Displaying items by tag: ABB

Anhui Conch Cement held an event in Wuhu, China, this week showcasing its new artificial intelligence (AI) model for the cement sector. The cement company and Huawei started the project in April 2024 with the support of the China Building Materials Federation. The companies say they have now identified over 200 “promising AI application scenarios across 15 categories” across the entire production process from quarrying to packaging and logistics. Conch has set up an AI training centre using the Huawei Cloud Stack product. It is using Huawei’s Pangu prediction, computer vision (CV) and natural language processing (NLP) models to create an AI operating system that integrates central training, edge inference, cloud-edge synergy, continuous learning and ongoing optimisation.

Thankfully Huawei gave some examples of what this actually meant for operators in the real world. The model is able to give real-time recommendations of key quality features enabling the prediction of three-day and 28-day clinker strength. The predicted strength values closely match test results, with deviations within 1MPa and an accuracy rate exceeding 85%. Other benefits include reducing kiln fuel consumption by 1%, monitoring and managing various components and machines along the production line, staff safety gains and creating a ‘smart digital assistant’ that can answer technical questions from employees.

Little of this seems particularly novel, so far, compared to what other companies are already doing in this field. For example, ABB said in early 2022 that it was using machine learning to predict 28-day strength on the day of sampling and in 2023 that it was doing it using production data provided every two - three hours. Another example is the work that Inform does using AI-based software to support logistics for heavy building materials. Plenty of other western-based companies also offer production optimisation and/or predictive maintenance products.

Conch’s use of an NLP model to create a knowledge base assistant does seem new for the cement sector. Although how specific the software running it might be to one business or industrial area remains to be seen. One could easily imagine this kind of product being sold to lots of different kinds of industries in the manner of current enterprise style software. Along these lines though, Juan Beltrán, digital manager of global sales excellence at Holcim, told McKinsey in an interview about Holcim’s pilot project in Spain testing an AI-enabled copilot customer-ordering assistant via WhatsApp.

Recent events in AI for the cement sector include ABB’s agreement to work with UK-based Carbon Re in late 2024. This collaboration was intended to combine ABB's expertise in automation and process control with Carbon Re's AI and machine learning technologies. It followed a pilot at a cement plant in the Czech Republic. On the producer side, Holcim said in mid-2024 that it was preparing to expand the use of AI-based software to 100 production plants by 2028. It noted that it had installed the system at 45 plants so far at the time of this announcement and that it was using a predictive maintenance solution from software supplier C3 AI. Titan Cement said that it had invested in Spain-based AI software supplier Optimitive in February 2025. Then, Cemex announced this week that it too had invested in Optimitive, via its corporate venture capital arm Cemex Ventures. Molins has also worked with Optimitive.

What isn't being disclosed much are the examples of the mistakes of introducing AI into cement production. These are valuable learning opportunities for any company implementing this kind of software. However, the developers and cement producers are extremely unlikely to admit anything publicly. Global Cement Weekly has heard off-the-record information previously about AI projects at cement plants that have gone wrong but we can’t reveal it either. To his credit though Beltrán mentions an incident, in his interview with McKinsey, where the WhatsApp ordering assistant was tricked during testing into almost placing an order for a truck of gazpacho soup!

We’re still watching how AI is being deployed in heavy industries such as cement. The announcement by Conch is exactly the kind of thing its peers are doing around the world. So far what they’ve done is impressive but not unique. Yet, China’s large but shrinking cement sector and its determination to develop its own AI-based software sector may start to deliver more cutting-edge advances in the future. Companies elsewhere are also pressing ahead to find out how AI products will deliver efficiency gains.

Vietnam: Xuan Son Group held the launch ceremony for Xuan Son Cement at the Xuan Son cement plant in Hoa Binh province on 21 February 2025. The plant spans 40 hectares, with a US$196m investment and a production capacity of 3.5Mt/yr. The plant integrates Polysius grinding technology, Flender transmission systems, Haver & Boecker automated packaging technology and electrical equipment and motors from Pfeiffer, Vacuum and ABB. Heat consumption is below 680kCal/kg of clinker, and electricity consumption is under 71kW/t of cement, according to the company. The plant uses refuse-derived fuel in the kiln, as well as waste heat recovery to reduce its reliance on fossil fuels. It aims for zero NO_x and CO₂ emissions.

Switzerland: ABB has launched a white paper outlining the challenges the global cement industry must tackle to decarbonise operations in line with global emissions reduction targets and the role technology will play in this.

The white paper is supported by industry associations and, in it, ABB details a technology roadmap for potential solutions to achieve net-zero targets. It combines insights from a range of key industry players - including customers, technology partners, industry media and associations - along with ABB’s commercial specialisation. It details the benefits of advanced electrification used in tandem with technologies adopted through industry collaborations. The white paper also includes discussions around how sustainable cement could be defined, as well as practical advice as to what steps producers can immediately take in their decarbonisation journey. Electrification is identified as a major component in the decarbonisation of the cement industry, with the ability to replace fossil fuel burners with electrified, or zero-carbon, solutions. These are predicted to help significantly reduce emissions in line with industry ambitions.

ABB sells products in the electrification and automation sectors. Its Process Automation business automates, electrifies and digitalises industrial operations that address a wide range of essential needs. Its products are marketed to help customers in process, hybrid and maritime industries improve performance and safety of operations.

The full white paper can be accessed online here: https://new.abb.com/cement/campaigns/cementing-a-sustainable-future

Canada: Lafarge Canada has selected ABB to update the process control system at its Bath cement plant in Kingston, Ontario. ABB will supply, commission and support its ABB Ability System 800xA distributed control system, which aims to enhance plant process visibility and control. The Bath plant produces over 1Mt/yr of OneCem low-carbon cement and is the site of a pilot carbon capture project.

