Optimization of Cement Manufacturing Process

Abstract

Cement manufacturing process is now operated with the aid of various control systems, such as raw meal composition control, kiln control and mill control. Those systems have greatly contributed to achieve uniformity of quality as well as cost reduction of cement. But from the viewpoint of optimization of cement manufacturing operation, it is desirable to build an integrated control system, which supervises and directs each control system.One of the biggest problems in process control of cement manufacturing was that the time lag of quality judgement is very long, because one of the most important indexes of quality is 28-day compressed strength of cement mortar. But this problem was practically solved by the appearance of Ono-method.From our experience and technical knowledge accumulated through the use of Ono-method for long years, we have succeeded in developing a real-time quality prediction system, which is very effective for process control, on the basis of fundamental concept of Ono-method.By putting the quality prediction system at the center of the control systems and making use of it for feedback control and feedforward control, it has become possible to establish an integrated control system for optimizing cement manufacturing operation.