Kiln ACE (Advanced Control Expert)

Lime kilns are a major energy consumer and it is a challenge for plant operators to run them efficiently. Long thermal response times of kilns make stable operation difficult, as consequences of operator actions are not observed until several hours later. Frequent disturbances caused by changing production rates, mud solids content, and NCG waste gases prevent the kiln from running smoothly.

Operators typically run the kiln at high temperatures and high excess oxygen to avoid producing under-burned lime or causing emissions violations. These practices lead to increased fuel consumption, excess wear on the kiln refractory, increased ring problems, and poor lime quality. 

ACE is a virtual expert operator that manages a process area with the goal of keeping costs as low as possible, while continuously delivering a product that meets specification. ACE manages all the operational constraints and limits, reconciles lab test data with operational goals while validating instruments, and provides shift-to-shift stability.