The heavy industry sector – particularly cement, steel, chemicals, and paper production – is quietly facing a difficult challenge: how to simultaneously increase productivity, reduce energy costs, and meet net-zero emission targets?
At the heart of this challenge lies the rotary kiln – a massive machine dozens of meters long, consuming tons of fuel every hour. For decades, kiln operation has relied heavily on the manual experience of engineers, leading to instability and energy waste. It is precisely this gap that has paved the way for AI and Advanced Process Control (APC) to become a true game-changer for the industry.
1. Real-time Optimization: The Key to Sustainable Production
The core strength of APC is not about replacing humans, but rather its ability to monitor and adjust thousands of signals every second. AI continuously analyzes pressure, temperature, gas flow, and rotational speed to automatically make numerous decisions that keep the system in its “golden” state – the most optimal condition.
The result is measurable, proven results:
- At a nickel kiln in Asia (ANDRITZ): The implementation of APC reduced fossil fuel consumption by 4-7%, while simultaneously increasing production capacity by 2-4%. Notably, temperature fluctuations inside the kiln were reduced by 40-50%, resulting in more consistent product quality.
- At Bursa Cimento Cement Plant (Turkey – ABB): Thanks to the Model Predictive Control (MPC) system, the plant achieved a 2-3% improvement in both average feed rate and thermal energy consumption. Oxygen levels in the kiln are now controlled at a lower threshold, meaning more efficient combustion.
Looking more broadly, these cases share a common insight: real-time optimization not only saves energy but also “smooths out” the entire production process.
2. The “Double Benefit”: When Economic Efficiency and Environmental Protection Converge
In a context of volatile energy prices and increasing pressure from emission regulations (such as Carbon Border Tax), APC is not just a “green” story – it is a survival issue regarding costs.
For example case study :
- Sappi (Paper Industry – Europe): This group deployed AI to manage energy at its Maastricht plant. Previously, operations relied on fragmented, manual data. Now, the AI platform automates data collection, helping the plant (which both consumes and supplies electricity to the national grid) optimize energy flow in real time.
- CRH Ozarow (Poland – Cement): With a 99-meter kiln – one of the largest in Europe – CRH used ABB’s Expert Optimizer. The goal was not just electricity savings but also increased use of alternative fuels (RDF) – a complex challenge that the human brain struggles to balance continuously. AI solved that problem, burning waste for energy while keeping the kiln stable.
- Borouge (Petrochemicals – UAE): In partnership with Honeywell, Borouge demonstrated a concept for fully automated AI-driven operations. The results showed potential for a 20% increase in efficiency, a 20% reduction in downtime, and a 15% reduction in operating costs.
Despite operating in different industries, the common thread remains clear: AI helps businesses simultaneously reduce costs and reduce emissions – a rare “double benefit.”
3. From “Experience” to “Data”: A Foundational Shift
The core element behind all of the above improvements is the shift from experience-based operation to data-driven decision-making.
If previously engineers had to “read the flame to control the kiln,” now AI uses historical data and machine learning models to predict system conditions 30–60 minutes in advance. This enables:
- Proactive adjustment instead of late reaction
- Continuously stable system operation
- Reduced risk of incidents
Summary from real-world industry deployments:
| Metric | Improvement |
| Energy savings | 2–7% fuel reduction |
| Productivity increase | 2–4% (without additional equipment investment) |
| Temperature fluctuation reduction | 40–50% |
| Operational load and risk reduction | Significant |
Conclusion
APC is no longer an experimental technology – it is rapidly becoming the new standard in heavy industry operations. By combining AI with real-time data, companies can simultaneously achieve three seemingly contradictory goals: increase productivity, reduce costs, and lower emissions. In the context of accelerating digital transformation and mounting pressure to reach Net Zero, APC is truly the game-changer that helps heavy industry redefine how it operates.