Andrew Stewart, vice president of cement at Lafarge Canada, said "We are dedicated to advancing sustainable construction, not least through rigorous decarbonisation efforts. From working with ABB to upgrade our process control system, to integrating low-carbon fuels and upgrading to energy-efficient kiln technology, we are significantly leading the way in sustainable construction by reducing our carbon emissions per tonne of cement produced. For example, our pilot carbon capture initiative with Hyperion has also been critical, as it leverages innovative processes to capture and sequester CO₂, bringing us closer to our goal of net-zero emissions."

Switzerland: ABB has entered into a memorandum of understanding with UK-based climate tech company Carbon Re, to explore integrated solutions aimed at accelerating the decarbonisation of cement production while improving productivity. The collaboration will reportedly combine ABB's expertise in automation and process control with Carbon Re's AI and machine learning technologies. The partnership follows a successful pilot at a cement plant in the Czech Republic, where ABB plans to augment its ‘Ability Expert Optimizer’ solution with Carbon Re's AI platform. This integration is expected to automate and optimise plant conditions, potentially reducing specific energy consumption by up to 5% and increasing alternative fuel use by 50% by maintaining optimal kiln conditions.

CEO at Carbon Re, Josh Vernon, said “At Carbon Re we are accelerating industrial decarbonisation through the use of cutting-edge AI – our models have demonstrated that AI can find efficiencies within the complex chemical processes of material production, especially cement.”

Global portfolio manager for Business Line Digital, ABB Process Industries, Tyron Vardy said “Driving down the emissions of cement production is a pressing priority for the industry. Our collaboration with Carbon Re will bring us closer to achieving this. Enhanced by cloud-based AI technology, our decision support software will be able to help customers enhance and improve the efficiency of their systems faster than ever before.”

Germany: Switzerland-based ABB has acquired analytics equipment supplier Födisch Gruppe. ABB says that the acquisition will enhance its offering of continuous emission monitoring systems and expand its technology and innovation competitiveness.

Stephan Schumann, CEO of Födisch Group’s parent company Dr. Födisch Umweltmesstechnik, said “This acquisition is a testimony of our strong performance in recent years. Leveraging ABB’s global footprint will allow to scale the impact of our offering internationally.”

ABB’s Measurement and Analytics President Jacques Mulbert said “We are very impressed by what the Födisch Gruppe has achieved and are eager to welcome their team to the ABB family. Integrating the Födisch Gruppe into ABB will unlock significant opportunities for new and existing customers.”

Switzerland: ABB and Captimise have enhanced their collaboration, focusing on advancing cost-effective carbon capture, utilisation, and storage (CCUS) technologies in the cement industry. Under a new Memorandum of Understanding, the partnership will develop various studies, including screening, feasibility, and FEED, aiding cement producers to identify efficient carbon capture solutions across their operations. The joint effort is expected to bolster the cement industry's efforts to meet its climate and net-zero targets.

CEO of Captimise, Mattias Jones, said “We draw on a track-record of more than 25 live case studies with CO₂ emitters across Europe and the US and know we’ll be able to support operations of all sizes in cement through combined CCUS, automation and electrification technologies.”

Global Business Unit Manager at ABB Process Industries, Max Tschurtschenthaler, said “Reducing the CO₂ emissions from cement manufacturing is a major challenge and a top priority for this industry. We are on a mission to make it more cost-effective. By combining our world-class automation, electrification and digital technologies with the know-how of partners like Captimise, we can further support the cement industry in achieving their climate and net zero targets.”

Switzerland/Sweden: ABB and Sweden-based Salt X have agreed to develop Electric Arc Calcination (EAC) technology, with ABB also becoming a Salt X minority shareholder. This partnership aims to decarbonise cement production and similar industries by replacing fossil fuel-based heating with renewable energy and CO₂ capture during calcination. ABB will enhance the EAC with control and electrical systems, contributing to the technology's commercialisation.

Salt X CEO Carl-Johan Linér said "This strengthens us as a company and enables us to progress with our growth plans. With ABB and our other partners, we can significantly improve our capability to take a leading role in the electrification wave sweeping through the industrial sector.”

ABB's Global Growth Industries Business Line Manager Michael Marti said, "Our collaboration with Salt X marks a significant milestone in this journey. The technology benefits are two-fold; replacing the use of fossil fuels through renewable electricity in the calcination process and enabling cost efficient capture of the carbon emissions at the same time. It will be a highly effective way of curbing lime production emissions.”

Japan: Tokuyama Corporation has installed ABB’s Expert Optimizer automated optimisation system in the kiln line of its Nanyo cement plant. The system controls the line’s calciner, kiln and cooler processes. The supplier says that the technology will reduce the Nanyo cement plant’s thermal energy consumption by 3%.

Tokuyama Corporation "We selected ABB's Expert Optimizer to equalise operations and improve operational efficiency. As expected, we have significantly reduced the number of the operator manual operations normally spent on manual tasks.” It added “We believe that this solution will also support our young operators in learning the know-how of our operations efficiently."

Finland: Geoprime producer Betolar has named Riku Kytömäki as its new president and CEO. Riku's professional background is in materials technology, having served as president and CEO of Exel Composites and held senior positions in Switzerland-based ABB. Kytömäki holds board positions in several international companies and organisations, including polymers producer Teknikum Group. He has management experience in Asian markets where Betolar has expanded during the past few years.

Betolar said "Riku will lead Betolar through its next growth phase as its Geoprime solution is entering active production. Geoprime is a next-generation, low-carbon solution and sustainable alternative to cement: it delivers 80% fewer emissions and 100% cement-free building materials with the same performance as traditional concrete."