Transforming Cement Industry Operations with AI: Best Practices and Future Trajectory

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Artificial Intelligence (AI) has become a pivotal technology across various industries, including cement. AI now goes beyond the concept of a “thinking machine” and is rapidly transforming operations and setting new trajectories for future advancements. At ABB, we observe AI’s expanding role in optimizing processes, enhancing quality, and driving sustainability in the cement industry.

Key Drivers of AI Adoption in Cement Production

Several factors are driving AI adoption among leading cement producers:

• Computing Power: Enhanced computational capabilities and faster training of deep neural networks.
• Connected Devices: Proliferation of connected devices and extensive data storage accessible via the cloud.
• Algorithms: Advanced algorithms identify patterns and optimization opportunities through vast data access.

AI at the Cutting Edge

AI functions like an adaptable formula, continually evolving to achieve goals in new situations. Within AI, Machine Learning (ML) allows machines to learn independently and develop their own algorithms to improve specific tasks. Neural Networks, modeled after the human brain, and Deep Learning, a sophisticated ML version, are integral to handling complex tasks and decision-making processes.

AI in Cement Operations

AI’s impact on cement production involves addressing persistent issues with innovative solutions. This includes:

• Data Management: Standardized data aligned with business strategies, cleansing data, and removing anomalies.
• Process Optimization: Uncovering hidden relationships between data points to optimize plant operations.
• Asset Management: Utilizing AI to understand and optimize every asset within a cement plant, from quarries to dispatch.

Use Cases of AI in Cement Industry

Enhancing Cyber Security

AI-powered analytics continuously monitor, diagnose, and resolve security issues, safeguarding assets and reputation. ABB’s solutions help plants simulate various scenarios to improve cybersecurity strategies.

Sustainability and Emissions Control

AI plays a crucial role in achieving sustainability targets by optimizing energy use and reducing emissions. For instance, ABB’s advanced process control solutions have enabled CEMEX to improve SO2 emissions control and reduce hydrate consumption by 11%.

Process Performance Optimization

AI-driven advanced process control (APC) solutions address thermal efficiency, fuel switching, and clinker-to-cement ratio reduction, leading to increased productivity and consistent quality. These solutions also enable real-time process corrections, reducing additive consumption and optimizing operational variables.

Asset Performance Management (APM)

AI in APM enhances maintenance and reliability, ensuring assets perform optimally based on evolving production goals. Predictive asset models help in scheduling maintenance effectively, extending asset life, and reducing operational costs.

Connected Workforce

AI technologies, including mixed reality and human-centric control environments, improve workforce productivity and safety. These technologies enable operators to interact with control systems more efficiently, capturing and utilizing operational knowledge.

Looking to the Future

AI technologies are continuously evolving, offering cement producers advanced tools for operational excellence and sustainability. Future AI implementations will gather data from various sources, enabling autonomous operations with fewer human interventions. As AI becomes easier to implement, more producers will adopt it to meet sustainability goals and enhance profitability.

At ABB, we are committed to collaborating with cement industry leaders to drive digital transformation, leveraging AI to set new standards and achieve remarkable results.

Learn More

Discover how ABB can help your cement production facility leverage AI for operational excellence and sustainability. Learn more.

By embracing AI and its myriad applications, cement producers can look forward to a future of optimized operations, enhanced sustainability, and continuous improvement in performance.

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