Situation

A cement manufacturing company aimed to improve its product quality, reduce production fluctuations, and minimize its environmental impact by leveraging advanced data analytics and artificial intelligence (AI). By implementing a cement strength prediction system and adjusting production parameters in real-time based on these predictions, the company searched to stabilize product quality, reduce the clinker factor, and subsequently lower its CO2 footprint.

Challenge

Cement manufacturing involves a complex process with multiple variables which affect the final product’s strength and quality.
The production of clinker, a key component of cement, releases a significant amount of CO2. The company aimed to minimize the clinker factor to reduce its carbon footprint.
Managing and processing large amounts of real-time data from various sensors and production parameters requires a robust data infrastructure.
Developing accurate predictive models to forecast cement strength is crucial to enable precise real-time production parameter adjustments.

Solution

  • Implement a comprehensive solution for cement strength prediction and real-time production parameter adjustment. The solution includes the following components:
  • Sensor Deployment: A network of sensors is installed throughout the cement production process to measure critical variables such as raw material properties, temperature, humidity, and pressure.
  • Data Integration and Storage: Data from sensors, historical production records, and weather data are integrated and stored in a centralized data repository.
  • Machine Learning (ML) Model Development: ML models, such as regression and neural networks, are developed using historical data to predict cement strength based on input parameters.
  • Real-Time Predictions: ML models are deployed on edge devices for real-time prediction of cement strength as the production process progresses.
  • Real-Time Production Parameter Adjustment: Based on the real-time cement strength predictions, an AI-based control system adjusts production parameters such as raw material composition, grinding time, and kiln temperature to optimize the final product’s quality.
  • Clinker Factor Optimization: The AI system also optimizes the clinker factor by adjusting the cement blend composition to minimize clinker usage while maintaining the desired strength.

How a Cement manufacturing company used a machine learning (ML) model to predict product quality and lower CO2 emissions.

energy mix optimizer

Results

Smart sensors plays a crucial role in cement production process to ensure reliable and efficient operations.

  • Stabilized Product Quality: By predicting cement strength in real-time and adjusting production parameters accordingly, the company achieved consistent and stable product quality, reducing variations in the final product by 30% deviations.

  • Minimized Fluctuations: Real-time adjustments based on predictions helped minimize production fluctuations and optimize the manufacturing process by 10%.

  • Reduced Clinker Factor: The AI-based system successfully reduced the clinker factor by optimizing the cement blend composition, leading to a reduced CO2 footprint of 35%.

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ML model stabilized product quality in real time by predicting cement strength.

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