ACE Control Systems (kiln

ANDRITZ Kiln ACE is a control optimization system powered by BrainWave that improves product quality, reduces fuel consumption, maximizes yield, and increases the effective production rates of rotary kilns.

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.

As a result, 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.