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.