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ECS/ProcessExpert®: Advanced Process Control for Kilns and Coolers

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Introduction

The cement manufacturing process involves complex and sensitive operations that require precise control to ensure optimal efficiency, product quality, and environmental compliance. The ECS/ProcessExpert® system, developed by FLSmidth, provides an advanced process control solution specifically designed for kiln and cooler operations. By leveraging expert control techniques, this system enhances the stability of pyroprocessing, increases production rates, improves clinker quality, and reduces energy consumption.

Key Benefits of ECS/ProcessExpert®

The ECS/ProcessExpert® system offers significant advantages to cement plants, including:

Improved Process Stability – Maintains operational consistency even with high rates of alternative fuel usage.
Enhanced Production Efficiency – Increases clinker production by up to 7%.
Energy and Emissions Reduction – Reduces specific fuel and power consumption by up to 7%, while lowering the overall CO₂ footprint by approximately 2.0%.
Minimized Process and Quality Variations – Reduces process fluctuations by up to 40%, ensuring higher reliability.
Optimized Alternative Fuel Utilization – Allows for at least a 10% increase in the use of green fuels, leading to reduced NOₓ emissions.

Challenges in Pyroprocessing and the Need for Advanced Control

Managing a cement kiln is inherently challenging due to the variability in raw materials, fuel types, and process conditions. The push toward sustainability has introduced additional complexity as plants integrate higher percentages of alternative fuels. These fuels, while cost-effective and environmentally friendly, introduce fluctuations in calorific value, moisture content, and chemical composition, making traditional kiln operation more difficult.

ECS/ProcessExpert® addresses these challenges by continuously monitoring and adjusting process parameters with greater precision than human operators, ensuring:

Stable burning conditions
Consistently high clinker quality
Reduction in unwanted issues like cyclone blockages and kiln ring formation

Features and Capabilities of ECS/ProcessExpert®

1. Normal Control Mode: Establishing Process Stability

Before optimizing the kiln operation, ECS/ProcessExpert® first stabilizes the system by managing critical process variables. Key stabilizing actions include:

Burning Zone Control – Adjusts fuel injection rates to maintain optimal burning conditions.
Kiln Operation Stability Index – Ensures consistent operation by modulating kiln speed, feed rates, and cooler airflow.
Heat Consumption Index – Manages fuel efficiency to prevent excessive energy use.

Through these stabilizing efforts, the system achieves steady temperature control in the calciner and kiln, reducing fluctuations that impact clinker quality.

2. Optimization Control: Enhancing Efficiency

Once stability is achieved, ECS/ProcessExpert® moves to process optimization by pushing operational limits safely and efficiently. This includes:

Maintaining Free Lime Levels – Adjusts burning zone indicators to optimize clinker composition.
Lime Saturation Factor (LSF) Monitoring – Regulates kiln feed chemistry to maintain target calcination levels.
Minimizing Over-Burning Risks – Prevents excessive energy use while ensuring clinker remains within desired specifications.

By continuously adapting to process conditions, the system reduces fuel consumption without compromising clinker quality.

3. Upset Condition Management: Rapid Recovery

Cement plants frequently encounter process disturbances, including:

Coating Falls in the Kiln – Sudden loss of protective coatings can disrupt operations.
Gas Pressure Fluctuations – Variations in ID fan speed or main baghouse operation can affect airflow.
Preheater Exit CO Spikes – High carbon monoxide levels indicate combustion inefficiencies.

ECS/ProcessExpert® rapidly detects and mitigates such issues by adjusting kiln feed, fan speeds, and alternative fuel ratios, ensuring quick recovery to normal operating conditions.

4. Emissions Control: Ensuring Regulatory Compliance

Environmental regulations mandate strict control over emissions, particularly NOₓ and CO₂ levels. The ECS/ProcessExpert® system includes customizable emissions management features, such as:

Ammonia Injection Control – Ensures NOₓ emissions remain within permissible limits.
Alternative Fuel Optimization – Reduces reliance on traditional fossil fuels while maintaining thermal efficiency.

By implementing predictive control strategies, the system helps cement plants achieve sustainability targets while remaining compliant with local environmental standards.

Fuel Optimization Control: Maximizing Cost Efficiency

One of the key innovations of ECS/ProcessExpert® is its fuel distribution application, which optimizes the use of multiple fuel sources based on:

Cost Efficiency – Prioritizes lower-cost fuels while maintaining thermal stability.
Heat Value Considerations – Balances fuel types to ensure consistent combustion conditions.
Multi-Fuel Compensation – Automatically adjusts for fuel shortages by redistributing available resources.

This approach enables cement plants to increase their thermal substitution rate by at least 5%, reducing overall fuel costs without sacrificing operational reliability.

Conclusion

The ECS/ProcessExpert® system represents a major advancement in kiln and cooler control, helping cement plants achieve greater efficiency, sustainability, and profitability. By leveraging expert process automation, this system minimizes human error, optimizes fuel use, and stabilizes key process parameters, resulting in:

Higher clinker production rates
Reduced energy consumption
Improved alternative fuel utilization
Compliance with emissions regulations

For cement manufacturers looking to enhance operational efficiency while reducing costs and environmental impact, ECS/ProcessExpert® provides an industry-leading solution backed by decades of process automation expertise from FLSmidth.