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Feb 21

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How to Optimise Cement Manufacturing Process

Aim: To achieve maximum output with the required level of grinding fineness.

Optimisation of the clinker-making process is typically done to decrease the heat consumption, to improve the clinker quality, and to improve the lifetime of the equipment (the refractory lining, for example). This is achieved by keeping the process parameters stable.

Optimisation includes measures/techniques like ensuring excellent composition of fresh meal, managing combustion processes correctly and improving the cooler operation. The cost of operating an optimised kiln is usually reduced, among others, based on reduced fuel and refractory consumption, higher productivity and lower maintenance costs.


Combustion management is of utmost importance for optimisation and attention should be paid to the following things:
  • Fuel grinding management : grinding of fuel need to be managed to attain optimal fineness.

  • Air ratio management : To keep up with an appropriate air ratio, the concentration of oxygen in the combustion exhaust gas needs serious management.

  • Exhaust gas management : NOx (oxides of Nitrogen) and CO (Carbon Monoxide) have to be measured and their data for their measurement to be utilised for control of combustion.

  • Kiln burner control : the basic designs like the angle of the lamp's fuel discharge, the primary air ratio, etc., have to be reviewed to keep up with the optimum combustion conditions.
  • Cooler operation management : Heat recovery at the cooler significantly affects the combustion control of the kiln burner..




Computerised control systems, for instance, can be utilised to optimise the combustion process and conditions. Enhanced process control will equally assist in improving the quality of the product which might lead to more competent clinker grinding. Most current monitoring systems use the self-styled "expert control" systems or "model predictive" controls.

Process control systems comprise the use of on-line analysers that allow operators to instantly conclude the processing chemical composition of raw materials, thus permitting immediate changes in the mix of raw materials.

An identical feed allows steadier kiln operation, thus saving on fuel supplies. Process control of the clinker cooler can assist in improving heat recovery.

Contemporary versions of process monitoring and optimisation systems utilise advancements in information and communication technologies and allow direct surveillance and modification of process parameters by multiple users have simultaneous access and the increased use and implementation of mobile devices.