Cement rotary kiln: Constraints handling and optimization via model predictive control techniques

In this work an Advanced Process Control approach aimed to the control and the optimization of a cement rotary kiln is proposed. Model Predictive Control techniques have been adopted for the controller and a system architecture based on two optimization layers is proposed. A suitable design of each layer and their interaction policy allowed to improve control performances and to meet possibly variable economic goals. Simulation results show the effectiveness of the adopted control architecture and optimization problem formulation. Results of practical implementation of the proposed controller on a cement rotary kiln unit confirm the improvement of the performances in terms of energy efficiency, product quality and environmental impact when compared to the previous control system.