Development of an artificial intelligence-PLC temperature controller for a cement factory for decreasing contamination

In this study, temperature control of the cooling tower (CT) system is developed and implemented using fuzzy-programmable logic controller (PLC) control technology to improve electric static precipitator (ESP) performance, output, and quality while minimizing losses within the CT in the cement plant. This method makes use of the fuzzy logic controller and integrates it into the PLC. The valve system is programmed to avoid the “wet bottom” phenomenon in the CT. A fuzzy valve controller is intended to solve the problem of opening and closing the valve in the return line at the appropriate time in order to regulate the temperature of the CT. A SIMULINK PLC coder converts the program from MATLAB to structured text language (STL). STL is a functional expression that improves the efficiency of the PLC-1200 work system. The amount of dust and flue gas emitted by the particulate control system is measured using continuous emission monitoring systems. The results show a significant improvement in ESP quality following the implementation of fuzzy control temperatures for the CT, which reduced dust emissions from the cement plant by 10% when compared to the traditional operator. This improved monitoring system detects sudden temperature changes and reduces dust emissions to improve cement production.