Smart Manufacturing of Cement
Project Lead: University of Louisville
Partners: Argos
Member % Cost Share: 32%
CESMII % Cost Share: 68%
Duration: 24 Months
Problem Statement
Cement manufacturing is energy-intensive (5GJ/t) and comprises a significant portion of the energy footprint of the composite material. Incorporating modern monitoring, simulation and control systems will allow lower energy use, lower environmental impact and lower costs.
Project Goal
Using predictive process models, data analytics, sensors and machine learning, a Smart Manufacturing for cement control system platform will be developed in partnership with ARGOS USA cement in an effort to provide a more energy-efficient clinker production process with better quality control.
Technical Approach
Lab and rotary cement kilns at the cement plant will be used as test beds to develop a sensor suite, predictive models and control system logic to characterize the product stream in the kilns. Additional systems states such as mass and air flow(s), along with rotational velocity will also be used to control the Kiln for optimal production quality and energy use using real-time predictive control.
Deliverables/Outcomes/SM Marketplace
-
Designed and Fabricated Lab Scale Cement Kiln
-
Developed Lab Kiln Multi-Physics Model
-
Developed Argos USA Roberta Plant Kiln Multi-Physics Model
-
Developed Argos USA Roberta Plant Kiln Cement Process Model
-
Designed Advisory Predictive Controller System for Argos USA Roberta Plant Kiln
-
Reduced order predictive control models for cement manufacturing
-
Machine learning algorithms for kiln performance prediction
-
Multi-physics based predictive control models for kilns
-
Data analysis algorithms
-
High temperature sensing system for thermal processes model
Potential Impact
Because energy (fuel) costs are a significant portion of the cost of the cement production, lowering firing temperatures and times will reduce cost and environmental impacts making this industry more viable through adoption of Smart Manufacturing technologies and processes.
Benefits
- Contributions will be made to the SM Platform™ core technologies (specifically in the data acquisition for high temperature manufacturing, contextualization, and control).
- A multi-physics cement manufacturing model will be developed that will serve as a basis for process analytics and control for similar processes through the SM Platform.
- Building on the SM Platform core technologies, data analytics and machine learning algorithms will be developed that can be used for process assessment and control across a wide range of high energy manufacturing processes.
