Sustainable Cement Production through Smart Manufacturing
From roads and bridges to skyscrapers and dams, cement is indispensable for modern construction. Yet the industry is facing complex challenges such as plant operation optimization, decarbonization, and equipment reliability that cannot be solved through individual optimization alone.
Yokogawa, as a trusted partner in this transformation, leverages decades of expertise in measurement and control to provide solutions that strengthen operational optimization, environmental performance, and asset reliability.
Together, we can go beyond conventional methos to achieve low-carbon, efficient, and highly reliable smart cement production.
Key Industry Challenges
Operation Optimization
- Numerous manual operations remaining
- Insufficient utilization of operational data
ESG / Environmental Impact
- Significant CO₂ emissions and energy use
- Lack of accurate CO₂ measurement
- Air pollution from exhaust and fuel use
Asset Maintenance
- Inappropriate maintenance schedule
- Missing the signs of equipment failure
Yokogawa's Solutions
Process Automation
Automating complex manufacturing processes to improve efficiency, reliability, and safety.
Solutions
- Delegate controlling and monitoring of the manufacturing process to the system
- Automatically optimize complex processes with high reliability using DCS (Distributed Control System)
Benefits
- Reduction of manual operations and human error
- Enhanced process reliability through redundant configuration
Operational Data Utilization
Leveraging plant data to enable continuous improvement and smarter decision-making.
Solutions
Automatically aggregate operational data in real time using PIMS (Plant Information Management System)
- Store, visualize, and analyze data with ease
Benefits
- Continuous improvement of operations
- Improved decision-making through data-driven insights
Standardizing Operations
Digitalizing work procedures to ensure consistency, safety, and efficiency across operations.
Solutions
- Digitize SOPs (Standard Operation Procedures) using intuitive flowcharts
- Systematize routine tasks such as startup operations of the raw material mill
Benefits
- Standardized procedures across operators
- Improved production efficiency
Advanced Control for Boiler Operations
Applying Advanced Process Control (APC) to stabilize boiler performance and improve efficiency.
Solutions
- Minimize process variability using APC
- Stabilize boiler operation to reduce energy loss
Benefits
- Improved energy efficiency
- Stable and reliable boiler operations
Combustion Optimization
Optimizing kiln combustion by accurately measuring O₂ and CO levels, even under dusty, high-temperature environments.
Solutions
- Measure O₂ and CO at the kiln outlet using an Infrared Gas Analyzer with and a sampling unit
- Adjust the induced draft fan speed, fuel feed, and raw material input based on gas analysis
Benefits
- Accurate assessment of combustion conditions
- Improved fuel efficiency and kiln performance
Energy and GHG Emission Management
Optimizing energy use and reducing GHG emissions to cut costs and meet sustainability requirements.
Solutions
- Monitor and optimize energy consumption in real time
- Simulate and plan for energy reduction through process improvements
Benefits
- Reduced energy costs and GHG emissions
- Accurate reporting and compliance with government regulations
Exhaust Gas Monitoring
Ensuring compliance and safety by continuously monitoring emissions.
Solutions
- Measure O₂ and up to four other components (NO, SO₂, CO, CO₂, CH₄) using the Infrared Gas Analyzer
- Continuously monitor exhaust gases to comply with environmental standards
Benefits
- Prevention of toxic gas releases
- Compliance with emission regulations
Waste Combustion Control
Conventional kiln operations result in high fuel costs and CO₂ emissions. Optimizing alternative fuel combustion improves efficiency, operational stability, and sustainability.
Solutions
- Stabilize the combustion of alternative fuels
- Facilitate higher rates of alternative fuel substitution while maintaining clinker quality
Benefits
- Reduced CO₂ and CO emissions
- Improved fuel flexibility and kiln stability
Asset Health Monitoring
Monitoring equipment conditions to detect failures early and support condition-based maintenance.
Solutions
- Monitor equipment conditions using advanced sensors and analytics
- Detect early warning signs of failure through continuous monitoring
Benefits
- Condition-based maintenance
- Reduced unexpected equipment failures
Resources
Automated wireless temperature monitoring at cement plants, lime kilns, and asphalt plants prevents expensive chute clogging issues.
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