Heidelberg Materials integrates Carbon Re’s AI on top of ABB Ability™ Expert Optimizer to improve kiln performance.
Carbon Re, an industrial AI spinout from the University of Cambridge, has partnered with Heidelberg Materials, a leading global cement producer and market leader in Czechia. Together, they aim to significantly enhance pyroprocess performance by integrating Carbon Re’s AI technology with the ABB Ability™ Expert Optimizer for cement.
In the first month of continuous operation at Heidelberg Materials Mokra plant, the integration of Carbon Re’s software led to a 4.1% reduction in the fuel cost index, a decrease in fuel-derived carbon emissions by 4.5kg/tonne of clinker (2% reduction) and a 33% reduction in C3S variance.
Carbon Re Dashboard
The Mokra team validated the results of the closed-loop evaluation period in a one-month on, one-month off test. When controlling for key variables, such as fuel mix and raw material quality, the plant observed a 2.2% reduction in specific heat consumption.
These improvements will further benefit the Mokra plant in grinding and cement blending, leading to additional costs and carbon savings. By augmenting the plant’s existing ABB advanced process control (APC) solution with Carbon Re’s AI, Heidelberg Materials is setting new heights in operational excellence and digital innovation.
Jiří Strapina, Mokra Plant Director, Heidelberg Materials Czechia, said:
“We had been searching for a system to enhance our APC solution using AI for a long time, and Carbon Re’s platform looked promising. Carbon Re’s understanding of the challenges of cement production and their expertise in AI were key to us working together.”
Josh Vernon, CEO Carbon Re, said,
“With the support of the team at Heidelberg Materials Czechia and ABB, we are delighted to showcase how Carbon Re’s AI can help cement producers leverage years of digital investments to reduce carbon emissions and save on fuel costs”
Tyron Vardy, Global Portfolio Manager for Business Line Digital, ABB Process Industries:
“ABB has been leading the way with advanced process control (APC) in the Cement industry for many years. Integrating Carbon Re’s AI capabilities is the next step in our portfolio’s evolution, as we continue to leverage the power of artificial intelligence into our industry leading APC solutions, increasing the benefits we can deliver to our customers.”
Building on these successful initial results, Heidelberg Materials and Carbon Re are planning their joint development roadmap. Meanwhile, ABB and Carbon Re are formalising their joint approach to enable more cement producers to use AI-powered optimisation and decarbonisation to advance their production and strategic objectives.
A detailed case study outlining the collaboration between Heidelberg Materials, Carbon Re and ABB can be found on Carbon Re’s website.
