Cemex: Real-Time Optimization in a cement plant

Ongoing Service

Heavy industry, and cement manufacturing in particular, faces a complex and interconnected set of operational challenges that directly impact efficiency, costs, and sustainability. Every shift brings variability — driven by quality fluctuations, asset wear, and the ever changing human factor in the control room. When left unaddressed, this variability erodes performance, environmental compliance, and asset lifespan.

Energy mismanagement compounds the problem: excess or incorrect energy use not only raises costs but generates avoidable CO2 emissions and risks severe physical damage to critical equipment such as kiln refractory, mills, and liners. Layered on top of this is the growing  nowledge gap — as experience  operators rotate or r tire, leaving plants increasingly exposed. Together, these factors create a cycle of instability that makes consistent, high-performance operations exceptionally difficult to achieve and even harder to scale globally.

Addressing these challenges requires a solution capable of bringing stability, intelligence, and adaptability across all plant assets simultaneously.

OPTIBAT®, by OPTIMITIVE, is a unified AI platform that delivers stability, intelligence, and real-time optimization across plant assets, from the raw mill to the kiln.

Through continuous micro-corrections, it guides process variables toward optimal conditions, helping prevent equipment damage, energy waste, and quality deviations. Each critical signal is individually modeled, validated, and monitored, ensuring decisions reflect both process data and operational reality.

The system dynamically adapts to changing conditions, incorporating external events such as feed failures and downstream disruptions. By automating routine adjustments on supporting assets, including mills, OPTIBAT® enables operators to focus their expertise on critical tasks.