Estimation of Industrial Heat Balance Based on Actual Plant Data: A Case Study for Cement Plant

The industrial sector plays a significant role in anthropogenic effect on the environment due to greenhouse gases emissions associated with energy-intensive processes. To advance in the sustainability goals, it is essential to propose new modeling methodologies to assess the yield performance of clean technologies on industrial processes. However, due to the complexity and variety of such processes it is particularly challenging to assess the non-linear performance of industrial process in terms of heat loads, temperature, and others. The present study introduces a novel methodology to configure an estimation model of the heat released by the clinkering process in the cement industry, based only on operational data. Furthermore, a methodology is proposed to evaluate the correlation between the heat of the process and the operational parameters. The result of this methodology provides a function for the heat consumed or released by the chemical reactions of the process, based on the relevant operational parameters. The approach proposes a global specific enthalpy, parameter that represents the response of the process, only through the heat consumed or released by the chemical reactions. A methodology is proposed for evaluating the correlation of operational parameters with the proposed specific enthalpy. The methodology is validated by assessing the pyro-processes in the cement industry, renowned for its high energy intensity and pollution emissions. The proposed methodology could facilitate the evaluation of clean technologies into different industrial processes. This approach can guide industries in identifying opportunities for reducing pollution emissions while optimizing energy efficiency.