Metals, Mining & Cement

Metals, Mining & Cement -
Dx Transformation in Process Manufacturing

Industry Overview

In the face of rising global demand for raw materials, the metals, minerals, and cement industry faces the challenge of handling dynamic demand patterns while prioritizing environmental responsibility and cost reduction. Digital technologies become a key enabler to optimize processes intricately. AI algorithms analyze vast amounts of data to identify inefficiencies, predict equipment failures, and optimize production schedules, leading to reduced energy consumption, minimized waste, and increased resource efficiency. This fosters sustainable production practices while enhancing operational performances, profitability and ensures competitiveness in an ever-evolving market landscape.

shape-cricle

Dx Opportunities

The convergence of digitization, vast data volumes, and large-scale operations presents an expansive opportunity. Despite the expanding potential, this sector faces disparity between digital aspirations and actual implementation impacting the digital effectiveness. Tridiagonal specialize at implementing these technologies at scale and helps can unlock the full potential of their operations, by driving efficiency, innovation, and environmental stewardship simultaneously.

Energy Management

Leverage predictive models to Improve the energy efficiency and AFR usage to reduce overall carbon footprint of the shop floor operations. Optimize the coal blend for providing optimal combustion to improve the reaction chemistry.

Blast furnace fuel consumption optimization, Aluminum smelter energy optimization, Sinter plant fuel consumption optimization, Air compressors energy management, Burning zone temperature prediction in rotary kilns

Predictive maintenance

Improve the availability, maintainability of critical assets through the digital intervention. Improve the performance of ESP, Cylone separators, Kiln refractory lines and cement mills.

Compressors performance prediction, Predictive maintenance of ball mills, bag house filters, roller press units. Channelling prediction in blast furnace operations

AI Based Inferential

Using non-linear inferential for predicting the feed, fuel and product quality in real time. Prediction of hot metal ferro-alloy composition in the secondary steel making to prediction of clinker and residue quality in cement manufacturing operations.

Inferential for prediction of clinker quality, Fuel / AFR %sulfur prediction, Blaine prediction in cement mills, Internal crack prediction in cast house for metals

Process optimization

Maximizing the production throughput with desired quality specifications in the blast furnace operations and secondary steel making. Enhancing the production of clinker in rotary kiln operations with desired hardness specifications.

Optimization of %return fines on blast furnace, Improving the productivity of blast furnace operations, burning zone temperature prediction in rotary kiln, Improving the throughput of cement mill operations.

Generative AI

Leverage the zero shot and few shots LLMs to interpret and analyze the unstructured dimensions. Integrate the interpretation from quality reports, product compliance report, incident reports and many others for improving the productivity and gaining deeper insights about the operational dynamics.

Alarm report analytics, RCA/Incident reports correlation with real time process anomalies, conversational AI for real-time production information.

Operator Training Simulator (OTS)

An Operator Training Simulator (OTS) is a high fidelity, computer based system that enhances operator skills, safety, and efficiency in complex industrial environments by providing a realistic, risk-free training environment. It ensures operators are well-prepared for both routine and emergency situations, contributing significantly to the overall success and safety of the organization.

Realistic Training Environments, Risk Free Simulations, Scenario-Based Learning, Performance Tracking, Knowledge Retention, Regulatory Compliance are the highlights of OTS.

Use Cases

In the realm of metals, mining, and cement, digital innovations persist as catalysts, helping these energy intensive industries to optimise their process and improve resources allocation in their quest of sustainable production. Below is the list of use cases specific to given that resonates with the actual challenges faced by in mineral processing industry.

Accelerate your Dx transformation projects with Smart Apps and Time-to-value (TTV) program

Integrate ready-to-deploy smart apps with your existing IT-OT infrastructure and scale across plants.

Tridiagonal Solutions launches ‘Process optimization framework’ for manufacturing industry. We optimize processes for energy, efficiency, quality using cutting-edge technology and engineering expertise. From custom column design to process intensification, we're driving innovation for a sustainable future.

Leveraging these frameworks allows the industry to implement the ML models at scale.

TTV A33

Time to Value program leverages advanced scalability frameworks to deliver superior analytics solutions to manufacturing industries. Designed for rapid implementation, our program ensures larger delivery with unparalleled speed and efficiency. By utilizing scalability frameworks, we significantly reduce the time and cost associated for standard approaches. and accelerates deployment, allowing manufacturers to quickly gain insights and drive improvements in their operations. With our program, clients benefit from faster, data-driven decision-making, enhanced productivity, and a swift return on investment, making it the optimal choice for modern manufacturing analytics projects.

Why Choose Us

Why Tridiagonal?

Team new
Team
300+ experts with masters and Ph.D’s in chemical engineering. 
Consulting Expertise
Consulting Expertise
With over more than 30yrs of experience in delivering consulting for operational excellence in this domain.
Solution new
Solutions
Open source-based frameworks for reducing the energy, emission and enhancing the smart plant initiatives.
Engagement models
Engagement models
Flexible options including time and material, dedicated centers, and project-specific arrangements
Value Creation
Value Creation
Deploying best practices and methods to efficiently create and deliver value for customers. 
Multi Skilled Expertise
Multi Skilled Expertise

Team having exposure and expertise of developing scalable solutions across multiple platforms.

Industries

Explore more Industries

Oil & Gas
Oil & Gas
Life Sciences/Pharma
Life Sciences/Pharma
Food, Beverages & CPG
Food, Beverages & CPG
Chemicals & Petrochemicals
Chemicals & Petrochemicals
Power Renewables
Power Renewables
Other Manufacturing
Other Manufacturing

Looking for Trusted Partner for executing your programs?

We bring together unparalleled expertise with combination of skillsets and technology to address your digital, computational and testing needs