Predictive control and optimization applications in a modern cement plant

A series of software automation applications has been implemented at Capitol Cement's plant in San Antonio, Texas. These control and optimization applications are implemented on two finish mills and one dry kiln line (including the precalciner and grate cooler). The kiln-cooler controller is designed to maximize production and reduce fuel consumption. It reduces NOx emission as part of a multivariable control solution and improves clinker consistency. All of these applications use neural network models of the individual processes and have proved highly effective in practice, with a very low maintenance burden.