From Data to Action

The global cement industry is increasingly focused on enhancing operational efficiency, reducing emissions, and driving profitability. Achieving these objectives necessitates the integration of advanced digital solutions, real-time process monitoring, and precise measurement technologies. Since 2021, aixprocess relies on mobile gas measurement technology from Testo to advance process optimisation and emission control in the cement sector, addressing key challenges through data-driven solutions and expert knowledge.

Digital pioneers in industrial process optimisation

Germany-based aixprocess GmbH is a provider of consulting and digital solutions, leveraging over two decades of experience in optimising industrial processes. Specialising in AI-driven modelling, digital twins, CFD modelling, and process and emission monitoring, the company develops advanced control strategies to improve energy efficiency, increase production output, and reduce the environmental impact of cement production. aixprocess utilises both commercial and proprietary modelling tools to enhance process control and sustainability across industries, including cement manufacturing, chemicals, metallurgy, and pharmaceuticals. By doing so, the core of the offering lies in transforming digitally generated knowledge into real-world solutions that enhance process design and management while optimising systems both economically and ecologically.

In addition to its consulting expertise, aixprocess has developed AI-driven real-time optimisation solutions for cement mills and pyro-processing lines. These optimisers integrate advanced physical modelling with machine learning-based data models to enhance process control and efficiency. By combining these technologies with in-depth cement production expertise, aixprocess has created a robust software and consulting offering for optimising cement plant operations, improving both performance and sustainability.

Delivering accurate gas data in extreme conditions

Testo plays a role in providing high-fidelity emission and process gas data needed for aixprocess’s consultancy services. In this regards the Testo 350 exhaust gas analyser offers accurate real-time monitoring of key process gases, such as carbon monoxide (CO), nitrogen oxides (NOx), and oxygen (O₂), even in extreme industrial environments in high-temperature, high-dust atmospheres.

It is widely known that cement production is a highly energy-intensive process and a major source of greenhouse gas emissions. To develop physical process models and AI-driven control concepts a precise understanding of each plant’s operating conditions and dependencies is required. Since a digital twin can only deliver reliable predictions when supplied with high-quality input data, precise measurement of process gases is essential for the success of such projects.

“However, the data generated by cement plants is often incomplete or lacks the necessary quality for dependable system modelling,” says Matthias Schumacher, Director of Cement Technology at aixprocess GmbH. “Moreover, extreme temperatures, high dust concentrations, fluctuating operational conditions, and confined spaces pose significant challenges for data acquisition.” The Testo 350 exhaust gas analyser addresses these challenges: As part of aixprocess’s process audits, which typically last 2 – 3 days and also include combustion calculations and chemical balances, the Testo 350 helps to establish a comprehensive mass and energy balance of the plant. To achieve this, manual measurements of CO, NOx, and O₂ are performed at various points in the plant’s process and exhaust gas stream. These measurements are conducted in environments with temperatures ranging from 300 – 1000°C, often under very dusty conditions and in restricted areas.

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Read the article online at: https://www.worldcement.com/special-reports/20062025/from-data-to-action/