Page 54 - IBT Sept 2021 (1)

CEMENT MANUFACTURING:
Construction Industry BANGLADESH STRIVING FOR
GLOBAL STANDARD

the stages, we ensure that quality is never FLSmidth of Denmark is one of the leading
compromised, and with the implementation technology providers for Cement Vertical
of Level-3 automation, we have the capacity Roller Mill with a long and proven track
to monitor and control operations remotely. record. FLSmidth designed a new cement
Shah Cement has achieved an un-beaten vertical roller mill capable of large-scale
track record of continuous product cement production with a state-of-the-art
conformance to quality standard in all quality management system. They
testing labs for the last 18 years. We have incorporated the most advanced AI and
successfully established a culture of digital technology in their design and were
continuous development in all operation looking for a suitable partner to implement
parameters. These parameters can be the design. Shah Cement decided to partner
fine-tuned to meet specific customer with FLSmidth to commission the world’s
requirements and minimize lead time most advanced and the largest vertical mill
between product ordering to customers in cement manufacturing.
receiving them.
The VRM machine can produce many
How have you shaped the company’s varieties of cement at once. Can you machine and deep-learning algorithms that create their own
Quality Management Policy for Shah and innovation is and will be the key driving factor of the 21st talk us through the options and what understanding of a process by finding patterns in the raw
Cement to become an industry leader? century. Globally leading cement producers have already makes Shah Cement’s cement the process data. They then use this understanding to solve
We believe that we provide a construction embarked on the path to digitalization and are thriving. sustainable choice?
solution to the customers and treat quality Worlds’ biggest building materials companies deployed a The industry is currently facing increasing problems that help improve performance and sustainability
As one practical example of AI at work, the facility's predictive
as “a pursuit of excellence”. Our employees digital solution to derive decisions from big data in their demands for diverse compositions of
are dedicated to quality training in order to facilities spanning worldwide. This digitized solution high-quality cement to cater to different modeling process data signals that are either unreliable or
unavailable – such as real-time clinker quality measurements,
ensure our reputation for outstanding deployment was not only about the production system, but mega projects. Another important aspect of
quality can permeate throughout the also covered day-to-day operations like finances as well. This the new Shah Cement facility is the addition these are then used to create
a more accurate model and
country. Being a market leader for more kind of data-driven decision making definitely benefits the of a multi-compartment silo. This will give
than a decade at a stretch means, we needed rock-solid base for automation and optimizes the production us the flexibility to ensure steady supply of controller of the actual
process conditions.
to work in a way that the customers trust potential. It also massively helps the manufacturers to reduce customized cement formulations to the exact
the quality of Shah Cement and we have waste in terms of money and manpower, which makes them requirement of mega projects without The benefits of AI controlled
operations is an improved
managed to do that successfully so far. more sustainable and eco-friendly. disrupting normal production. The newly
As a manufacturing industry, sustaining Shah Cement is the leading cement brand of Bangladesh and introduced 'multi-compartment silo', together ability to maintain optimal
set points and faster
quality is a major concern in the cement we are bringing breakthrough technology in our cement with the largest VRM in the world, will be
sector. We have heavily invested on production operations through the use of Artificial Intelligence able to produce cement of different response to conditions that
may result in undesirable
international standards for quality (AI) powered Vertical Roller Mill (VRM.). Shah Cement has set compositions according to the different
equipment as well as in-house test facilities the Guinness World Record for the world’s largest vertical requirements in a much more efficient way. situations. AI is opening the
door to create new solutions
to protect the brand value of Shah Cement. roller cement mill in 2019. The OK81-6™ vertical mill, set up in We are proud to introduce the world’s most
Since the beginning we have adopted the Shah Cement plant, was manufactured by FLSmidth of advanced cement technology to the that efficiently offer more
value, to further improve the
latest technology in our production and Denmark. Bangladesh cement market.
quality control system. Added care along The World’s Largest VRM has incorporated the latest The record-winning VRM at Shah Cement is intelligence of our process
ou’ve served Shah Cement for more than 15 years. Can with the technology lead to the discovery advancements in the field of Artificial Intelligence (AI). The equipped with state-of-the-art AI-systems control solutions, which is a
you tell us about the operations you oversee and are in and correction of “bugs” in the production that are guided by data-driven algorithms. big part of our commitment
charge of? Intelligent Monitoring Control System evaluates every stage of With the integrated Intelligence Monitoring to make Shah Cement plant
I look after the total manufacturing operation, starting from system. Investing in training means the production process from a central computer panel. If any System and Intelligent Knowledge Solution, smarter, more productive and
implementing and improvising the vision of the company by investing in quality. Whenever we invest in operation on the machine encounters a problem, the Artificial the cement production at Shah Cement is not increasingly sustainable.
strengthening the leadership; to improve the quality of living training, our employees work more Intelligence will be able to identify the problem and solve it only automated, but also has reduced waste,
across Bangladesh. Shah Cement has always led the way in knowledgeably and efficiently since they with its built-in tools. This superior technology largely increased production and improved product How do Intelligence Monitoring System and Intelligent
new innovations. The newest addition to its efforts is the understand their job and can find ways to eliminates the chance of a human error. This groundbreaking quality. Knowledge Solution help to reduce waste?
World’s Largest Vertical Roller Mill (VRM). improve. Having said that, we always technology ensures consistent and uninterrupted production of The world's largest Vertical Roller miller is also equipped with
In the last 18 years we evolved from a basic Ball Mill to the considered that training begins with people high-quality cement and that makes VRM a revolutionary Tell us about the function of the AI a built-in knowledge solution system. Built-in tools in the
present having state of art AI enabled World’s Largest VRM & in leadership positions. machine. system that is guided by data-driven Intelligent Knowledge Solution keep the VRM updated with the
Horizontal Roller Press. Shah Cement Industries Ltd. is the Tell us about the World's Largest VRM The Guinness World Record holding VRM machine has algorithms. AI is essentially supposed latest best available data through the FLSmidth cloud
largest cement producing plant in Bangladesh, now with a technology and what makes it certainly upped the stakes in the industry – before we to improve operations – are we networks and resource system. It’s guided digitally, by a
capacity of 10 million metric tons per annum. revolutionary? discuss the technology further, can you talk about Shah potentially glimpsing a future of the system coupled with analytics-driven maintenance and
cement industry where the entire
At Shah Cement, safety and quality gets the highest priority. I The futuristic cement plants will be Cement’s technology partner FLSmidth? process can be machine driven and not process-knowledge experts to follow the best course of
am directly involved in the selection and sourcing of raw digital-heavy to ensure sustainability and to For over three decades vertical roller mill technology has been require human intervention? operation and troubleshooting. Any problems faced by the
materials that stand up to the quality we aspire towards. achieve competitive advantages over other recognized across the world for the production of superior These new AI technologies are based on machine can be resolved with no manual intervention which
Through strict monitoring and control of product quality in all market players. Embracing digitalization quality cement and for its efficient energy management. ensures a high run factor.

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