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Key Results
4%↓
reduction in fuel cost index by leveraging a 2.2% reduction in specific heat consumption
33%↓
reduction in C3S variability
2%↓
reduction in fuel-derived carbon emissions
8
weeks to go live with plant
This collaboration aimed to enhance the Mokra plant’s Expert Optimizer (EO) with Carbon Re’s AI to reduce fuel costs, lower emissions, and improve clinker quality.
The plant maintains a stable production process with a thermal substitution rate of up to 86%, primarily using refuse-derived fuels. Yet, the plant team sought to extend the capabilities of its EO to deliver improved automation and optimisation for the kiln.
Carbon Re was chosen because it is the market-leading AI platform for pyroprocess optimisation. Carbon Re’s AI and machine learning models give operators dynamic targets for better decision-making and efficiency.
To learn more, download the full results of our deployment below.
We had been searching for a system to enhance our Expert Optimizer with AI for a long time and Carbon Re’s AI platform looked promising. ABB’s confidence in the company, along with Carbon Re’s understanding of the challenges of cement production and their expertise in AI, were key to us working together.
Jiří Strapina, Mokra Plant Director
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Through Carbon Re’s cloud-based AI platform, Heidelberg Materials is unlocking the full potential of its process, laboratory, and chemical data, enabling real-time, dynamic optimisation for maximum efficiency and sustainability.