OYAK Cement
OYAK Cement accelerates its energy transition with AVEVA PI System
OYAK Cement brings together five cement companies along with integrated concrete and paper bag businesses in Turkey, Portugal, Cape Verde and West Africa. With electricity accounting for 80% of the industry's costs and energy demand generating 8% of global CO2 emissions, energy management is a major strategic issue. However, the group struggled to collect accurate data from disparate sources and lacked information on critical assets to plan efficiency gains. Deploying AVEVA PI System met the challenge at a remarkable pace, with seven plants equipped in just 100 days, enabling genuine energy optimization. The benefits were immediate: renewable sources have replaced 30% of the fossil fuels used, durably transforming the cement maker's energy mix. Every 1% reduction in energy consumption represents €5 million to €7 million in savings, demonstrating the power of a data-driven strategy.
FAQ
How does AVEVA support the modernization of the cement industry?
The cement industry, which is highly energy-intensive and complex, benefits from AVEVA solutions to supervise its rotary kilns, mills and quarries. For OYAK Cement, AVEVA makes it possible to unify industrial supervision across several sites, optimize thermal and electrical consumption and improve the consistency of clinker quality. This digital transformation is crucial to staying competitive in a sector under heavy pressure on margins and CO? emissions.
Why is energy performance strategic for a cement plant?
Energy accounts for a major share of cement production costs. AVEVA Historian and System Platform allow OYAK Cement to continuously measure the energy consumption of each piece of equipment, identify drift and optimize operating parameters. Cutting a rotary kiln's thermal consumption by just a few percent represents several million euros a year and a significant reduction in CO? emissions, both key issues for the cement sector.
How can an MES ensure consistent clinker quality?
Clinker quality depends on fine physico-chemical parameters (composition, firing temperature, cooling rate). AVEVA MES centralizes process and laboratory data to ensure full traceability of each batch. Operators have real-time visibility into critical parameters and can adjust setpoints to stay within specifications. It is an essential lever for customer satisfaction and a cement producer's competitiveness.
What operational benefits does a cement producer gain from unified monitoring?
Unified AVEVA industrial monitoring gives cement producers a consolidated multi-site view, standardized best practices and faster decision-making. Unplanned shutdowns decrease thanks to predictive maintenance, energy consumption falls through continuous optimization, and quality improves through better control of critical parameters. These gains add up and create a lasting competitive advantage in a highly competitive market.
How does AVEVA support decarbonization of the cement industry?
Cement is responsible for about 7% of global CO? emissions. AVEVA gives cement producers the data tools to measure, model and reduce these emissions: optimized energy consumption, integration of alternative fuels and real-time emissions tracking. These capabilities are essential to reach carbon neutrality targets by 2050 and meet the growing demands of financial markets and environmental regulations.