Displaying items by tag: monitoring

Anhui Conch Cement held an event in Wuhu, China, this week showcasing its new artificial intelligence (AI) model for the cement sector. The cement company and Huawei started the project in April 2024 with the support of the China Building Materials Federation. The companies say they have now identified over 200 “promising AI application scenarios across 15 categories” across the entire production process from quarrying to packaging and logistics. Conch has set up an AI training centre using the Huawei Cloud Stack product. It is using Huawei’s Pangu prediction, computer vision (CV) and natural language processing (NLP) models to create an AI operating system that integrates central training, edge inference, cloud-edge synergy, continuous learning and ongoing optimisation.

Thankfully Huawei gave some examples of what this actually meant for operators in the real world. The model is able to give real-time recommendations of key quality features enabling the prediction of three-day and 28-day clinker strength. The predicted strength values closely match test results, with deviations within 1MPa and an accuracy rate exceeding 85%. Other benefits include reducing kiln fuel consumption by 1%, monitoring and managing various components and machines along the production line, staff safety gains and creating a ‘smart digital assistant’ that can answer technical questions from employees.

Little of this seems particularly novel, so far, compared to what other companies are already doing in this field. For example, ABB said in early 2022 that it was using machine learning to predict 28-day strength on the day of sampling and in 2023 that it was doing it using production data provided every two - three hours. Another example is the work that Inform does using AI-based software to support logistics for heavy building materials. Plenty of other western-based companies also offer production optimisation and/or predictive maintenance products.

Conch’s use of an NLP model to create a knowledge base assistant does seem new for the cement sector. Although how specific the software running it might be to one business or industrial area remains to be seen. One could easily imagine this kind of product being sold to lots of different kinds of industries in the manner of current enterprise style software. Along these lines though, Juan Beltrán, digital manager of global sales excellence at Holcim, told McKinsey in an interview about Holcim’s pilot project in Spain testing an AI-enabled copilot customer-ordering assistant via WhatsApp.

Recent events in AI for the cement sector include ABB’s agreement to work with UK-based Carbon Re in late 2024. This collaboration was intended to combine ABB's expertise in automation and process control with Carbon Re's AI and machine learning technologies. It followed a pilot at a cement plant in the Czech Republic. On the producer side, Holcim said in mid-2024 that it was preparing to expand the use of AI-based software to 100 production plants by 2028. It noted that it had installed the system at 45 plants so far at the time of this announcement and that it was using a predictive maintenance solution from software supplier C3 AI. Titan Cement said that it had invested in Spain-based AI software supplier Optimitive in February 2025. Then, Cemex announced this week that it too had invested in Optimitive, via its corporate venture capital arm Cemex Ventures. Molins has also worked with Optimitive.

What isn't being disclosed much are the examples of the mistakes of introducing AI into cement production. These are valuable learning opportunities for any company implementing this kind of software. However, the developers and cement producers are extremely unlikely to admit anything publicly. Global Cement Weekly has heard off-the-record information previously about AI projects at cement plants that have gone wrong but we can’t reveal it either. To his credit though Beltrán mentions an incident, in his interview with McKinsey, where the WhatsApp ordering assistant was tricked during testing into almost placing an order for a truck of gazpacho soup!

We’re still watching how AI is being deployed in heavy industries such as cement. The announcement by Conch is exactly the kind of thing its peers are doing around the world. So far what they’ve done is impressive but not unique. Yet, China’s large but shrinking cement sector and its determination to develop its own AI-based software sector may start to deliver more cutting-edge advances in the future. Companies elsewhere are also pressing ahead to find out how AI products will deliver efficiency gains.

Türkiye: Cimpor Global has launched an initiative in partnership with Fizix to enhance operational efficiency and reduce energy losses in cement plants. The system will use 10,500 sensors for global machine health monitoring, enabling early detection of potential failures before they occur.

The initiative will be implemented across 25 facilities in 10 countries, including Türkiye and Portugal. The optimisation phase will begin in 2025, with initial deployment in six countries, followed by expansion to Cimpor’s operations in China and Taiwan by 2026.

Iraq: Iraq’s largest cement plant in Kirkuk has resumed operations after a shutdown in November 2024 due to environmental non-compliance and an issued fine of US$343,000. Upgrades include a new dust control system and pollution monitoring equipment. Residents of nearby Lailan have previously protested against the plant, stating that the pollution caused adverse health effects and poisoned local crops, according to Intellinews. Following inspections, the factory now reportedly meets relevant pollutant standards.

