Application of the high dimensional model representation (HDMR) algorithm in the realm of advanced process control systems within the cement industry

• The calcination process of cement clinker has potential for saving energy and reducing emissions in the industry. • Study utilizes a unique combination of mechanism analysis and HDMR for precise modeling of cement energy consumption. • The energy model demonstrates high accuracy in predicting outcomes, which assists in optimizing production in real time. • The application model reduces coal consumption per clinker unit, resulting in annual savings of 9819.2 tce energy and a decrease of 6578.9 tCO2 emissions. • This study opens possibilities for energy savings and reduced carbon emissions in cement and similar energy-intensive industries. Against the background of the current global energy shortage and increasing pressure on carbon emissions, energy saving and emission reduction have become the key to the transformation and upgrading of various industries. As a key area of high energy consumption and high emissions, it is particularly important for the cement industry to improve its energy efficiency and green transformation. Based on this background, this study selects a 5000t/d new dry-process cement production line as the research object, aiming to explore the energy efficiency optimization path of cement clinker calcination system through in-depth energy-saving diagnosis. During the research process, we integrated the mechanism analysis and HDMR algorithm to construct an accurate energy consumption model of the cement clinker calcining system. The model not only shows good approximation ability to accurately reflect the energy consumption characteristics of the system, but also has excellent generalization ability, which provides the possibility of predicting the energy consumption under different working conditions. Further, we combined this model with an advanced cement production control process system for targeted energy-saving modification and optimization of the cement calcination process. The results show that this integrated approach significantly improves the energy efficiency of the cement calcination system. Specifically, the standard coal consumption per unit of product was reduced by 6.46 kgce compared with the pre-optimization period to 93.28 kgce, with an annual energy saving of up to 9,819.2 tons of standard coal (tce), while the annual carbon emission was reduced by about 6,578.9 tons of carbon dioxide (CO 2 ).