Optimization of Rotary Cement Kiln Using Genetic Algorithms

Rotary cement kiln as heart of a cement production plant plays an important role in overall energy consumption and product yield. Therefore, the process behavior and physical parameters affecting the final production need to be investigated. Modeling and simulation of the rotary cement kiln have been done by several researchers considering dynamic and steady state behavior of the process. In this research, different models presented by other researchers were evaluated and their advantages and disadvantages were studied. Next, a general and comprehensive model was developed with the aim of optimization of the process. Due to the complexity of the Differential and Algebraic Equations (DAE’s) constructing the model, a powerful method should be employed in order to solve the complex system. Simulation results were compared to the result from a case study presented in the literature. Moreover, Genetic Algorithms (GA) was used as a strong tool to find optimum parameters and operating conditions for production of different cement types. Having maximum production as objective function, different values for the parameters and conditions were resulted from the numerical optimization of the process. It was found that for some fixed plant geometries, different optimum values exist for production of a specified cement type.