Titan: Pennsuco Cement Balls Mills
Real-time optimization
Optimitive AI delivered a 7.1% throughput increase and 4.7% energy reduction for TITAN Group mills.
From 2020
Ongoing Service
Shaping the present and future of the Cement industry
Client
TITAN located at Miami, Florida (USA)
Description
A global leader in sustainable building materials. TITAN Group is a premier international cement and building materials producer with over 120 years of history. Operating in 25 countries with a workforce of 5,700, the Group is a pioneer in digital transformation and sustainability.
Industry
Electric power
3,700kW
5,300kW
4,600kW
Supplier
FLSmidth
Total cement production
450 t/h
Why AI, Why Now?
In the pursuit of Operational Excellence
TITAN Group recognized that traditional control methods had reached their limit. To further reduce their carbon footprint and maximize cost-efficiency, they needed a solution that could handle the non-linear complexity of cement grinding. The goal was to move beyond manual intervention and implement a self-learning, closed-loop system capable of making millisecond-perfect decisions 24/7.
The Problem
- Energy Intensity: High specific energy consumption in their three FLSmidth ball mills (ranging from 3,000 to 5,000 kW).
- Output Limits: The need to increase throughput without compromising the strict Blaine and residue quality standards.
- Process Instability: Frequent mill fluctuations that prevented the system from running at its theoretical "sweet spot."
The Solution
Optimitive deployed the Optibat®, providing a full-scale AI transformation:
- Non-Linear AI Modeling: Using historical and real-time data to map complex process relations.
- Closed-Loop Autonomy: Connecting directly to the existing control system to automatically adjust set-points in real-time.
- Smart Multi-Variable Control: Managing 4 key variables per mill simultaneously to balance energy, quality, and volume.
Quality
The system maintained same or better estimated completion time for this kind of project is 3-4 months values of both Blaine and passing.
Specific Energy Consumption
Throughput (Production)
Per mill controlled variables
Estimated completion months
success study
Solutions applied to Titan
Consistent product quality
Optimize production with Optibat®. Leverage real-time data to predict quality outcomes, reduce variability, and ensure product consistency while boosting efficiency and profitability.
Lower CO₂ emissions and measurable sustainability impact
Advanced emissions management by Optibat®. 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 Optibat®. 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 Optibat®. 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
In the initial phase, a comprehensive data analysis was performed using both historical and real-time plant data. This allowed our team to map complex process relationships and develop advanced non-linear AI predictive models tailored specifically to the Pennsuco mill operations.
PHASE 2
Optimization Strategy & Design
Engineering team utilized the AI models to design a custom optimization strategy. This phase involved close collaboration with Titan to define specific process constraints, ensuring the AI-driven strategy respected all operational safety and quality boundaries required by the plant.
PHASE 3
Integration, Commissioning & Training
The final phase involved the seamless connection of Optibat® to the existing control system. After the technical integration, we conducted on-site commissioning and specialized training for the plant staff to ensure a smooth transition to autonomous, closed-loop operations.
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
