ABB has signed a Memorandum of Understanding (MoU) with Carbon Re, an industrial artificial intelligence provider, to assess ways to accelerate the decarbonisation of cement production while improving productivity. Together, they will explore a joint go-to-market solution for the cement industry, which will potentially unite ABB’s domain expertise and experience in delivering successful global automation and advanced process control (APC) projects with Carbon Re’s advanced artificial intelligence (AI), machine learning (ML) and cement expertise.
Building on the success of an exploratory project at a cement plant in the Czech Republic, ABB will explore opportunities to integrate Carbon Re’s AI platform on top of its existing ABB Ability Expert Optimizer for cement APC solution. Carbon Re leverages AI and ML technologies, which could add continuously updating, cloud-based optimisation software to ABB’s portfolio. With the addition of this AI layer, Expert Optimiser targets – such as post-combustion oxygen to improve combustion efficiency – would automatically be set based on ever-changing plant conditions. These automated adjustments would deliver enhanced operational and energy efficiency benefits.
One of the most pressing challenges in the cement industry is the high energy demand. Kilns are central to the current cement production process, but they are also among the most energy-intensive components. ABB’s Expert Optimiser helps maintain optimal kiln conditions, leading to improved energy efficiency and reduced emissions. It typically reduces specific energy from 1-5% and increases alternative fuel usage by up to 50%. With the addition of Carbon Re’s technology, plants can further reduce their specific energy by up to 5% and increase kiln stability with real-time pyro process optimisation without intervention from the control room operator.
“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,” said Josh Vernon, CEO at Carbon Re. “ABB has led the way in the cement industry for decades, consistently pushing the boundaries of innovation. However, the next set of challenges, including carbon reduction in an increasingly complex production environment, requires a new approach and advanced technology. We’re excited to work with ABB to bring forward the AI-driven solutions necessary to meet the industry’s evolving needs.”
“Driving down the emissions of cement production is a pressing priority for the industry,” said Tyron Vardy, Global Portfolio Manager for Business Line Digital, ABB Process Industries. “Current technology is already making a positive impact; however, to reach the next phase of decarbonisation, new, innovative approaches are required. 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.”
This announcement follows the recent launch of ABB’s ‘Do More With Digital’, a global campaign highlighting the opportunities for the process industries to realise their full potential through digital transformation. In the cement industry, ABB is delivering digital solutions to use less energy and raw materials when producing cement while also facilitating the use of alternative fuels, allowing it to operate with a smaller carbon footprint.
