In cement operations, the reliability of the Vertical Roller Mill (VRM) underpins up to 30% of grinding efficiency and accounts for approximately 25% of plant energy usage. VRMs also enable significant cost savings by reducing energy consumption compared to ball mills.
Hence, ensuring the operational reliability of this asset is critical to achieving the target cost per ton of cement production. Now, even a 24-hour production halt can result in a production loss of $500K (10,000 TPD × $50/ton).
In this case, the cement plant had an output of 10,000 TPD; hence, the role of the VRM unit was essential to achieve this output.
The VRM unit encountered 3 critical anomalies, which were detected on the UptimeAI Expert solution:
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Steady decline in gearbox oil pressure
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Rise in thrust-pad temperature
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Correlated with abnormal lubrication behaviour
Learn how the site team followed UptimeAI’s prescriptive recommendation to prevent a lubrication system failure in this critical asset, restoring optimal flow one week early to avoid production loss.
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