Focusing on the critical pre-heater and kiln process stages of cement production, Carbon Re optimises fuel use to reduce carbon emissions.
Carbon Re’s AI powered solution is especially developed for energy-intensive process manufacturing. It applies the latest advances in AI and machine learning to uncover energy efficiencies and reduce costs and carbon emissions in industrial processes.
Carbon Re Cement is the decarbonisation technology that brings the most advanced AI to optimise the pre-heater and kiln process stages of cement, enabling significant efficiencies, cost savings and emissions reductions
Fast set-up and deployment
No capital or hardware investment
No plant shutdown
Carbon Re is uniquely positioned to provide the cement specific AI solutions the industry has been lacking thanks to its world-class in-house machine learning, software engineering and industry expertise. Carbon Re is built on the foundations of our world-leading domain knowledge.
Carbon Re Cement applies AI and machine learning to uncover energy efficiencies and reduce costs and carbon emissions. The calculator below uses pre-set values to demonstrate savings.
Click below to get a customised calculation of the potential savings in your plant.
Carbon Re Cement simulates the chemical and physical processes in a plant, enabling our AI agents to find solutions tailored to each plant. Each AI model is a bespoke digital twin of the cement plant.
Our software takes into account quality metrics, such as clinker free lime, and defined operating limits – precalciner temperature lower & higher bounds to provide clear quantified recommendations to reduce the mass of CO2 emitted per useful heating value (kgCO2/UHV). This enables lower fuel costs and lower emissions.
Carbon Re Cement provides dynamic and live optimisation on live data and our models are continually retrained to match actual plant performance. We build confidence in each model by reviewing sensitivity curves to key variables and feature importance for each model.
The cement industry has yet to take advantage of the decades of research and investment that has been poured into AI, software engineering and computing as previously there were no specific solutions available.
Carbon Re Cement is built using cutting edge systems architecture and machine learning frameworks specifically for the cement industry.
We use the most advanced cloud based storage databases to handle the complexity and volume of data produced by cement plants and we conduct world-first machine learning research at the highest level of scientific rigour.
We deliberately designed the platform as a human-in-the-loop solution, where the plant operator maintains control over production processes.
Carbon Re provides specific and quantified predictions and recommendations to be actioned by the operator. The dashboard simplifies a complex operating environment and uses the latest design tools to reinforce positive behaviours and augment human expertise.
Where desired by the client, Carbon Re predictions and recommendations can be directly fed into expert optimiser by the client to optimise the process.
For example, Carbon Re can feed a new prediction directly into the expert optimiser every 15 minutes, with recommendations provided to the Control Room operator every 2 hours.
Alternatively, all predictions and recommendations can be fed directly to the expert optimiser with no action required by the Control Room
Locally available fuel supplies, raw materials, and market conditions are key factors to consider when designing a cement plant for both the material properties of the clinker and production costs. Rules-based ‘Expert Systems’ typically use industry-standard relationships to set production parameters that are not necessarily optimal for individual plants. AI systems naturally adapt to the specific properties of each plant. The decarbonisation technology behind Carbon Re Cement adapts to different kiln sizes, fuel types and mixes, raw materials, and production requirements.
