More precise quality, less Co₂

The demand for resource-saving and clinker-reduced concretes is increasing, as the most important and resource-intensive component of cement is limestone, the so-called clinker, which is fired at more than 1,400 °C. Its production is not only energy-intensive but also releases considerable amounts of CO₂. Nevertheless, the clinker plays an essential role in the strength of the cement. To enable precise prediction of cement strength as well as closer and more accurate quality monitoring of concrete production, alcemy founders Robert Meyer and Leopold Spenner developed AI-based solutions. This allows production processes to be analysed and optimised.

AI ensures more efficient and climate-friendly cement and concrete production

Both software solutions are based on machine learning with existing data. The AI for cements continuously analyses quality-relevant data from chemistry, mineralogy and particle size distribution. On this basis, the software calculates dynamic target values for the mill control station operator to further improve the uniformity of the cements despite fluctuations in the limestone, granulated blast furnace slag and secondary fuel, for example. The accuracy of the predictions depends on the quality of the data. The AI for ready-mixed concrete predicts the quality parameters of slump flow and w/c ratio in real time during production and delivery. It links plant data such as dosing, temperature and active power with sensor values from the truck mixer such as oil pressure and water level. This provides plant personnel with a transparent overview of the actual concrete status during the journey and on the construction site.

Both AI solutions are a basis for more efficient and environmentally-friendly cement and concrete production and a reduction in the CO₂ footprint of up to 50%, for example by reducing the proportion of clinker in interior components. They therefore make an important contribution to increasing efficiency and decarbonising the industry. They are already being used in over 50 German cement plants and ready-mix concrete plants.

New prospects for sustainable construction

MC-Bauchemie has been working with alcemy since 2024 and is part of the German Sustainable Concrete Leaders Network, which was founded by alcemy two years ago and is intensively involved in the development of sustainable concrete. In joint information events and webinars, MC also shares its experience and expertise in concrete technology, thus underlining its pioneering role in sustainable construction, now also with AI.