Applying AI in cement pyroprocess

operations for optimal performance

and sustainability

Erlangen, 12.2023
With the trusted legacy of more than 150 years of
engineering expertise, we are and have always been
the backbone of reliable motion for industries and
infrastructure worldwide. Now, we’re about to take
this to the next level with Innomotics. To support you,
our customers and partners, and your business on
the road to the future – sustainable, digital, reliable.

What we do:
As an industry-leading company, we
put your ambitions into innovation
and reliable motion by delivering
superior motors and drives.
As a proven end-to-end partner, we
persistently scale up industrial
electrification, sustainability, and
digitalization – on a global scale.
As global player with the spirit of a
mid-sized champion, we generate
around €3 billion of revenue with
15,000 employees. They are what
we call: our most powerful engine.

3 Restricted | Innomotics | 2023

We have a well-balanced footprint across regions and industries.
Mining

16
factories
Cement
Oil & Gas
Metals
Water

49 HVAC Countries with

regional sales
setup

Chemicals
countries with sales & service setup Food & Beverage HVM FACTORIES MVD FACTORIES LVM FACTORIES

Marine

11
Pulp & Paper
Power
project execution centers
Automotive
Intralogistics
4 Restricted | Innomotics| 2023
 LV Low Voltage Motors in asynchronous, reluctance, and permanent magnet
technology. Highest quality and efficiency offering.

HV High Voltage Motors outperforming global standards in industrial

applications and supporting megatrends in key vertical applications.

MV Medium Voltage Drives are first choice for a better, more sustainable future
in primary & process industry and in all applications, incl. power-to-power.

SO Our state-of-the-art electrification-, automation-, and digitalization-solutions

support our customers in productivity, efficiency, and sustainability.

CS Customer Services that provide industry-leading services & digitalization to

ensure the productivity, availability, and reliability of our customers’ assets.

5 Restricted | Innomotics | 2023

Low Voltage Motors
Product portfolio

Severe Duty
General Purpose
Geared Motors
Definite Purpose 1) Lorem ipsum

Explosion Proof
Weiss Spindle
6 Restricted | Innomotics 2023 |
MV Drives and Systems
Product portfolio

GH180 a/c

GH150 / SH150 / GH180 w/c

GL150 / SL150

GM150 / SM150
7 Restricted | Innomotics 2023 |
High Voltage Motors
Product portfolio

Compact Motors
Modular Motors
ANEMA Motors
High-Power & Special Motors
8 Restricted | Innomotics 2023 |
Solutions portfolio integrate specific products for
Mining, Metals, Energy

SIMOTICS HV Ring Motors

SIMOTICS HV Series Metals
SIMOTICS HV Series Mining

SIMOTICS HV Series Energy

9 Restricted | Innomotics 2023 |
Solutions Minerals Offering
Electrification, Automation and Digitalization for Mining & Cement
E L E C T R I FI C ATI O N A U TO - D I G I TA L I ZATI O N
M AT I O N
M AT E R I A L H A N D L I N G GRINDING ELECTRI-
FICATION

SIC Integrated Process

Operations Centre Digital Twin

Bucket wheel Mine Hoist/ Pinion mill E-House Solutions Automation

Solutions
excavator Winder drives

OTHERS
PLM COMOS
MES/MOM MAQ
based
PIMS

Conventional Gearless Gearless mill

Conveyor drive Conveyor drive
drives People Mover
APM: Asset Performance Management SIC: Short Interval Control
Consultancy of APC / AI for
AHA: Asset Health Analytics PLM: Plant Lifecycle Management Cyber Security APM / AHA
APC: Advanced Process Control MES/MOM: Manufacturing Execution System / Digital Cement
AI: Artificial Intelligence Manufacturing Operation Management for OT
MAQ: Material and Quality Management
Transformation

10 Restricted | Innomotics | 2023

A - Innomotics is premium solution provider of Siemens PCS7 CEMAT
Cement automation standard with 45+ years of product expertise

1000+ installations worldwide

11 Restricted | Innomotics 2023 |
 Watts up,
future.

12 Unrestricted | © Innomotics 2023 | Dan Fodor I IN SO

Artificial intelligence-based control for cement pyroprocess and mills

Challenges Solution Benefits

− Stabilization of clinker production, due
to its complex thermodynamics and
limitation of sensor technologies.
− High dependence on highly
experienced operators / challenging
onboarding of new personnel.
− Apply data-drive AI techniques to
forecast key process parameters.
− Development of a knowledge database
with critical control situations and
suitable correction interventions for
decision support for the operator.
− Up to 95% forecast accuracy helps
prevent process drift outside acceptable
parameters, i.e. standstill.
− CO2 footprint reduction based on optimal
heat utilization, i.e. increased share of
alternative fuels.

