Optimization of the clinker production phase in a cement plant

In this paper, the control and the optimization of the clinker production phase of an Italian dry cement industry is described. A tailored Advanced Process Control architecture has been proposed, based on a two-layer Model Predictive Control strategy. The critical process variables have been included in the controller setup through linear models with delays. The controller moves are computed through two subsequent constrained optimization problems with cooperation and consistency assumptions. The developed controller replaced a previous control system based on operators’ conduction. Thanks to the predictive approach, more profitable operating points have been guaranteed, significantly improving the process control performances. Energy consumption and environmental emissions have been reduced, taking into account quality and production requirements.