International Cement Company Increases Throughput 5.7% and Reduces Power 4% with Advanced Process Control

A subsidiary of an international cement company with revenues over $500 million sought an advanced process control system to maximize efficiency, enhance quality, minimize process upsets, and decrease energy costs on two finish mills at its headquarters facility.

Rockwell Automation deployed FactoryTalk Analytics with closed-loop multivariable predictive control on two cement finish mills. The solution combined steady-state optimization with model predictive control and dynamic process modeling, managing setpoints and transitions in real-time.

Throughput increased on both mills — one by a notable margin and the other by 5.7% — with finish mill production increasing 5% overall. Power consumption was reduced by 3.5 KWh/ton of cement produced, with total mill motor power also meaningfully reduced. Product quality improved with standard deviation in cement reduced from 130 to 80 — a 38% reduction — achieved in just four months.

• Model predictive control delivers simultaneous improvements in throughput, energy, and product quality • Phased ROI validation programs reduce financial risk for manufacturers evaluating advanced process control • Dynamic process models outperform static expert system solutions for complex non-linear processes like cement milling