13 Restricted | Innomotics | 2023

 Addressing the pain points of the cement industry

Reduce fuel consumption Reduce production loss

Reduce energy Bring transparency

consumption across plants

Reduce downtime Increase uptime

14 Restricted | Innomotics | 2023

D - Innomotics is the owner of AI APC Solution for Cement
Fast and scalable AI driven solutions to optimize cement production
Solution at a Glance

• Functionalities: AI modules, reporting modules, user

management, alarm notification, and asset
management.

• Web based enterprise wide information system

that allows central or local KPI visualization.

Combining real-time data with predictive intelligence

• Improve production with easy to interpret data

comparison.
• Analyze operations through trend visualization.
• Optimize inventory planning and maintenance.
• Achieve transparency through production tracking
and quick access to relevant information.
• Identify issues across sites through alarm analysis.
• Reduce breakdown and increase asset durability
with real-time monitoring and maintenance.

15 Restricted | Innomotics | 2023

Artificial Intelligence
Step 1: Assisted Kiln Operation System
System Variables Solution at a Glance
(Customer specific)
• Prediction of key parameters of kiln (e.g. kiln sinternzone
temperature) in 15min and 30min into the future
• Training of prediction model with machine learning (e.g.
Deep Learning) by using historical data to create a stable kiln
model

16 Restricted | Innomotics | 2023

Artificial Intelligence
Goal: Autonomous Kiln Operation

Trained AI Kiln forecast model

Sensor Data AI Module Forecasted Range

Desired Range
Process Data
Influx Database
(Process Control System)

New best New Interface - Input

possible setpoints
setpoints
Kiln Fuel Kiln Fuel Configurable Kiln Set Point AI
Kiln Fuel
Kiln Feed Kiln Feed Module
Kiln Feed
Kiln Stability
Backend API Kiln Kiln
(Sintering Zone Kiln Speed
Speed Fingerprint Speed
Temperature) g Cooler
Cooler Cooler
Pressure
Pressure Pressure Measures difference between forecasted and desired
…..
User Interface ….. ….. considering other signals that affect the kiln stability.
Dashboard

17 Restricted | Innomotics | 2023

 Application of Artificial Intelligence
AI Assisted Kiln Operation – Added value
Energy Saving by Stabilization of Burning Process using RDF (Refused-derived fuel)

Improved Situation:
• An early and appropriate adjustment on coal supply, assisted by the AI forecasting, will provide the process more stability and even potential of further energy
saving.
Coal Saving = Σ (Purple) – Σ (Yellow)

1300
2900
2700 1250

2500 1200
2300 1150
2100
1100
1900
1700 1050

1500 1000
RDF Coal Supply_NEW Coal Supply Sinterzone Temp

Additional savings: Extended life Social cost of CO2 Freight costs

of brick emission reduction
18 Restricted | Innomotics | 2023
 Potential Benefits from AI Mill Digital Solution

Benefits Observed from AI Assisted Mill Solution

3.8 Hrs. Average Run Hours per day (~25% of Total Mill Running Hrs.)

3.5% 2.2% 2.4% 2.4% 376.9 MT/Yr.

Increased (with 1.3% Error Savings in Power Reduced Specific Power Potential Reduction in
Production Margin) Consumption Consumption CO2 Emissions
300+ k Euro/Yr.** Potential Increased Revenue 20+ k Euro/Yr.** Potential Energy Cost Savings

Input tph Output tph AI Input tph AI output tph

334
9,00 8,82
326 8,80 8,68
8,54
318 8,60
8,36 8,39
8,65
310 8,40 8,56
8,20 8,38
302 8,00
8,06 8,10
294 7,80
286 7,60
Mai 23 Jun 23 Jul 23 Aug 23 Sep 23
278
Specific power consumption kWh AI Specific power consumption kWh
270
Mai 23 Jun 23 Jul 23 Aug 23 Sep 23

19 Restricted | © Siemens 2023 | IN APAC&ME RC-IN SO MN A&D DH | Nov 2023

Example Benefits from AI Pyro Process Digital Solution

Page Restricted | Innomotics | 2023

20
ROI (One of the plant in India)

Page
21
Thank you.
Appendix
 Temperature and Gas Management across complete pyro is a great challenge

Preheater Jamming
Addressing high chloride and Sulphur inputs without bypass is a tricky task.
High flame momentum can enhance cyclone clogging, yet it's a necessary evil when dealing with high-sulfur
fuels like petcoke.

