, the second section describes the project goals, the third section describes the new expert system approach and the fourth section discusses risk management and project results.