CONSULTING IN CEMENT INDUSTRY PROCESSES:
We are a multidisciplinary team of senior consultants with over 30 years of experience, specializing in solving critical problems in cement plants. We combine practical expertise in cement chemistry, operations and production, automation, and digitalization. Our approach is not only technical: it is strategic, operational, and applied. We provide solutions that enable informed decisions, increase productivity, improve quality, and reduce operational and economic risks.
CONSULTING SERVICES WE OFFER:
-
Process Evaluation, Studies or Audits for optimization in calcination systems to increase clinker and cement production, reducing specific consumption, through optimizations.
-
Optimization of operating and/or maintenance costs of calcination systems by maximizing their performance and/or production capacity, annual utilization, and operational efficiencies through optimizations.
-
Studies to define the potential production capacities of clinker and cement from the main and auxiliary equipment of the calcination system through optimization.
-
Technical and economic pre-feasibility studies and projects for the expansion of clinker production capacity for calcination systems
-
Supply of calcination system technologies for the production of gray and/or white clinker
-
Grinding and drying systems for raw materials, cement, solid fuels, and dryers for materials or solid fuels.
-
CALCINATION: Induced Draft Fans, Preheaters, Cyclones, Ducts between cyclones, Calciners, Rotary Kilns, Main or calciner burners, Clinker Coolers (Gray or white), gas conditioning systems, Gas dust removal systems.
-
Power and Energy Audits for Cement Plant Optimization.
-
Audits and/or technical-economic studies of heat recovery systems for power generation in the cement industry
-
Consulting on investment projects, from the technical and economic pre-feasibility study phase through the various project phases, such as engineering, equipment and services procurement, construction, commissioning, and start-up, up to warranty and/or performance testing.
-
Conversion of cement plants from burning high-reactivity primary fuels such as natural gas, fuel oil or coal to burning low-reactivity fuels such as petcoke and/or alternative fuels.
-
Consulting in computational fluid dynamics (CFD) analysis.
-
ISO 9001:2015 Quality Systems Audits: Preparation, Implementation, Lead Auditor, and Continuous Improvement.
-
Diagnosis and solution of physicochemical problems in clinker, cement and production processes.
-
Formulation and design of raw material (Raw Mix) based on chemical module criteria (LSF, SM, AM, etc.)
-
Evaluation of raw materials and analysis of their impact on clinker and the final product.
-
Expert support in the transition to difficult alternative fuels, anticipating impacts and avoiding critical deviations in clinkering and quality.
-
Characterized deposits and control by strategic sampling.
-
Comparative analysis of cements for competitive positioning
-
Consulting for increased productivity, operational stability, and cost reduction.
-
Design and remote support for operational technical decision-making.
-
Design and remote support for operational technical decision-making.ctivo.Design an
-
Analysis and evaluation of operational, physicochemical, and quality risks in cement processes, using a preventive and corrective approach.
-
Process automation and digitalization (SCADA, PLC, HMI, Industry 4.0)
-
Quality systems modeling and real-time operation
-
Comparative analysis of cements and formulations
-
Simulation of critical conditions with proprietary tools
-
Implementation of ISO 9001:2015 methodologies
AREAS IN THE CEMENT PROCESS: (We attend to each link in the cement process with a comprehensive vision)
Hammer and cone crushers for primary and secondary crushing in limestone and clay banks
Equipment for park areas (stackers, reclaimers, and sampling towers).
Raw material mills (ball and vertical)
Flow control silo extraction systems.
Rotary kilns (from feeding system to clinker silo), with satellite or grate cooler).
Coke mills (reception, grinding, transportation, calciners and main furnace burners)
Material handling equipment: Clinker and additives (gypsum and pozzolan), up to cement mill hoppers
Cement mills (ball and vertical).
Packaging lines (bagging machines, transport, palletizers, and bulk loaders).
Energy monitoring and control systems, and heat recovery
Equipment for general plant services
Aggregate crushing plants and concrete plants.
Automation, control, and industrial instrumentation
METHODOLOGY
PHASE 1: Initial diagnosis and evaluation - Review of operational and quality data - Identification of critical points in conjunction with the client - Management report with short, medium and long-term projections.
PHASE 2: Planning and solution proposal: - Evaluation of technical and economic alternatives - Work plan by module or system - Conceptual engineering and technical specification
PHASE 3: Implementation and support - Execution of technical activities (in person or remotely) - Automation, operational adjustments and start-up - Validation of results, delivery of documentation and support
APPLICATIONS AND EXPECTED RESULTS
Improving clinkerization factor and thermal efficiency
Stability in the quality of the cement produced.
Reduction of crusts, rings and line interruptions
Successful transition to low-reactivity fuels
Predictive control and intelligent operation with real data (Artificial Intelligence).
Efficient use of raw materials and reduction of variability.
AUTOMATION