Optimal Heat Utilization by minimizing the

amount of coal and at the same time
maximizing the ratio of alternative fuels
between main and calciner burners

Emission control (CO2, CO , Nox)

Optimizing energy at cooler section

24 Unrestricted | Author | Department | 2023

Artificial Intelligence - Always the best control for the kiln
Industry challenges
Kilns / Mills are difficult to control
due to unknown variables e.g.
alternative fuels
Traditional APC requires
continuous maintenance and is
often out of service
It requires years of experience to
become an expert operator
Excellent control saves money
Poor control leads to unwanted,
costly stops
26 Restricted | Innomotics | 2023
AI solution
Historical-data-based model
training and real-time data
analysis.
Data labelling by kiln expert
Pattern recognition to allow the
system to predict key-parameters
for the next 15 and 30 minutes.
➢Operator reacts according to the
prediction.
➢AI advises which setpoints to set
➢Auto Pilot controlled by AI.
Benefits
• Higher operation efficiency:
Predictive monitoring.
AI is trained with expert
operator’s experience.
• Better decision accuracy
through identification of
correlations based on a
historical database
• Increased plant uptime
through avoidance of shut-
downs by predicting the future
behaviour.
Parameter Accuracy
Range
Sintering Zone Temperature 90 – 95%
Calciner Head Temperature 90 – 95%

Tertiary Air Temperature 90 – 95%

Kiln Inlet Temperature 90 – 95%
Alite 85 – 95%
Free Lime 85 – 95%
Kiln Inlet O2 85 – 90%
Kiln Inlet Pressure 85 – 90%
Kiln Main drive current 85 – 90%
Cooler Exhaust Air 90 – 95%
Chamber Pressure 90 – 95%
O2 After calciner 90 – 95%
O2 Before filter 90 – 95%
Grate Speed 90 – 95%
Cooler exhaust air 90 – 95%
Page Restricted | Innomotics | 2023
27
 AI for the Pyro Process
An essential potential of improving efficiency lies in
cutting-edge analytics. Cement manufacturers have
the potential to secure fuel savings of no less than 2%
through the utilization of Innomotics AI Solution's
self-learning models for the pyro process and
optimization of the heat profile and kiln flame
intensity
further, incorporating alternative fuels such as waste
and biomass to replace fossil fuels, could reduce
emissions by nearly 10 percent by 2050.

28 Restricted | Innomotics | 2023

Significant parameters of the Kiln System
• Secondary and Tertiary air
Temperature
• Kiln Inlet Temperature
• Sintering Zone Temperature
• Calciner Temperature
• Gas Duct temperature
• Average Temperature before ID Fan
• Cooler Exhaust air temperature
• Differential pressure of baghouse
filter
• Kiln Inlet Pressure
29 Restricted | Innomotics | 2023
• Backstroke pressure
• Precalciner fuel rate
• Specific Heat Consumption (Calorle)
• Kiln Main Drive Current
• Kiln Inlet O²
• Kiln Inlet Nox
The most important chemical
contents of clinker for kiln
operation are:
• CS3 – Alite – target: 62% ± 2%
• CaOfree – Free lime – target 1,5 ± 2,5%
AI Mill Solution

The heart of AI Mill solution lies in its closed-loop control

system, which seamlessly integrates with the whole
production process, providing real-time insights and
intelligent decision-making capabilities. By continuously
analyzing data from various sensors and leveraging
machine learning algorithms, AI Mill optimizes the entire
grinding process with precision and foresight.

