Digital technologies and automation boost productivity and efficiency

Digital technologies and automation boost productivity and efficiency in cement production, helping navigate cost challenges and stay competitive.

Some of the technologies are mentioned below:

Lining evaluation scan

The lining evaluation scan is a significant advancement in assessing the remaining thickness of a rotary kiln’s lining, which is crucial for optimizing kiln performance. This technology allows for rapid, fact-based, and holistic decisions regarding necessary repairs. Within just two hours after scanning, plant operators can access accurate data, enabling efficient decision-making during shutdown phases. The swift results, ready in 2 to 4 hours, minimize downtime and associated costs.

Additionally, the digital documentation provided via a customer portal offers an organized record of both used and new linings, enhancing maintenance planning. This technology also allows for virtual inspections of the kiln at any time, making it easier for managers and engineers to monitor its condition remotely. Moreover, by reducing the need for manual inspections, the Lining Evaluation Scan significantly increases safety in the challenging environment of cement production.

Kiln firing coal optimisation through AI-based technology
AI-based technology is transforming the optimization of kiln firing processes, primarily through the integration of real-time condition monitoring and advanced algorithms. Using a kiln camera, this technology continuously monitors the kiln’s internal conditions, categorizing its status as hot, dusty, or ideally healthy. The camera feeds data into a software system that autonomously assesses the kiln’s condition, providing quick and consistent evaluations.

This autonomous assessment helps optimize the coal firing process, ensuring that the kiln operates at peak efficiency. By making real-time adjustments based on accurate, up-to-date information, the technology improves cement quality and reduces energy consumption and operational costs. This approach not only enhances performance but also ensures more reliable and consistent operations.

Process Stability Index (PSI)

PSI is a critical tool for maintaining stability in cement production processes. It monitors and analyzes key parameters such as temperature, pressure, and composition, identifying deviations from the norm. This continuous monitoring ensures that any potential issues are promptly detected and addressed.

By analyzing the stability of these parameters, the PSI helps maintain consistent quality in cement production, which is essential for meeting industry standards and customer expectations. In addition to this, understanding the stability of the process allows for fine-tuning and optimization, leading to more efficient operations and reduced waste. The PSI also supports predictive maintenance by anticipating when equipment might need attention, thereby minimizing unexpected downtime and extending the lifespan of the machinery involved.

Software-based cement mill blaine and free lime prediction

This technology uses advanced software to predict the Blaine fineness and free lime content in cement. By providing accurate predictions, it helps optimize the milling process, ensuring consistent product quality and reducing waste.

Roller monitoring through digitalization

Digital tools are being deployed to monitor rollers in the clinker production process. This technology helps identify any missing rollers, preventing potential breakdowns and damage to buckets, thus maintaining smooth and uninterrupted production.

Mechanical equipment health monitoring technology

This technology applies a system that monitors the health of mechanical equipment, such as fan and gearbox vibrations and temperatures. By using real-time data, the system can detect early signs of wear and tear, enabling proactive maintenance and avoiding unexpected failures.

Cyclone jamming prediction with AI data analysis

AI-driven data analysis predicts potential cyclone jamming issues. This predictive capability allows for timely interventions, reducing the risk of production halts and maintaining optimal operational efficiency.

Digital technologies for better productivity and enhanced efficiency

Adopting digital technologies and innovations is crucial for advancing into Industry 4.0 and improving cement production. With rising costs of raw materials, fuel, and equipment, it's essential to implement accurate process controls and technical support to lower operating costs and optimize production rates.

Efficiency in cement production depends on precision. Tools like the Lining Evaluation Scan, AI-based kiln optimization, and the Process Stability Index allow real-time monitoring and adjustments, ensuring optimal performance and reducing waste and downtime.

Automation further enhances our processes by reducing human error, streamlining operations, and maintaining consistent product quality. It also minimizes downtime by quickly identifying and resolving issues, leading to smoother and more reliable production.

Parmod Sagar MD & CEO RHI Magnesita India Limited