One record across every maker: energy per tonne of clinker, every kiln stop, and the evidence behind the emissions report.
Every unit has its own screen and its own clock. Energy arrives as one monthly bill, a kiln stop is pieced together from three trend screens, and the emissions data is assembled in spreadsheets.
A read-only edge reads each unit over the interface it already has. Pragmatos puts them in one namespace with one clock, on the plant's own servers.
Pragmatos does not run or tune the kiln. The control system and the operators keep that. Pragmatos reads, records and shows.
Four results for a plant of this size, each with its inputs on sheet 7. Thermal energy and CO2 are shown, not counted.
A plant like this has two kiln lines with preheater and calciner towers, each making about 2,500 tonnes of clinker a day. Five mills, a fuel yard and five analysers surround the two kilns. Most of it was bought in different decades, from different makers.
| Area | Equipment | Maker | In since | Read path | Where its data lives today |
|---|---|---|---|---|---|
| Raw side | Crusher and stacker | A | 1990s | OPC UA via control system | Control-room trend screens |
| Raw mills ×2, vertical roller | B | 2008 | OPC UA | The mill's own operator panel | |
| Cross-belt analyser | C | 2015 | OPC UA | The analyser's own PC | |
| Kiln lines | Preheater, calciner, kiln ×2 | D | 1998 · 2006 | OPC UA via control system | Control-room trend screens, two generations |
| Clinker coolers ×2 | E | 2006 | OPC UA via control system | Control-room trend screens | |
| Burners and fuel dosing | F | 2021 | OPC UA | The dosing station's panel | |
| Kiln-shell scanners ×2 | C | 2017 | Survey | The scanner's own PC | |
| Gas analysers ×4, kiln inlet and stack, both lines | G | 2014 | OPC UA via control system | Analyser PC, a monthly export | |
| Finish side | Cement mills ×3, ball mills | B · H | 1995 · 2011 | OPC UA via control system | Control-room trend screens |
| Utilities | Main fans and mill drives | I | mixed | OPC UA via control system | Drive panels; the site meter |
| Sub-meters, per feeder | J | mixed | Survey | Read by hand, or not at all | |
| Fuel yard | Alternative-fuel receipts | – | – | Survey | Weighbridge tickets and lab sheets |
Makers are lettered, not named. Survey means the interface survey confirms a read path before scope is fixed. A unit without one stays out of scope until it has one.
The incoming shift reads the paper log, walks the control-room screens, and asks what happened at 03:40. The kiln trend shows the drop and the mill panel shows the trip. The analyser PC shows something else again, and each of the three runs on its own clock.
The night's alternative-fuel deliveries are on a weighbridge ticket in another building. The energy figure for the night does not exist yet: it arrives on next month's bill, for the whole site.
Each of these is an industry-wide pressure, sourced below. In each case the plant has the data, but the data is never on one record.
S1 EU JRC, BAT Reference Document for Cement, Lime and Magnesium Oxide, 2013.
S2 VDZ, Environmental Data of the German Cement Industry 2023, Sept 2024; and S1.
S3 S1, as above.
S4 European Parliament, 18 April 2023; European Commission, CBAM page, 2026; ICAP, 17 July 2026; EU JRC, cement transition mapping, 2026.
S5 EU Implementing Act 2018/2066; Swedish Energy Agency, 26 March 2026.
S6 Destatis, press release N039, 23 June 2026.
A read-only edge on the plant network reads each unit over the path the survey confirmed. The edge holds about 72 hours if the link drops. Pragmatos Live gives every value a name and a timestamp on the plant's own servers.
The edge has no write path. Pragmatos does not set a fuel rate, a fan speed or a feed. It writes nothing back to the kiln, and it closes no loop. Operators and the control system decide. Pragmatos gives them one record to decide from, and keeps it after the shift goes home.
