InterCement, one of Brazil’s largest companies with 15 factories located nationwide, has funded two engineering teams working on an in-house project over the past four years to develop a system to increase the profitability of its industrial operations.
After conducting the initial project study, the company’s engineers focused on one of the most important stages of cement manufacturing: grinding, where the raw material is transformed into raw flour and then moved on to grinding the mixture of clinker (limestone and clay), gypsum and complementary materials. This is because any problem at this particular stage of the cement production process could be improved.
To avoid these problems and optimize operational performance, InterCement Brazil decided to internally develop an automation solution called the InterExpert Special System (SE). The software is based on the system that simulates automated operation in single- and double-chamber ball mills.
The project began in 2018 through a collaboration between two engineering teams working within the company: Process and Quality Engineering, and Engineering and Maintenance. The implementation of this system was carried out in different phases from 2019 to 2023.
According to the various technical reports prepared by the two engineering teams required to monitor the results obtained from the beginning of its implementation, this system generated significant energy savings of 66 GWh by the final phase of the project, equivalent in economic terms to approximately $3.8 million. Furthermore, SE InterExpert reduced the specific consumption of the installed mills by 3.7%, and the system is currently estimated to generate annual savings of $1.2 million.
In general terms, the InterExpert Special System uses a series of sensors installed on the equipment responsible for the milling process and quality data on the milled products. By cross-referencing this information, the system is able to determine which variable is most critical in the process and seeks to optimize it, ensuring improved performance.
Daniel Mendonça, process engineering and quality manager at InterCement Brasil, states: “In addition to reducing energy consumption, real-time monitoring and management of manufacturing processes provides several benefits, such as increased productivity and greater control over product quality.”
The software developed uses logic. InterExpert works by evaluating process variables individually and basing control on the most critical system variable at any given time. Control is performed on a single variable at a time, with the most critical variable being the one that must take control of the system. The control decision for this critical variable is based on programmable mathematical rules developed by the two engineering teams.
In this way, the InterExpert SE uses existing resources to monitor and operate the mills and, in the event of any failure, immediately corrects, stabilizes and optimizes the operation.
Finally, Daniel Mendonça states that while the market already has some tools, the company opted to create a customized solution as part of its internal Digital Transformation program.
Currently, the InterExpert SE is being implemented at the following InterCement plants: Apiaí (São Paulo), Bodoquena (Mato Grosso do Sul), Cajati (São Paulo – shown in photo), Campo Formoso (Bahia), Cezarina (Goiás), Ijaci (Minas Gerais), Nova Santa Rita (Rio Grande do Sul), and Santana do Paraíso (Minas Gerais).
However, it is important to note that in recent months, the same company, InterCement, also made another significant investment, which allowed it to achieve a record 42.9% in the thermal regeneration of Kiln 1 at the Cezarina cement plant. This project allowed it to replace a significant portion of the fossil fuels used to manufacture cement with alternative energy sources obtained through co-processing.
This technology involves the use of industrial and urban waste, biomass, and unusable and non-recyclable tires to replace traditional fossil fuels, such as coal and petroleum coke. Among the benefits of the process are a significant reduction in greenhouse gas (GHG) emissions and a reduction in the need to dispose of materials in landfills, strengthening the circular economy.
At Cezarina, thermal substitution was achieved through the Venturi kiln, a device that allowed for greater incorporation of alternative fuel without compromising the kiln’s oxygen levels. In addition to installing this ventilation system, it was essential to add tires to the waste mix used in co-processing, as they have a higher calorific value and, even in smaller quantities, are capable of generating more energy.
Between 2014 and 2023, InterCement Brasil invested $20 million, of which $7 million was invested in co-processing equipment and structures and $13 million in the installation and commissioning of a baghouse filter at the Bodoquena plant, replacing the electrostatic filter. The technology is part of the company’s plan to achieve its energy transition goals, which will allow it to increase its thermal substitution rate from 17.5% in 2014 to 28% by 2023. This means that almost a third of its fuels will come from alternative energy sources. According to information provided by InterCement, the implementation of co-processing has reduced emissions by 300,000 tons of CO2 per year.
InterCement currently has 15 production units with an installed capacity of 16.3 million tons. It is present in 24 Brazilian states. The company serves clients across a range of segments, from small retailers to large construction and industrial projects.
Mauro Nogarin is Cement Optimized’s Latin American correspondent.
Dry kiln at the Apiaí cement plant. Photos: InterCement Brasil
