Using Response Surface Methodology Approach to Modeling and Optimization of the Combustion Process in Cement Kiln

In this study, this process has been modeled and optimized using the design of experiment technique and response surface methodology (RSM). The RSM was employed to optimize the combustion process in the cement kiln. Kiln feed (X1 = 160-190 t h-1), fan speed (X2 = 840-870 rpm), kiln rotational speed (X3 = 2.8-3.4 rpm), kiln fuel rate (X4 = 3800-4150 L h-1), calciner fuel rate (X5 = 5700-6200 L h-1), pressure of kiln inlet (X6 = 98-102 Pa), and limestone saturation factor (LSF) (X7 = 94-95.8 %) as independent variables were investigated. The carbon monoxide and the kiln body temperature in RSM were considered as response variables. The absolute average error in the model predictions for the combustion process in the cement kiln, for the kiln body's temperature, is about 1.6 % and for carbon monoxide is about 15.5 %. In this study, the combustion process in the cement kiln was optimized using response surface methodology. The independent variables investigated were kiln feed, fan speed, kiln fuel rate, calciner fuel rate, and limestone saturation factor. Response variables included CO and kiln body temperature. The model predictions for the combustion process showed an absolute average error of about 1.6 % for kiln body temperature and about 15.5 % for CO. image