A new refractory lining is heated in stages, with holds, so that nothing cracks. The rollout follows the same pattern. Each hold is a point where the plant checks the record before more is added.
| Weeks | Step | What happens | Who signs it |
|---|---|---|---|
| 0 – 2 | Interface survey | Lists what is measured today and confirms a read path for each unit. Units without a path are named out of scope. | Plant electrical and process engineers |
| 3 – 5 | Line 1 on the record | The edge goes in. Kiln, cooler, burner and gas analysers on line 1 are read, and the tag dictionary is agreed. | Process engineer, line 1 |
| 6 – 9 | Line 2 and the mills | Line 2 and five mills follow. Energy per tonne of clinker runs per line, per shift. | Production manager |
| 10 – 12 | Drives and sub-meters | Electricity is split per mill and fan wherever a sub-meter or drive value exists. | Electrical engineer |
| 13 – 16 | Stops, drift and the month | Stop-cause rules go live once a named engineer approves them. Advisory baselines run on mill and fan vibration. The first monthly evidence pack goes to the environmental team. | Maintenance lead; environmental officer |
Each strip runs like a chart recorder. The pen sits at today's level, then steps to the modelled level with one record, drawn to scale from a zero line at the bottom. Every input is on sheet 7 and can be replaced with the plant's own figure.
Engineer-days a year spent pulling fuel, analyser and production data together for the annual emissions report.
Engineer-hours per stop to line up three trend screens, three clocks and the shift log.
The stops that fall away are repeats of a cause the record already holds, approved by a named engineer.
Site electricity a year. With each mill and fan showing its own kWh per tonne, the plant’s engineers find drives running empty or idling and act on them.
Total, a year, for a plant of this size (sheet 7, Total row). The four do not overlap: R-02 counts only the stops that still happen, and R-04 counts electricity only.
€293,350Energy per tonne of clinker, per line and per shift, sits beside the fuel receipts on the record. That is what a CO2 figure is built from, so the plant sees it every shift. The heat balance of the kiln is the control room’s work, and the model counts nothing for thermal energy, fuel mix or CO2.
| Row | Input or step | Value | Kind |
|---|---|---|---|
| C-01 | Engineer-day, loaded cost | €800 | ASSUMED |
| C-02 | Kiln lines | 2 | ASSUMED |
| C-03 | Clinker per line per day | 2,500 t | ASSUMED |
| C-04 | Operating days a year | 320 | ASSUMED |
| C-05 | Clinker a year = C-02 × C-03 × C-04 | 1,600,000 t | DERIVED |
| C-06 | Clinker factor (clinker per tonne of cement) | 0.78 | ASSUMED |
| C-07 | Cement a year = C-05 ÷ C-06, rounded | 2,050,000 t | DERIVED |
| C-08 | Electricity per tonne of cement (source range 90 to 150) | 100 kWh | S3 |
| C-09 | Site electricity a year = C-07 × C-08 | 205,000 MWh | DERIVED |
| C-10 | Electricity price | €110 / MWh | ASSUMED |
| C-11 | Engineer-days on emissions evidence a year, today | 60 | ASSUMED |
| C-12 | The same, with one record | 20 | ASSUMED |
| C-13 | R-01 = (C-11 − C-12) × C-01 | €32,000 | DERIVED |
| C-14 | Unplanned kiln stops a year = 12 a line × C-02 | 24 | ASSUMED |
| C-15 | Share that repeats a known cause | 25% | ASSUMED |
| C-16 | Repeats avoided = C-14 × C-15, one in three of them (assumed), rounded | 2 | DERIVED |
| C-17 | Output lost per stop | 20 h | ASSUMED |
| C-18 | Clinker per hour = C-03 ÷ 24 | 104 t | DERIVED |
| C-19 | Contribution per tonne of clinker / restart fuel per stop | €25 / €8,000 | ASSUMED |
| C-20 | Cost per stop = C-17 × C-18 × C-19 + restart; R-03 = C-16 × C-20 | €60,000; €120,000 | DERIVED |
| C-21 | Hours to piece together a stop: today / with one record | 16 / 3 | ASSUMED |
| C-22 | Stops still happening = C-14 − C-16 | 22 | DERIVED |
| C-23 | R-02 = (C-21 difference) × C-22 ÷ 8 × C-01 | €28,600 | DERIVED |
| C-24 | Electricity found per mill and fan | 0.5% | ASSUMED |
| C-25 | R-04 = C-09 × C-24 × C-10 | €112,750 | DERIVED |
| C-26 | Electricity found a year = C-09 × C-24 | 1,025 MWh | DERIVED |
| Total | R-01 + R-02 + R-03 + R-04 | €293,350 | DERIVED |
ASSUMED a stated input for a plant of this size; replace it with the plant’s own. DERIVED arithmetic on the rows above. S3 taken from the source listed on sheet 3.
A kiln line outlives several control systems and several suppliers. The record sits in a namespace the plant owns, on servers the plant holds, and reads every maker over the interface it already has. When a unit is replaced, its new interface is surveyed and mapped to the same names on the same record.