Revolutionize your Kiln Operations with AI-driven control solution

The paper presents an AI Kiln Control Solution developed by Siemens to optimize the clinker process in cement production, focusing on reducing energy consumption and emissions. The solution utilizes machine learning algorithms, specifically artificial neural networks (ANNs), to predict process changes and recommend actions for maintaining optimal kiln operation. Key benefits include increased process reliability, significant fuel savings, and reduced CO2 emissions. The solution is integrated into a digital platform that offers functionalities like asset health analytics and KPI analysis, providing both open-loop and closed-loop variants for control. The paper highlights the challenges in kiln control, such as temperature variations and fuel consumption, and how the AI solution addresses these issues through advanced process control strategies. The results show a reduction in heat consumption from 845 kcal/kg to 823 kcal/kg of clinker and a decrease in CO2 emissions by up to 36 MT per day. The solution is designed to be a long-term partner for cement manufacturers, enhancing operational efficiency and contributing to sustainability goals.