OVERVIEW // DCS RUNTIME

CONTINUOUS CLINKERIZATION FEED & THERMAL TELEMETRY STREAM

POLL: 1000MS | STATION: CR-04 (PRIMARY) | lock INTERLOCK: ENGAGED

BURNING ZONE local_fire_department

1529 °C

▲ +1.2%

CALCINATION percent

87.8 %

■ STABLE

FREE LIME (LAB) science

0.62 %

▼ -0.05

SECONDARY AIR air

812 °C

▲ DEGRADED

CLINKER RATE conveyor_belt

31.9 kg/s

114.8 t/h

SPECIFIC HEAT speed

3.30 GJ/t

■ OPTIMAL

CURRENT WORK VS. PREDICTIVE MODEL

AI ENGINE v4.2 // LIVE INFERENCE

REALTIME DCS SENSOR STREAMS CONVERGED WITH PHYSICS-INFORMED ML DIGITAL TWIN

CONFIDENCE: 98.4%

HORIZON: +4.0 HRS

KILN BURN ZONE TEMP NOMINAL

ACTUAL RUNTIME 1420 °C

PREDICTED TARGET 1412 °C

Variance Delta: +8 °C (+0.56%)

CALCINER FUEL RATE OPTIMAL

ACTUAL RUNTIME 8.40 t/h

PREDICTED OPT 8.60 t/h

Variance Delta: -0.20 t/h (-2.3%)

CLINKER PRODUCTION TRIM ADVISORY

ACTUAL RUNTIME 245.0 t/h

TARGET MODEL 250.0 t/h

Variance Delta: -5.0 t/h (-2.0%)

SPECIFIC HEAT EFFICIENCY 99.1% TARGET

ACTUAL RUNTIME 3.30 GJ/t

MODEL ESTIMATE 3.33 GJ/t

Variance Delta: -0.03 GJ/t (SAVING)

Actual Realtime Telemetry (DCS Sensor Poll)

Predicted AI Model Baseline (±1.5% Confidence Band)

12-HOUR WINDOW & 4-HR PREDICTIVE HORIZON

02h 00m 04h 00m 06h 00m 08h 00m 10h 00m 12h 00m 14h 20m (LIVE) +2h (Forecast) +4h (Forecast)

BURNING ZONE & CALCINER THERMAL PROFILE

STABLE

Burning Zone: 1529 °C

Calciner: 892 °C

08h 00m 09h 00m 10h 00m 11h 00m 12h 00m 13h 00m 14h 20m

HEAT RECOVERY & COOLER EFFICIENCY

ALERT REQ

Secondary air: 812 °C

Clinker out: 148 °C

08h 00m 09h 00m 10h 00m 11h 00m 12h 00m 13h 00m 14h 20m

ACTIVE OPERATIONAL FINDINGS

2 ACTIONABLE

AUTO-INFERENCE STREAM

warning Cooler Heat Recovery Loss TIER 1 WARNING

Secondary Air to Kiln 630 °C (baseline threshold > 760 °C)

Root Cause: Grate speed over-feed #2 Apply Model Action

error Burning Zone Thermal Overshoot TIER 1 CRITICAL

Measured vs Modelled 1568 °C / 1521 °C (+47 K delta)

Recommendation: Reduce coal rate -0.3 t/h Engage Auto-Trim

PRIMARY TELEMETRY TAGS

DCS POLL 1000ms // ACTIVE 10

TAG DESCRIPTION	ACTUAL VALUE	RESIDUAL Δ
Burning zone pyrometer	1529 °C	+1.2
Calciner outlet temp	892 °C	-0.4
Preheater exit gas	342 °C	+0.8
Kiln gas exit (inlet box)	1045 °C	-1.1
Secondary air thermocouple	812 °C	+2.4
Clinker cooler exit bed	148 °C	-0.2
Kiln shell max hotspot	382 °C	+4.1
Raw meal kiln feed mass	165.2 t/h	+0.0
Total pulverized coal flow	11.4 t/h	-0.3

verified_user INTERLOCK STATUS KILN MAIN DRIVE: RUNNING (2.8 RPM) ID FAN: 88% LOAD COOLER GRATE SPEED: TRIM REQ

SESSION: 14h 20m 18s | 0 SYSTEM SHUTDOWNS