The main process objective of lime kiln operation is to produce a uniform quality lime. Additional operating objectives include minimizing fuel consumption ad complying with environmental regulations. Given the long process delays and variable interactioninherent to lime kilns, these objectives are extremely difficult to achieve under manual or standard closed-loop kiln operation. A predictive control algorithm, MACS~(TM) (Multivariable Advanced Control System) has been achieved while simulataneously extending the operating life of the refractory. In addition to the kiln temperature profile, flue gas oxygen and CO are also explicitly regulated by the controller. By sustaining stable kiln operation at the process limits, the advanced controller is able to minimize energy use while ensuring safe combstion conditions are maintained.
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