Why the move from condition monitoring to predictive maintenance is the next big thing in the cement industry?

 

The increasing urbanization in the world has consistently put demand pressure on the cement industry. Consequently, the industry has streamlined its operations from time to time and focused on high-quality throughput. Fortune Insights report says the global cement market will grow from $326.80 billion in 2021 to $458.64 billion in 2028, a steep 5.1% globally. Keeping pace with the rising demand and changing market scenario, digital transformation in the cement industry for efficient operation and maintenance is an immediate requirement. 

While condition-based monitoring has seen wide adoption to support digital transformation initiatives in cement manufacturing, predictive maintenance is shaping to be the next big thing. With plant reliability objectives and operational excellence goals on the line, this shift must happen. In this article, we will compare both technologies and deliberate on why this evolution is necessary for cement manufacturers.

Condition-based Monitoring (CBM) in the Cement Industry


In the cement industry, machinery works under challenging conditions- with fume, gases, dust, and high temperatures. The continuous nature of the cement manufacturing process also ensures that halts in production cannot be without a substantial reason. Thus, routine manual check-ups are sometimes impossible

Asset Maintenance in cement plants is today being practiced using condition monitoring technology. Condition monitoring gives real-time machine working conditions via alerts and allows the maintenance team to take action when the problem is detected. In the cement industry, CBM performs vibration analysis of rotating equipment, oil, grease analysis, thickness measurement of kiln shell and chimney ducting, etc., to examine the assets’ health.

Predictive Maintenance (PdM) in the Cement Industry


The highly competitive & quality-focused requirement of cement plants today means that condition monitoring falls short in many aspects. This gives rise to Predictive Maintenance: a proactive approach to maintenance that uses IoT and machine learning to predict impending machine failure.

Predictive Maintenance solutions consist of hundreds of strategically placed sensors that record data and send it to a central IoT platform. The IoT platform monitors and analyses any anomalies and notifies the plant manager of the equipment’s life. This is a more advanced form of cement plant equipment condition monitoring, providing deeper insights and foresight into machinery health.


To Know more about condition monitoring to predictive maintenance in cement industry: https://www.infinite-uptime.com/why-the-move-from-condition-monitoring-to-predictive-maintenance-is-the-next-big-thing-in-the-cement-industry/

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