A system and method for controlling operations of a cement kiln plant. The system comprises first and second processing logic. The first processing logic is configured to perform an integrated modeling computer program comprising a Virtual Cement and Concrete Testing Laboratory (VCCTL) modeling computer program and a virtual cement plant (VCP) modeling computer program. The first processing logic receives output of the VCP modeling computer program and imports the output into the VCCTL modeling computer program. The second processing logic is configured to perform one or more multi-objective metaheuristic optimization computer programs on output of the integrated modeling computer program to adjust control parameters that are used to control the operations of the cement kiln plant. The integrated model can provide a quantitative optimization tool for different energy efficiency measures addressed from cement plants and reduce energy, material consumption and greenhouse gas emissions without losing the performance of material.

A system and method for controlling operations of a cement kiln plant. The system comprises first and second processing logic. The first processing logic is configured to perform an integrated modeling computer program comprising a Virtual Cement and Concrete Testing Laboratory (VCCTL) modeling computer program and a virtual cement plant (VCP) modeling computer program. The first processing logic receives output of the VCP modeling computer program and imports the output into the VCCTL modeling computer program. The second processing logic is configured to perform one or more multi-objective metaheuristic optimization computer programs on output of the integrated modeling computer program to adjust control parameters that are used to control the operations of the cement kiln plant. The integrated model can provide a quantitative optimization tool for different energy efficiency measures addressed from cement plants and reduce energy, material consumption and greenhouse gas emissions without losing the performance of material.

An apparatus for thermal treatment of mineral materials may include a first combustion chamber, a second combustion chamber, and a reactor for the thermal treatment of mineral materials. The first combustion chamber is configured for burning a first fuel fed by a first fuel feed device, and the first combustion chamber and the second combustion chamber are connected via a first conduit for transferring hot gases from the first combustion chamber into the second combustion chamber. The second combustion chamber is configured for burning a second fuel that is different than the first fuel and is fed by a second fuel feed device. The second combustion chamber and the reactor are connected via a second conduit for transferring hot gases from the second combustion chamber into the reactor. The reactor has a third feed conduit for introducing a third fuel.

An apparatus for thermal treatment of mineral materials may include a first combustion chamber, a second combustion chamber, and a reactor for the thermal treatment of mineral materials. The first combustion chamber is configured for burning a first fuel fed by a first fuel feed device, and the first combustion chamber and the second combustion chamber are connected via a first conduit for transferring hot gases from the first combustion chamber into the second combustion chamber. The second combustion chamber is configured for burning a second fuel that is different than the first fuel and is fed by a second fuel feed device. The second combustion chamber and the reactor are connected via a second conduit for transferring hot gases from the second combustion chamber into the reactor. The reactor has a third feed conduit for introducing a third fuel.

In the disclosed solution sand to be cleaned is thermally cleaned by rotating the sand being cleaned in a large oven (1) by rotating the oven (1). Before cleaning, the sand may be pre-processed by crushing any lumps and cleaning the sand fraction by magnetic separation. Preprocessed sand to be cleaned and heat energy are fed (5) into the rotating oven. The oven (1) is set slightly inclined so that a second end of the oven (1) is lower than a first end. The inclination and rotating speed of the oven (1) as well as the feed amount of sand are adjusted, whereby the advancing speed of the sand may be adjusted, as well as the ratio of the sand being cleaned to the volume of the oven (1) kept as desired. The temperature of the oven (1) is monitored at the coldest area of the oven, which is substantially at the second end of the oven. The temperature of the oven (1) is adjusted by adjusting the amount of heat energy fed in. By means of temperature monitoring and knowing the advancing speed of the sand, it is also possible to determine the average temperature of the sand and adjust it as desired by adjusting the supplied heat energy. Finally, the cleaned sand is let run (12) from the second end of the oven (1).

In the disclosed solution sand to be cleaned is thermally cleaned by rotating the sand being cleaned in a large oven (1) by rotating the oven (1). Before cleaning, the sand may be pre-processed by crushing any lumps and cleaning the sand fraction by magnetic separation. Preprocessed sand to be cleaned and heat energy are fed (5) into the rotating oven. The oven (1) is set slightly inclined so that a second end of the oven (1) is lower than a first end. The inclination and rotating speed of the oven (1) as well as the feed amount of sand are adjusted, whereby the advancing speed of the sand may be adjusted, as well as the ratio of the sand being cleaned to the volume of the oven (1) kept as desired. The temperature of the oven (1) is monitored at the coldest area of the oven, which is substantially at the second end of the oven. The temperature of the oven (1) is adjusted by adjusting the amount of heat energy fed in. By means of temperature monitoring and knowing the advancing speed of the sand, it is also possible to determine the average temperature of the sand and adjust it as desired by adjusting the supplied heat energy. Finally, the cleaned sand is let run (12) from the second end of the oven (1).

A process for producing cement clinker, may involve preheating raw meal in a preheater, calcining the preheated raw meal in a calciner, and burning the preheated and calcined raw meal in a furnace to give cement clinker. The furnace may be supplied with a combustion gas having an oxygen content, and the temperature within the furnace is ascertained. The process may involve cooling the cement clinker in a cooler. The oxygen supply to the furnace is under closed-loop control as a function of the temperature ascertained within the furnace. The temperature ascertained is compared with a target value and, in the event of any variance of the temperature ascertained from the target value, the oxygen supply to the furnace and/or to the calciner is increased or decreased. The target value is adjusted depending on a particle size distribution and/or a lime standard.

A process for producing cement clinker, may involve preheating raw meal in a preheater, calcining the preheated raw meal in a calciner, and burning the preheated and calcined raw meal in a furnace to give cement clinker. The furnace may be supplied with a combustion gas having an oxygen content, and the temperature within the furnace is ascertained. The process may involve cooling the cement clinker in a cooler. The oxygen supply to the furnace is under closed-loop control as a function of the temperature ascertained within the furnace. The temperature ascertained is compared with a target value and, in the event of any variance of the temperature ascertained from the target value, the oxygen supply to the furnace and/or to the calciner is increased or decreased. The target value is adjusted depending on a particle size distribution and/or a lime standard.

Disclosed is a method for producing sintered material from organic raw materials, implemented in an apparatus comprising, a cyclone preheater, a rotary furnace and a grate cooler, and in which the raw materials are preheated in the cyclone preheater, the preheated material is calcined and sintered in the rotary furnace, and the calcined materials are cooled by blowing cooling air in the grate cooler, producing hot air. The hot air is separated into three upstream-to-downstream fractions, the three hot air fractions being at decreasing temperatures. The first air fraction acts as combustion air in at least the combustion zone of the rotary furnace and/or of the potential precalciner of the apparatus. The second air fraction is greater than the combustion air needs to produce energy. The third air fraction is directed at least in part to the combustion zone of the apparatus, providing combustion air with the first air fraction.

Disclosed is a method for producing sintered material from organic raw materials, implemented in an apparatus comprising, a cyclone preheater, a rotary furnace and a grate cooler, and in which the raw materials are preheated in the cyclone preheater, the preheated material is calcined and sintered in the rotary furnace, and the calcined materials are cooled by blowing cooling air in the grate cooler, producing hot air. The hot air is separated into three upstream-to-downstream fractions, the three hot air fractions being at decreasing temperatures. The first air fraction acts as combustion air in at least the combustion zone of the rotary furnace and/or of the potential precalciner of the apparatus. The second air fraction is greater than the combustion air needs to produce energy. The third air fraction is directed at least in part to the combustion zone of the apparatus, providing combustion air with the first air fraction.