I a South Asia ceme t ma ufactu i g applicatio , Visio aize’s AI-d ive kil optimizatio solutio helped educe specific heat co sumptio f om
“Ceme t ma ufactu i g is a ideal e vi o me t fo I dust ial AI because ope atio al p ofitability depe ds o thousa ds of i te co ected va iables ac oss the kil , mills, equipme t, e e gy systems a d p oduct quality,” said
Ceme t pla ts ge e ate exte sive data ac oss DCS, SCADA, histo ia s, co ditio -mo ito i g systems, labo ato y systems, mai te a ce applicatio s a d e gi ee i g docume ts. Howeve , much of this i fo matio t aditio ally emai s f agme ted ac oss sepa ate systems.
Visio aize c eates a i tellige t Digital Twi e vi o me t co ecti g ope atio s ac oss the ceme t p oductio lifecycle-f om
By co textualizi g eal-time a d histo ical i fo matio a ou d equipme t a d p ocesses, Visio aize gives ope atio s, p ocess, eliability a d mai te a ce teams a u ified e vi o me t to mo ito pla t pe fo ma ce, ide tify developi g p oblems a d take faste , data-d ive actio .
The ceme t kil ep ese ts o e of the i dust y’s la gest oppo tu ities fo imp ovi g fuel efficie cy, p oductio stability a d emissio s pe fo ma ce.
Fo a South Asia ceme t p oduce , Visio aize i teg ated mo e tha
The impleme tatio delive ed:
9.8% eductio i specific heat co sumptio 60% eductio i mill a d kil dow time 50% i c ease i ef acto y life - App oximately
$1.4 millio i a ual savi gs - App oximately
8,000 to s eductio i CO₂ emissio s
The solutio helps pla ts adapt ope ati g ecomme datio s to cha gi g feed cha acte istics, fuel quality a d kil co ditio s i stead of elyi g o ly o static ope ati g ta gets.
Visio aize also applies AI a d machi e lea i g to c itical ceme t-pla t assets i cludi g ve tical olle mills, fa s a d gea boxes.
I a p edictive-mai te a ce applicatio fo a Lati Ame ica ceme t ma ufactu e , Visio aize a alyzed vib atio , tempe atu e a d elect ical-cu e t i fo matio togethe with histo ical fault eco ds to detect developi g equipme t p oblems befo e failu e.
The impleme tatio achieved:
55% eductio i u pla ed dow time 80% eductio i eme ge cy gea box failu es 45% eductio i ove time labo costs
By co ecti g p edictive i sights with mai te a ce wo kflows, ceme t p oduce s ca t a sitio f om eactive a d cale da -based mai te a ce towa d co ditio -based a d p edictive mai te a ce.
Visio aize also applies AI to help ceme t ma ufactu e s educe e e gy co sumptio a d ca bo i te sity.
By combi i g p ocess data with fuel-mix, feed-chemist y a d combustio i fo matio , the platfo m ca help ope ato s u de sta d the elatio ship betwee p oductio , e e gy use, emissio s a d p oduct quality.
I a ESG optimizatio applicatio , a ceme t ma ufactu e achieved a epo ted
This e ables ma ufactu e s to t eat p oductio efficie cy a d sustai ability as co ected ope atio al objectives athe tha sepa ate i itiatives. Visio aize’s app oach exte ds beyo d i dividual AI models by c eati g a co textualized Digital Twi e vi o me t fo the complete ceme t pla t.
“The futu e ceme t pla t will ot simply tell a ope ato what happe ed,” Vikas Ag awal, CEO added. “It will ide tify developi g co ditio s, explai why they a e occu i g, p edict thei ope atio al a d fi a cial impact, a d ecomme d the best cou se of actio . That is the t a sitio f om mo ito i g to i tellige t, i c easi gly auto omous i dust ial ope atio s.”
Real-time ope atio al assista ce available to imp ove pla t efficie cy a d educe outages by utilizi g bette esou ce of data-d ive O&M a d p oactive i te ve tio s with a guidi g tool that ca be adviso y fo the ope ato .
By combi i g pla t-wide co textualizatio with p edictive a alytics, Digital Twi s a d AI-d ive optimizatio , Visio aize aims to help ceme t ma ufactu e s co ve t existi g ope atio al data i to measu able imp oveme ts i EBITDA, eliability a d sustai ability.
Its solutio s combi e AI-powe ed a alytics, p edictive mai te a ce, eal-time optimizatio , co textualized i dust ial data a d imme sive Digital Twi visualizatio to help o ga izatio s educe dow time, optimize pla t pe fo ma ce a d accele ate sustai ability i itiatives.
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