Main Benefits of the Closed Loop Control:

• Optimized Energy Usage
• Predictable output
• Reduced Downtime
• Consistent Quality
• Increased Process stability = Increased Production

30 Unrestricted | Author | Department | 2023

More Production Efficiency with AI Mill
Higher process Efficiency:
Better process stability results to:
• Less downtime
• More throughput ton per hour
• Consistent quality
The closed loop enables at least an
average of 1 - 2 percent increase in
production:
At our reference customer we
achieve a production increase of
2,6% over the overall runtime of the AI
Solution.
The increased production capacity
enable our customer an additional
revenue of up to 160.000€ per year.
31 Unrestricted | IN SO MN A&D | 2023
Energy Savings:
More process stability ensures minimal
energy wastage and enables energy savings.
This means Less kw/h power consumption
and a smaller CO2 footprint of the cement mill
process
A better process stability entails less setpoint
changes.
Less Vibration.
Les chances to get a skew.
Less operational costs.
= Optimized Energy Usage
AI Mill Operations and KPI dashboard & Analytics

KPIs Analyzed Prediction

• RP Mill KW1 + KW2 • Roller Press kW1
• Skew • Roller Press kW2
• Vibration
• Working pressure Left
• Working Pressure Left + Right
• Slider Position Left + Right • Working pressure Right
• Left + Right Working Slider Gap • Ball Mill kW
• RP feed bin weight • Skew (positioning of the roller) instant action
• Corse feed rpm (gravel grate)
• Separator rpm • Roller press bin weight (Vibration instant
• Separator fan rpm action)
• Total Mill feed
• Mean gap
• Polycom elevator Kw

32 Unrestricted | Author | Department | 2023

AI based Mill - Closed Loops

#1 Slider Position #2 Fresh Feed #3 Separator speed

Control of the Slider Position Control of the Clinker feed Separator fan speed / rpm to
left and right into the Mill = Ton per hour control grinding to a certain
particle size. The coarse
Implemented and Operating Implemented and Operating powder returns to the
since 15th Feb 23 since 15th May 23 cement mill for re-grinding.

Run Hour in AI mode: 427 h Run Hour in AI mode: 603 h Implemented and Operating
since 15th May 23

Run Hour in AI mode: 338 h

33 Unrestricted | Author | Department | 2023

Reference Case
Digital Twin of iron ore body for controlling ROM quality
Challenges
− Continual loss of valuable material to
the waste dump due to
misclassification of the run of mine.
− High sampling and laboratory costs
prevent comprehensive analysis of
material quality in the mine.
34 Restricted | Innomotics | 2023
Solution
− Estimation of the quality of the excavated
material, based on the coordinates of the
vehicle and the geological block.
− Data analysis provides further insights
into quality tracking, such as intermediate
stockpiles and material feed to the
crusher.
Benefits
− Recovery in a single analysis of 15
thousand tons of ore initially identified as
waste, worth approximately 2,0 Mio USD.
− Greater predictability of feed quality
results in more stable process plant
operation.
Reference Case
Digital Twin of a complex Crushing & Transport System in a copper mine
Challenges
− Achieve & sustain designed material
handling capacity from mine to the
plant stockyard.
− Production losses caused by
unplanned shutdowns & intermittent
load on the crushers.
35 Restricted | Innomotics | 2023
Solution
− Modelling and simulation of material
flow behavior from truck unloading to
stockyard.
− Integration w/ real time process data
for online simulation and analysis of
incidents, root causes, critical areas.
Benefits
− Increased transportation capacity,
eliminating losses of $17.1 million per
year.
− Decongestion of the unloading area.
Reference Case
Digital Twin of Stockpile for advanced stockyard management
Challenges
− Operate smoothly and efficiently bulk
material handling facilities in changing
conditions e.g. quality requirements
− Hazardous conditions for operators
working in the field.
36 Restricted | Innomotics | 2023
Solution
− High resolution 3D representation of
stockpiles updated in real-time by belt
scales & scanning.
− Remote/autonomous operation of
stackers and reclaimers enabled by
the digital twin.
Benefits
− Significantly improved productivity
and safety with up to 98.5% machine
availability in autonomous operation.
− Blend materials more efficiently and
accurately, according to contractual
specifications.
Reference Case
Artificial intelligence-based asset health analytics for grinding mills
Challenge
− Unexpected mill failures and
shutdowns can result in operating
losses of up to several million dollars
per day.
37 Restricted | Innomotics | 2023
Solution Benefits
− Real time analysis of equipment health, − Prevent or shorten unplanned shutdowns
using mathematical and AI models to by providing early warning of deviations
detect anomalies in components and from normal operation combined with
subsystems, such as lubrication. timely response for corrective action.
− Contextualization of anomalies using
knowledge base and expert knowledge
for root cause analysis & corrective action
recommendations.