AI Driven Manufacturing is becoming a thing

AI-Driven Cement Manufacturing Is Becoming A Thing With The Sector Expecting A CAGR Growth Of 28.5% Until 2026

The integration of artificial intelligence (AI) into various industries marks a significant milestone in the era of Industry 4.0. President Biden's recent executive order promoting AI's safe, secure and trustworthy use underscores its growing importance. While debates on its application in politics and social media continue, industries such as cement, steel, energy, and chemicals are swiftly embracing AI to streamline operations and enhance efficiency.

AI-driven solutions are revolutionising cement manufacturing processes in the cement industry. By leveraging machine learning (ML) and AI, cement manufacturing companies are capturing valuable manufacturing data to optimise end-to-end maintenance procedures and improve process control and production output.

Using existing plants’ sensors, process flow diagrams, and historical data, AI models first build a plant digital model incorporating process and equipment hierarchies and dependencies, establishing an operational baseline. 

Next, the system applies analytics to the continuous data flow from the plant. Meaningful differences or abnormalities are detected, compared to historical operating conditions, which predict and direct maintenance interventions. This transformative technology has already demonstrated its potential in reducing unplanned downtime and minimising costs associated with equipment replacements.

A notable example is Titan America's Pennsuco plant, where ML/AI has significantly improved energy efficiency. By deploying advanced sensors and integrating AI systems, Pennsuco has achieved remarkable stability improvements and record production levels, all while reducing energy consumption and greenhouse gas emissions.

Globally, the market for AI in cement production is poised for substantial growth, with a projected CAGR of 28.5% anticipated from 2021 to 2026. However, challenges such as fluctuating raw material prices, energy costs, and skill shortages persist, hindering the industry's progress.

Cement companies are turning to advanced process control (APC) technologies and embracing digitalisation to address these challenges. Several global AI startups, like CemAI, Petuum AI model, and SICEMENT, offer tailored solutions to optimise manufacturing processes and enhance efficiency. By integrating AI into cement manufacturing machinery, these companies use AI models to autonomously predict and adjust critical parameters, driving productivity and sustainability across the entire production process.

Furthermore, with AI's adoption, efficiency standards have become crucial in ensuring sustainability within the cement industry. In India, for instance, where cement consumption is expected to reach 450.78 million tonnes by 2027, there is a shift towards motors with higher efficiency as part of APC  in an effort to meet regulatory standards and environmental concerns.  

Combined, these stringent standards and enhanced AI/ML monitoring technologies solutions offer benefits such as improved heat utilisation, reduced energy consumption, and enhanced process control, all while maintaining product quality and environmental sustainability.

However, certain challenges loom on the horizon of ML/AI adoption in cement manufacturing, notwithstanding the promising trajectory. The proliferation of software and intelligent robotics may precipitate concerns related to unemployment, particularly within regions where awareness and adoption of AI-driven solutions remain limited. 

Developing nations and regions, in particular, may encounter impediments in embracing AI-driven cement production technology, potentially posing hurdles to market growth in the near term. Still, it is clear that AI is no longer a futuristic concept; it’s a practical solution for achieving operational excellence in this sector.