Unlocking Real-Time AI in Cement Production: Aignosi and Votorantim Cimentos Advance Clinker Kiln Optimization

TL;DR

We are proud to announce a new step in our journey with Votorantim Cimentos, one of the largest cement producers in the world.

This project is a milestone in applying Industrial AI and real-time inferencing in Operational Technology (OT) to unlock efficiency and sustainability in clinker kiln operations.

From Laboratory Delays to Real-Time Insights

In cement production, the clinker kiln is the most critical and energy-intensive asset. Advanced Process Control (APC), typically based on Model Predictive Control (MPC), depends heavily on timely and reliable data to keep the kiln stable, efficient, and compliant.

Until now, many of these critical variables — such as CO, NOx, and O₂ concentrations in the kiln flue gas — have relied on laboratory measurements or on probes subject to premature wear and downtime. That meant waiting up to two hours for key measurements, limiting the responsiveness of controllers and exposing the operation to inefficiencies and risks.

Enter SIENTIA™: AI at the Edge of OT

With Aignosi’s SIENTIA™ Industrial AIOps platform, Votorantim Cimentos can now deploy virtual sensors that estimate these critical variables in real time, directly within the OT environment.

This unlocks two immediate benefits:

🔹 Real-time inferencing for APC/MPC — controllers no longer need to wait for delayed lab data. Instead, they can use AI-powered estimates every second to stabilize the kiln, optimize fuel efficiency, and reduce emissions.

🔹 Reduced probe wear and maintenance costs — by relying less on physical probes exposed to extreme conditions in the kiln smoke box, the plant extends equipment life and avoids unplanned downtime.

Scaling AI in Cement Production

The true value of SIENTIA™ lies not only in enabling these models but also in ensuring they remain reliable, observable, and governable at scale.

• Models run fully on-premise, respecting the strict latency and cybersecurity requirements of OT.
• Automated retraining and end-to-end observability ensure long-term accuracy and trustworthiness.
• Integration with APC systems creates a closed feedback loop where AI and control engineering work hand in hand.
  

This is not just about deploying one model. It’s about building a scalable foundation for dozens of AI models in cement production, creating a new paradigm for operational excellence and sustainability.

A Shared Vision for the Future

Together with Votorantim Cimentos, we are setting a new benchmark for the cement industry: real-time AI seamlessly embedded in kiln operations, empowering engineers and controllers with insights that were previously out of reach.

The clinker kiln may be centuries old in concept, but with Industrial AI, it is entering a new era of efficiency, resilience, and intelligence.