Rockwell Automation and Building Material Company Cimento Itambé Optimize Predictability and Energy Usage in Cement Production

Rhea-AI Summary

Rockwell Automation (NYSE:ROK) collaborated with Cimento Itambé to implement model predictive control (MPC) technology in cement production, addressing challenges in kiln control and management. The project, completed in two phases, yielded significant results:

Phase 1 (Kilns, 2022):

• 5% increase in productivity
• 2% reduction in energy use per kiln
• More stable temperatures

Phase 2 (Grinding Operations, 2023):

• 5% reduction in energy usage
• 5-10% increase in productivity
• Fewer disruptions in feeding and high vibration-related stops

The implementation of MPC technology has enabled Cimento Itambé to standardize operational processes, improve equipment availability, and reduce energy consumption in cement manufacturing.

Positive

• Implementation of MPC technology resulted in a 5% increase in kiln productivity
• 2% reduction in energy use per kiln achieved
• 5-10% increase in grinding operations productivity
• 5% reduction in energy usage in grinding operations
• Improved operational stability and reduced disruptions in cement production

Negative

• None.

Industrial Automation Expert

The implementation of Model Predictive Control (MPC) technology by Rockwell Automation for Cimento Itambé represents a significant advancement in cement production efficiency. The 5% increase in productivity and 2% reduction in energy use in kilns, coupled with more stable temperatures, indicate substantial operational improvements. For the grinding operations, the 5% reduction in energy usage and 5-10% increase in productivity are impressive gains in an energy-intensive industry.

These results showcase the potential of MPC to address key challenges in cement manufacturing, particularly in managing resource variability and kiln control. The standardization of operational processes and increased equipment availability are likely to translate into long-term cost savings and improved production consistency. This case study demonstrates how advanced automation technologies can significantly impact industrial efficiency, potentially setting a new benchmark for the cement industry.

Sustainability Analyst

The implementation of MPC technology at Cimento Itambé aligns well with growing industry pressures for improved sustainability in cement production. The 2% energy reduction in kilns and 5% energy reduction in grinding operations are noteworthy achievements in an industry that's under scrutiny for its high energy consumption and carbon emissions. These improvements, while seemingly modest, can translate to significant environmental benefits when scaled across the entire production process.

Moreover, the increased productivity without proportional increases in energy use suggests a decoupling of production growth from environmental impact. This approach not only reduces the carbon footprint per unit of cement produced but also potentially enhances the company's competitiveness in a market increasingly focused on sustainable production methods. The project exemplifies how technological innovation can drive both operational efficiency and environmental stewardship in heavy industries.

NORTHAMPTON, MA / ACCESSWIRE / August 13, 2024 / Cement production has its challenges-notably, the variability of resources can make kilns difficult to control and manage. Cimento Itambé wanted to optimize kiln productivity, increase mill productivity, and reduce energy use.

Rockwell Automation (NYSE:ROK) worked with Cimento Itambé to implement model predictive control (MPC) technology. MPC allowed Cimento Itambé to standardize operational processes, gain more equipment availability, and use less energy in their cement manufacturing process.

The first phase of the project, targeting the kilns, was completed in late 2022. During this phase, Cimento Itambé experienced a 5% increase in productivity, a 2% reduction in energy use in each kiln, and overall, more stable temperatures.

The second phase, improving the grinding operations, was completed in 2023. During this phase, Cimento Itambé realized a 5% reduction in energy usage, a 5-10% increase in productivity, and fewer disruptions in feeding or stops related to high vibrations.

Learn more about how MPC technology can put cement plants on the path to more stable production, reduced energy usage, and higher throughput.

Process control for cement companies is complex. Model predictive control can help increase equipment uptime and reduce energy use.

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Contact Info:
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SOURCE: Rockwell Automation

View the original press release on accesswire.com

FAQ

What benefits did Cimento Itambé achieve by implementing Rockwell Automation's MPC technology?

Cimento Itambé achieved increased productivity (5% in kilns, 5-10% in grinding), reduced energy usage (2% in kilns, 5% in grinding), more stable temperatures, and fewer disruptions in feeding and high vibration-related stops.

When were the two phases of the MPC technology implementation completed for Cimento Itambé?

The first phase targeting the kilns was completed in late 2022, while the second phase improving grinding operations was completed in 2023.

How does Rockwell Automation's (NYSE:ROK) MPC technology benefit cement production?

Rockwell Automation's MPC technology helps cement plants achieve more stable production, reduced energy usage, higher throughput, increased equipment uptime, and standardized operational processes.

What specific challenges in cement production did Rockwell Automation's solution address?

The solution addressed challenges such as variability of resources making kilns difficult to control and manage, optimizing kiln productivity, increasing mill productivity, and reducing energy use in cement manufacturing.