Digitization of sensor-based data to reach Cement 4.0

Guests: Berkan Fidan, Performance and Process Director, Oyak Cement
Martin Provencher, Mining Metals and Materials Industry Principal, AVEVA
Berkan Fidan describes a team approach to improving cement operations with sensor-based data. He started a 2016 digitalization project at Oyak Cement in Turkey, which leads Europe in cement production. As the performance and process director of his nation's largest cement producer he was trying to address the realities of cement production: enormous energy and heat costs and a product that sells for less than bottled water. He created a team consisting of production personnel from 7 cement plants and 3 grinding plants around the world and implemented a data collection and visualization system they referred to as Cement 4.0. Fidan reports his team did 90% of the work themselves. Among their accomplishments are 1) creating digital twins of their plants in Analysis Framework where they used a template of a kiln ID fan they created themselves to enforce common benchmarks and visualizations across their entire organization, 2) defining conditions for email notifications to local and corporate stakeholders of cement rotary kiln stoppage, and 3) creating event frames definitions to track and analyze mean time between failure.

By engaging local production personnel who found the system easy to use and popular, the system has seen organization-wide adoption and he attributes a clear improvement in KW per ton to the cultural change that has resulted.

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