AI Agents for Kiln Reliability & Throughput
Predict kiln, mill, and conveyor failures before they force costly shutdowns. Keep clinker moving with AI agents purpose-built for cement plant operations.
Critical Assets
Coverage across kilns, mills, and material handling
Crushers & Grinders
Raw mills, hammer crushers, and ball mills that reduce limestone and clinker. Agents monitor vibration, bearing condition, and liner wear to prevent unplanned stops.
Kilns & Preheaters
Rotary kilns and preheater towers operating at extreme temperatures. Agents track shell temperature, refractory condition, and drive load to catch thermal stress early.
Conveying Systems
Belt conveyors, bucket elevators, and pneumatic systems moving abrasive material. Agents detect belt degradation, misalignment, and blockage risks across the full material path.
Top Maintenance Challenges
Abrasive, High-Temperature Environment
Cement plants subject equipment to extreme thermal stress and constant abrasion from raw materials. Kiln refractory wears unevenly, conveyor belts degrade from calcium-rich dust, and fans erode - all of which are difficult to monitor with standard sensors.
Continuous 24/7 Production
Kilns and mills run continuously with narrow maintenance windows. An unplanned kiln shutdown can take days to restart due to thermal cycling constraints, making every preventive intervention high-stakes.
Environmental Compliance
Cement operations are regulated by more than 15 state, local, and federal agencies. Maintaining continuous emissions monitoring systems (CEMS) and dust collection equipment is not optional - non-compliance results in shutdowns and fines.
What Our AI Agents Do
Kiln & Mill Health Monitoring
Monitor shell temperature drift, vibration patterns, and drive load changes to detect refractory wear, bearing degradation, and alignment issues before they force an unplanned stop.
- Thermal drift and hot-spot detection
- Vibration trend analysis for bearings and gears
- Drive load anomaly alerts
Maintenance Window Optimization
Schedule preventive work during planned slowdowns and product changeovers. Route tasks to qualified technicians with parts availability confirmed.
- Auto-scheduling aligned to production plans
- Skills-based technician assignment
- Spare parts availability checks before dispatch