Cement manufacturing

Rotary kiln

Business Problem

Optimizing rotary kiln operations can increase output, lower fuel consumption and enable consistent quality.

Challenge

Traditional control solutions struggle to control processes as complex as the rotary kiln, leaving the complexity to operators, making successful operations dependent on individuals expertise. To deal with the complexity of manually monitoring and controlling dozens of process variables, operators rely on unoptimized “standard recipes” resulting in lower yield and quality and higher costs.  

SentianController solution

SentianController learns from the available operational data, providing early impact by forecasting key process variables and quality metrics. Enabling operators to make proactive operational decisions to improve quality, stability and reduce cost. 

As the model learns and grows so does SentianControllers capabilities. Learning from the best operational performers to stabilize delivery by recommending optimized setpoints. Enabling consistent higher performance from all experience levels, making operations less dependent on individuals for success. Further increasing quality while minimizing energy consumption and other operational costs.

As a final stage operators utilize SentianControllers autonomous mode to autonomously tune process performance by applying optimized setpoints and corrections towards current quality and production targets. Freeing up operational experience and time for value-adding improvements.