Portugal: Cimpor has signed a 10-year extendable contract with Vodafone Portugal for private ‘pure’ 5G network installations at its plants, starting with the Alhandra plant and soon expanding to Souselas and Loulé. This network will aim to improve data management and operational efficiencies across Cimpor's cement business and eventual expansion to other sectors. Technology partners include Germany-based SAP and Sweden-based Ericsson.

Cimpor's chief technology officer Berkan Fidan said that the company felt the need to make this investment because the cement industry is data-intensive, and the collection of available data is a challenge due to the physical and operational conditions at the plants.

This partnership makes it possible to obtain precise quality reviews of the cement manufactured at the plants without having to wait 28 days. It also gives total visibility of the plant, making emission forecasts and maintenance easier. The deal involves around 10,000 sensors in 19 plants globally, 50 antennas, drones to measure stock levels and thermal cameras with real-time monitoring capabilities. The long-term strategy with Vodafone also involves the use of smart glasses with video streaming functionalities inside the plants. Fidan explained that the plants have some connectivity challenges, which is why the company is investing heavily in the mobile network.

Germany: Switzerland-based ABB has acquired analytics equipment supplier Födisch Gruppe. ABB says that the acquisition will enhance its offering of continuous emission monitoring systems and expand its technology and innovation competitiveness.

Stephan Schumann, CEO of Födisch Group’s parent company Dr. Födisch Umweltmesstechnik, said “This acquisition is a testimony of our strong performance in recent years. Leveraging ABB’s global footprint will allow to scale the impact of our offering internationally.”

ABB’s Measurement and Analytics President Jacques Mulbert said “We are very impressed by what the Födisch Gruppe has achieved and are eager to welcome their team to the ABB family. Integrating the Födisch Gruppe into ABB will unlock significant opportunities for new and existing customers.”

Portugal: Cimpor has published new standard procedures for the prevention of intoxicants use at its sites. Cimpor will conduct toxological screening of employees and third-party contractors to ensure a blood alcohol level of 0.0, as well as testing for narcotics and other psychotropic substances. The new protocol aims to protect the safety of everyone at Cimpor sites and host communities. The company says that it will support the screening regimen by implementing additional education and training.

North Korea: State-owned Sunchon Cement has completed an upgrade to its cement plant in Sunch'ŏn-shi, P’yŏngan-namdo Province, Korea News has reported. The upgrade included the installation of real-time monitoring equipment in the plant’s raw materials conveying system. The company says that this will help to increase the plant’s efficiency. It also fitted new crushers and vibrating feeders.

Philippines: The Department of Trade and Industry (DTI) is enforcing stricter measures against non-compliant cement importers to protect the local market from substandard products. The DTI Bureau of Philippine Standards recently made a suspension after it conducted a market surveillance in Iloilo as part of its intensified monitoring of cement imports entering the country. The Cement Manufacturers Association of the Philippines (CeMAP) praised the recent actions of the DTI against cement importers, arguing that there has been ‘excessive’ and ‘unfairly priced’ volume of imported cement in the country to the detriment of local manufacturers, according to The Philippine Star.

CeMAP said “This recent action of the DTI-BPS sends a resounding message that non-compliance and unfair trade practices will not be tolerated. The impact of the DTI’s actions extend beyond the cement industry itself. A strong and competitive local cement sector is vital in supporting the Philippines’ continued infrastructure development and economic growth.”

UK: CRH subsidiary Tarmac has successfully deployed France-based software developer Everysens’ Transport Visibility & Management System (TVMS) in its total operations processing system (TOPS) for rail transport. The TVMS digitally tracks trains, enabling the customer to measure performance, analyse patterns and ensure smooth anticipation and collaboration between stakeholders. Tarmac expects the upgrade to streamline its delivery monitoring and also allow for proactive decision-making.

Tarmac head of rail Chris Swan said "Everysens' integration with TOPS has significantly supported Tarmac to digitise its rail freight operations. Tracking our freight trains has become a lot easier and more precise through digital solutions. With real-time ETA data, we can optimise routes, manage resources, and provide an even higher level of service to our customers. This integration underscores our commitment to staying ahead in technology and embracing digitisation for more efficient and streamlined operations."

Sri Lanka: Switzerland-based SpectraFlow Analytics has received an order for a SpectraFlow Airslide analyser and raw mix proportioning software from Siam City Cement (Lanka). The equipment will analyse the composition of material exiting the raw materials mill at Siam City Cement (Lanka)’s Puttalam cement plant. The supplier says that this will help to increase kiln feed quality, lowering the chances of refractory problems and other causes of kiln stoppages.

SpectraFlow Analytics said “The ever increasing demand in cost savings and at the same time improving product quality led Siam City Cement (Lanka) to invest in the most advanced raw mill optimisation package available on the market.”