Every signal is a witness, and physics is the judge.

What MACBALANCE solves

Heat balances are usually done by hand a few times a year, one unit at a time, with the error pushed into a 'difference' line. Meanwhile feeders, gas meters and analyzers drift, and key flows such as clinker output, secondary and tertiary air and false air are not measured at all.

What it does

• Real-time heat and mass balance for the preheater, calciner, kiln and cooler
• Secondary and tertiary air, false air by section, and true heat consumption
• Flags drifting instruments and learns slow errors
• No extra sensors, and every number comes with its ± uncertainty

Step by step

1. MACBALANCE reads the instruments the plant already has. No extra sensors are needed
2. It solves every mass, element and energy balance of every unit at once
3. It weighs each instrument by the trust it has earned, and sets aside readings the rest of the plant contradicts
4. It learns slow errors such as feeder factors, analyzer offsets and heat losses

Outputs

• Reconciled flows, temperatures and compositions for every stream
• Clinker production, specific heat consumption, false air by section
• A ± uncertainty on every number, with the instruments it rests on
• A list of instruments that are lying, and by how much

What we need from you

• Process data from the kiln line, ideally through MACDATA
• Fuel and raw meal analyses