Cementos Lemona: Kiln Thermal Efficiency & Alternative Fuel Optimization
Real-time optimization
Optimitive AI delivered a 2.1% to 2.5% reduction in specific thermal energy consumption for Cementos Lemona. By optimizing 14 key variables across the kiln and cooler, the system increased the alternative fuel substitution rate by up to 14.9% (along with equipment operation changes) while ensuring the entire process remained stable and efficient.
From 2024
Ongoing Service
Kiln Thermal Efficiency & Alternative Fuel Optimization
Client
Cementos Lemona (Spain)
Description
Belonging to the Irish group CRH since early 2013, CEMENTOS LEMONA S.A. was founded in 1917. A benchmark company in the cement sector in northern Spain, it offers its customers a range of high-quality and homogeneous cements.Ā
Industry
Asset description
4 Stage precalciner, KHD rotary kiln, FLS 6 fans cooler
Production
2250 mtpd
Fuels (Kiln)
Petcoke, RDF, Animal meals, NFU.
Why AI, Why Now?
Shaping the future of the Cement industry
As part of an ambitious Digital Transformation and Industry 4.0 plan, Cementos Lemona sought to leverage data to optimize operations. The primary goals were to reduce specific energy consumption and increase the use of alternative fuels (AF)āsuch as RDF, animal meals, and NFUāto minimize the plant's carbon footprint. Achieving these efficiencies manually is difficult without causing process downtimes or quality deviations.
The Problem
Cementos Lemona, a CRH company located in Lemona (Spain), has an ambitious plan for the Digital Transformation and Industry 4.0 in its operations.
As part of that plan, Cementos Lemona is interested in the use of technologies that could improve the use of its data for the optimization of its operations and, in particular, in reducing its specific energy consumption while increasing the use of alternative fuels (AF) in its cement plant.
The Solution
Cementos Lemona chose OPTIMITIVE to implement OptibatĀ® in its kiln.
Real-Time Optimization by OptibatĀ® maximizes the valorization of alternative fuels (minimizing CO2 emissions), minimizing specific thermal consumption and ensuring compliance with safety, environmental and quality standards.
For that purpose, OptibatĀ® optimizes the set points of the selected operating variables to maximize substitution and maintain the process in stable conditionsāØBelonging to the Irish group CRH since early 2013, Cementos Lemona considers the safety and health of people, quality, environmental protection, and customer service to be priority and essential commitments in its strategy and daily activities.
Quality
The system ensures strict compliance with safety, environmental, and quality standards. OptibatĀ® maintains the process in stable conditions, securing the production of high-quality homogeneous cement while autonomously optimizing energy and alternative fuel usage.
Specific Thermal Energy reduction
Purity & UV Compliance
(7 in the kiln and 7 in the cooler)
Controlled Variables
Alternative Fuel Substitution Rate (along with equipment operation changes)
success study
Solutions applied to Cementos Lemona
Consistent product quality
Optimize production with OptibatĀ®. Leverage real-time data to predict quality outcomes, reduce variability, and ensure product consistency while boosting efficiency and profitability.
Lower COā emissions and measurable sustainability impact
Advanced emissions management by OptibatĀ®. Use AI models to monitor energy and process conditions in real-time, automatically applying optimal strategies to reduce emissions without sacrificing quality or safety.
Maximized throughput with lower energy use
Maximize yield with OptibatĀ®. Continuously analyze process data to anticipate disturbances and push assets to their maximum sustainable limits while maintaining stable, continuous operations.
Improve energy efficiency
Reduce energy consumption with OptibatĀ®. Implement Real-Time Optimization to identify invisible inefficiencies and maximize energy efficiency in your industrial operations without compromising quality.
success study
How it was carried out
PHASE 1
Process Data Analysis & AI Modeling
We analyzed historical data from the KHD rotary kiln and FLS 6-fan cooler to understand the complex dynamics of alternative fuel combustion.
PHASE 2
Optimization Strategy & Design
We defined targets to maximize fuel substitution and minimize thermal energy while establishing strict environmental and safety boundaries.
PHASE 3
Integration, Commissioning & Training
Following successful testing between late 2023 and early 2024, the system went fully operative, delivering confirmed improvements without operational interruptions.
Reviews del cliente
Mason Mitchell expressed his gratitude, stating that the team's innovative approach not only brought his vision to life but also enhanced the functionality of each space, making everyday living a delightful experience. Their commitment to excellence and customer satisfaction truly sets them apart in the realm of interior design.
Detailed Review
Design Execution
Project Planning
Budget Management
Implementation
Professionalism
We found it incredibly satisfying to discover how we could optimize our manufacturing processes by applying Optibat's analysis-based proposals. After reviewing the predictions, we drew up a plan and executed it in just a few months.
Mason Mitchell
TITAN US-MIAMI COO
