New project: Monarch Cement deploys new MPC pyroprocessing control system


Monarch Cement Co. has selected a model predictive control (MPC) platform from Pavilion Technologies for the two kilns at its Humboldt, KS, plant. The application is intended to improve operating stability, enhance product quality, reduce specific energy costs, and minimize NOx emissions. Pavilion says Monarch is the fifth company in six months to adopt its specialized cement industry control system.

“Our decision to invest in Pavilion Technologies’ pyroprocessing optimization solution reflects our commitment to continuous operational improvement and market leadership,” says Harvey Buckley, vp of operations for Monarch. “Pavilion has a solid track record in the cement industry and is known for delivering measurable results.”

Some of the specific results that new system is expected to deliver for the Humboldt plant include reducing:

• Process and clinker quality variability (free lime) by up to 50%;
• Downtime due to process upsets;
• Specific fuel consumption by 2-4%; and,
• NOx emissions per ton of clinker by 8%.

Pavilion has reportedly designed the MPC system to address challenges that are critical to cement manufacturers, including high energy costs, use of secondary fuels, environmental regulation, and changing customer demands. Its cement solution optimizes key operational areas of raw meal preparation, pyroprocessing, cement grinding, and environmental compliance reporting.

—Edited by Peter Welander, process industries editor, , Control Engineering Weekly News (Register here and scroll down to select your choice of eNewsletters free.)

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