Real Results from Real Clients
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Global Cement Manufacturer Boosts Mill Productivity with DigiTwin.ai
Client Overview
A leading global cement conglomerate operating multiple plants sought to modernize its mill operations, which were heavily reliant on manual processes and operator expertise, leading to energy inefficiencies and inconsistent quality.
Challenge
- Manual control based on operator experience, limiting consistency and scalability
- Legacy quality sampling processes causing delays and open-loop feedback issues
- Need to leverage digital technologies to improve mill productivity
- High energy consumption during cement milling operations
Solution
- A real-time Digital Twin model of the cement milling process
- Sensor data-driven AI Soft Sensor for real-time Blaine (fineness) prediction
- Closed-loop adaptive optimization to dynamically control mill parameters and improve process efficiency
Results
Following the implementation, the client achieved:
7%
Increase in Mill Productivity
6%
Reduction in Specific Mill Power Consumption
30%
Reduction in Quality Variation (STDV)