A rotary kiln is a pyro-processing device to raise materials into a high temperature (calcination) in a continuous process. Materials produced using rotary kiln include: cement, lime, or refractories. Exhaust gases are representing a large percentage (approx. 20%) of the total heat input used in the system. Optimization of residual hot gas from rotary kiln process is important to make the process more efficient. A blower is used to take the residual gas and the heat transfer mechanisms is forced convection heat transfer. Differential equation is solved to determine the suitable mathematical model. Based on the data, the temperature is increased exponentially. A differential pressure (DP) transmitter sensor is installed at the end of exhaust gas pipe to control fluid velocity. Data is analysed for optimization in MATLAB simulation and the Proportional Integral Derivative (PID) controller parameters are: Kp = 1.803, Ki = 0.08 and Kd = 0.03. Rise time is 0.238.
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