Case Study: a S&P 500 cement manufacturing company achieves $600k in annual savings with Seeq Corporation

S&P 500 Cement Manufacturing Company - Customer Case Study

Seeq Corporation worked with an S&P 500 cement manufacturing company that needed to overcome the challenge of controlling free lime levels in its production process. The customer was struggling with delayed lab results for this critical quality measurement, which made it difficult for operators to optimize fuel usage. This issue was exacerbated by the increasing use of varied alternative fuels, leading to potential energy waste and product quality problems that could harm their reputation.

The solution implemented by Seeq involved creating a near real-time soft sensor model that predicted free lime levels based on NOx signals from the process. This allowed operators to make immediate adjustments to the kiln, balancing energy consumption with quality control. As a result of Seeq's solution, the cement plant achieved annual savings of approximately $600,000, split evenly between reduced fuel costs and minimized product loss, while also safeguarding their business reputation.