Kiln Condition Monitoring at Ambuja Cement Bhatapara Plant, Chhattisgarh
Project 3
Challenges
Unplanned Kiln Downtime
- Frequent mechanical and thermal failures
- Reactive maintenance caused long outages
Limited Visibility
- Manual inspections were slow and lacked precision
- Early-stage issues like shell deformation went undetected
Refractory Failure & Hot Spots
- Thermal cycling and clinker chemistry stressed the refractory
- Hot spots led to emergency shutdowns
High Maintenance Costs
- Frequent refractory replacement and repairs
- Annual maintenance exceeded ₹1.2 Cr
Proposed Solution: AI-Based Kiln Monitoring
Sensor-Based Monitoring – IR shell scanners and accelerometers installed, torque and temperature sensors integrated across kiln line.
Real-Time Dashboard – Data centralized on CMS Dashboard, alerts triggered by vibration spikes and temperature anomalies.
Digital Twin Development – 3D kiln model created with real-time data overlay.
Predictive Maintenance – monitoring and automated reporting for operational and maintenance teams.
Delivering actionable insights Maintenance decisions based on actual condition data, reducing unnecessary interventions.
Benefit and Impact
Downtime Reduction
Unplanned outages dropped by
66%
Maintenance Cost
Expected to decreased by
33%
Efficiency
Improved clinker quality and fuel usage