Artificial Intelligence: Concrete solution for cement plant operations
by Jayaharan CJ | 4 min read
Cement is one of the greatest inventions of humankind. The sector is growing in terms of consumption as well as production – one complementing the other. It has become indispensable to the growth of several other industries. The spurt in urbanization leading to the development of real estate and infrastructure, which in turn has increased construction activities, has resulted in the growth of the cement industry.
World over, there’s a demand for cement, and countries are trying their best to manufacture or export cement. Here’s a snapshot of world cement production:
Source: Cement: 2020 World Market Review and Forecast to 2029 report
China is undoubtedly a leader in cement production, evident from the fact that it supplies cement to more than 50% of the global market. The second-largest manufacturer is India. Other parts of the world are catching up and the industry, overall, is on a growth trajectory. But to grow, the cement industry has to overcome obstacles. Chief among them are the following three challenges:
The solution to these problems lies in making use of new disruptive technologies.
Some of the best cement plants in the world have already adopted these new technologies that will help them overcome the above challenges, besides facilitating basic process control systems (BPCS) to efficiently supervise the facility and handle process control.
Energy-intensive cement manufacturing
In a typical cement plant, the cost incurred on energy (including thermal and electrical) would amount to around 50 to 60% of the total production cost. Here’s a snapshot of the cost incurred on resources, for a popular cement plant, that confirms our statement:
The power of the Artificial intelligence (AI) platform can be deployed here to optimize the cement-making process, by ensuring smooth operation at every level. The real value of AI is realized only when the implementation team has adequate knowledge and experience in implementing solutions for cement companies. This is what translates the AI experience into an organizational strategy fulfilling most of the organizations’ core vision statement, “To produce high-quality cement at a very optimal cost.” Data science and data analytics is paving the way for artificial intelligence (AI), the technology that has found takers in the cement industry.
AI learns patterns and detects anomalies previously invisible to the user, giving greater insights into process control and automation. The key benefits gained out of the AI-based advanced process control yields great results. Overall improved efficiency can be achieved by:
Look for a solution that will help run your cement business efficiently. Ramco ERP for cement manufacturers helped a major cement group, who used the Advance Process Control solutions, reap the following benefits:
And do not be misled by the small percentages, for even an infinitesimal change in the cement business means unbelievably, huge savings.
The return on investment (RoI) is phenomenal when you look to transform your cement company with digital transformation initiatives. And this may be like one small step towards cement plant digital transformation, but a giant leap towards building a connected organization.