10 Oct SECIL Group – Sibline Cement: AI/APC Kiln Process Optimizer

ES Processing successfully implemented and commissioned its advanced Kiln Process Optimizer (KPO) at Sibline Cement in Lebanon, marking a major milestone in the plant’s digital transformation journey. The project, featured in the October 2025 issue of World Cement Magazine, showcased how AI/APC-driven predictive control can unlock significant operational and energy efficiency gains in complex Kiln environments.

The KPO deployment at Sibline delivered exceptional, measurable improvements, including:

• Full Autopilot through continuous fully Autonomous operation of the kiln
• Enhanced Kiln throughput by increasing the production by 2% through continuous real-time optimization of key parameters
• Reduction in Thermal Energy consumption by around 1.8% driven by optimized fuel efficiency
• Reduction of Specific Electrical Energy consumption by 2.8% through
• Ensuring a high clinker quality by Stabilizing the C3S at 61 and the FreeLime at 1.5
• Generating a very uniform clinker by a significant reduction of the Freelime standard deviation by 48.5%, and the C3S by 5%
• Substantial reduction in process variability, increasing operational reliability and extending refractory life

This project stands as a reference within the region for the successful integration of AI/APC into pyroprocess operations, demonstrating Sibline’s and SECIL’s strategic commitment to innovation and sustainable performance improvement.