Avanceon’s deployed MPC solution achieved substantial energy savings through kiln operation optimization and reduced variability in process parameters

The cement industry is constantly wrestling with volatile commodity prices and complex customer demands. In view of these challenges, cement manufacturers are looking for innovative and reliable technology partners who can help them in increasing plant efficiency, process stability, and reducing energy cost. Energy cost in the clinker manufacturing process can amount up to 75% of variable costs. This alone can compromise the quality of the finish product and increase overheads for the manufacturer.

The client in discussion, one of the largest cement manufacturers in Pakistan with the accumulated yearly production capacity of 9 million tones, was approached by Avanceon to discuss and propose a viable solution that can help in optimizing kiln operations, decreasing operators’ intervention in kiln’s operational control, reducing energy cost and improving the quality of finished product. This essentially translated into increased plant’s efficiency and reduced process variability for plant operations.

After developing thorough understanding of various process areas, equipment and operations, Avanceon’s technical experts decided to implement Rockwell Automation’s Pavilion8 Dynamic Model Predictive Control (MPC) solution. The solutions offered multivariable predictive controlling using the state of art dynamic linear model configured in Pavilion8 software, followed by its integration with client’s existing Distributed Control System (DCS).

Avanceon deployed highly skilled, OEM trained delivery specialists for executing this critical project. After months of hard work, Avanceon team successfully commissioned the solution and achieved kiln’s “Control Optimization” compared to the conventional control, “Operational Stability” by variability reduction in target parameters and a tremendous reduction in “Operators Involvement” in kiln’s operational control.

For the bottomline impact, the client was able to save up-to US$ 150,000 per annum in fuel costs in addition to increased plant efficiency and process stability. Avanceon’s team earned high praise from the client for the quality of solution delivered and overall project management.

About Avanceon – (PSX: AVN) – Avanceon is an industrial automation consultation and system integration entity in Pakistan, Qatar, UAE, KSA and United States. The company follows an ethical, proactive and sustainable approach to business. As a leading innovator within the automation industry Avanceon provides state of the art automation solutions on three continents.

Established in 1984, Avanceon is committed to providing engineering excellence to its clients and partners. Providing end to end solutions, which include Design, Supply, Engineering, Installation, Testing, Commissioning and Maintenance, Avanceon’s executive management has more than a hundred years of experience and insight within the automation and system integration industry.

Find out more about Avanceon at www.avanceon.ae

Talk to us about our Innovative Solutions at sales@avanceon.ae

#advancedprocesscontrol #cementmanufacturing #kilnoptimization #processvariability

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