Case Study: Rotary Kiln achieves safer, more efficient kiln operations with SymphonyAI Industrial

SymphonyAI Industrial - Cement Plant Asset Health Solutions

Rotary Kiln, a cement plant operation, faced major asset-health and process challenges in one of the most demanding pieces of equipment in the plant. The kiln’s extreme heat, variable loads, and harsh operating conditions created risks such as gear vibration, gearbox and seal failures, refractory loss, shell deformation, unstable coatings, and unplanned downtime. Rotary Kiln needed a way to improve reliability, safety, and operating efficiency, and turned to SymphonyAI Industrial’s APM360™ for Process Health & Safety.

SymphonyAI Industrial implemented AI-driven predictive models, digital twins, IIoT monitoring, anomaly detection, and automated root-cause advisories to track kiln components, optimize combustion, and support mill quality control with soft-sensing for Blaine estimates. The result was improved thermal efficiency, better control of NOx and CO2 emissions, and stronger asset performance, with reported outcomes including up to 50% fewer safety incidents, 5%–10% lower NOx emissions, 40%–60% fewer unplanned incidents, and potential energy savings of up to $1M annually for a 350–400 TPH cement plant.