Cement Manufacturing
Optimize Process Precision and Reduce Costs
Current Issues In Cement Production:
- Competitive pressure for cost reduction
- Unplanned kiln shutdowns
- Lack of precision data on refractory performance for predictive maintenance data
- Lack of visibility of complete kiln for refractory management (i.e. tyres / rings)
- Lack of big data for deep predictive analytics on kiln performance
- Lack of artificial intelligence to automate predictive performance data
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QIR provides process optimization in these cement production areas:
- Burner
- KILN
- Preheater
QIR provides process optimization in these cement production areas:
- Burner
- KILN
- Preheater
Financial Benefits of QIR Systems
Increases revenue by reducing days of required maintenance
- Number of days extended production (Not down for maintenance)
- Daily production - 4,500 tons (Revenue of daily production $xxms)
- Benefit (additional revenue) per day
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Reduced maintenance costs to replace refractory
- Labor costs
- Material
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Extend useful life of kiln refractory
- Reduce / eliminate hotspots
- Reduce number of startup / shutdown cycles for refractory maintenance
QIR Technology Delivered Over The Cloud On Monthly Subscription Basis
Monthly Subscription Based Service - no capital equipments purchase required
24 - 7 KILN Condition Monitoring
Dedicated QIR Engineers monitor customer operations 24/7
SaaS based service delivery with onsite technical support
IR Installed equipment connection options : Satellite, Cellular, Gigabit Ethernet.
- with Web based access and mobile alerts.
Real-time Monitoring
Customer has global view of all plant operations in real-time.
KILN Refractory Predictive Maintenance
- Precise refractory thickness monitoring including coating on burner side
- Algorithm Predicts life of refractory and suggests optimum timing for replacement
- QIR Laser Scan Kiln each time shutdown to update thickness and improve algorithms
- Extends refractory useful life without risking unplanned shutdowns
High precision on kiln brick thickness
Refractory Laser Scanning 3D Model Input To QIR- QIR measures every time kiln shutdown
- QIR re-measures after refractory maintenance
- QIR AI Algorithms use 3D model to optimize accuracy
- After 3+ laser scans accuracy +/- 1cm
LIDAR scan 3D model & QIR AI infrared model- Using internal LIDAR scanning to build 3D model to be compared to the infrared model that QIR build and update every revolution of the kiln.
- The infrared model will be the one that have AI algorithm that update each brick thickness.
- The LIDAR 3D model is only used as the starting baseline - then it will updates QIR algorithms on the next shutdown for our predicted brick thickness VS actual thickness.
- After several shutdowns for maintenance QIR AI algorithms become very accurate in predicting brick thickness and operational time that can be used in the future
Kiln Shell Cooling System
- Automated steam spray system across total kiln (Includes under live rings)
- QIR system controls application of steam spray to each hot spot
- Precision spray nozzles controlled by QIR Thermal System
- Begins spray at user set temp level
- Stops spray when temp is reduced to optimum level (set by user)
- Applies spray only to designated hot spots
- Spray reduced as size and temp of hot spots are reduced
- Artificial Intelligence determines hotspot areas to be sprayed, timing of spray to gradually reduce, and monitoring to apply as new hot spots occur.
- Benefits :
- Controlling and resolving hot spots will extend the useful life of the refractory and kilmn by xx months.
- Automated systems resolves hotspots and provides precision historical data on each hot spot location with thermal details
- Kiln steel shell conditioning - Regular cooling application of complete shell
Preheater Thermal Performance Management
- Monitor real time temp at each level
- User defines optimum temps at each level
- Alerts if deviation from optimum temp
- Algorithms provide temp correlation between levels
- Preheater temps correlated to expected kiln input temp
- Historical analysis provides temp performance over any time period