Rockwell Automation implemented model predictive control (MPC) technology in Brazilian cement producer Cimento Itambé’s manufacturing process to standardize operational processes, gain more equipment availability, and reduce energy use.
FactoryTalk Analytics Pavilion8 is an intelligence layer on top of automation systems that continuously drives plants to achieve multiple business objectives. It calculates recommended setpoints for process control loops to optimize control performance in real time. Additionally, Pavilion8 can understand fluctuating input variables and is able to predict and control multiple process parameters, while continuously updating control actions based on actual process values.
In the first phase of the project, which was completed in late 2022, Rockwell targeted the kilns. During this phase, Cimento Itambé experienced a 5% increase in productivity, a 2% reduction in energy use in each kiln, and overall, more stable temperatures.
The second phase, improving the grinding operations, was completed in 2023. During this phase, Cimento Itambé realized a 5% reduction in energy usage, a 5% to 10% increase in productivity, and fewer disruptions in feeding or stops related to high vibrations.
Rockwell Automation noted that MPC is a logical place to start for cement producers that are not yet using AI or machine learning. MPC is easy and affordable to implement when the right infrastructure is in place.
