The world's first complete cement plant operator training simulator, fully customizable for any plant.
MACSIM is the cement operator training simulator built on your plant and your control system. Operators practice start-ups, upsets and trips on an exact copy of their own control room screens and interlocks, driven by physics calibrated to their own plant, with no risk to production.
MACSIM in action
Six ways MACSIM is your plant, not a generic one
Every value, drive and loop carries your DCS tag.
Redrawn from your DCS screenshots, with their look and feel.
Physics calibrated to your design and plant data.
Your permissives, trips and sequences.
Your raw materials, from quarry to clinker.
Your chlorine bypass design and behavior.
No other cement training simulator replicates your control system 100 %, at a subscription price, delivered in weeks.
Your training simulator is already your plant's digital twin
Most twin projects spend their first year building and calibrating a model. With MACSIM that work is already done for training, and every value already carries your DCS tag. Connect it read-only to your plant historian, and the same model tracks your plant in real time. It never writes to your DCS, and every decision stays with your operators.
Start a session from the plant's real state, or replay last night's upset for review.
Model-based estimates of fineness and clinker quality every minute, between lab samples.
When the plant stops behaving like its model, something has changed: a failing sensor, a blockage, a worn mill charge.
Try a setpoint change on the twin before the kiln or mill sees it, to find fuel and power savings with less risk.
- Stage 1, Replay: load historian snapshots into MACSIM. No live connection needed
- Stage 2, Live tracking: a read-only feed through the DMZ. The twin follows the plant, keeps itself calibrated and runs soft sensors and early warnings
- Stage 3, Advisor: what-if studies and setpoint suggestions, always advisory
What MACSIM solves
New operators learn the kiln on the real kiln, and the rare events that matter most, like start-ups, trips and coating drops, happen too seldom to practice. Mistakes cost production, refractory and sometimes safety.
What it does
- Covers the complete plant: preheater, calciner, kiln, cooler and mills
- Fully customizable to any plant: your screens, equipment and raw materials
- Calibrated to your plant's own history
- Practice start-ups, upsets and trips, and run what-if studies, without touching production
The whole plant, simulated
- Raw mill: feed proportioning, grinding, separator and gas circuit
- Kiln system: preheater, calciner, kiln and cooler, with fuel, draft, burnability and clinker quality
- Coal mill, with drying, inerting and fire protection
- Finish mills: ball mills or VRMs, fineness (Blaine and residue), recipes and grinding aid
- Optional: raw mix chemistry from quarry to clinker, and chlorine bypass
Step by step
- Instructor station: load a plant state, freeze, speed up, and inject any of 100+ faults
- Scenario library, plus scenarios built from your plant's own upsets and trips
- Automatic scoring on 30+ objectives in five groups
- A printable report for every session
What plants get from it
- Faster onboarding of new operators, without learning on the live kiln
- Safe practice of rare events: kiln trips, cyclone blockages, mill chokes, fan trips
- Confident start-ups and shutdowns, step by step with your real permissives
- Consistent crews: every shift trains and is scored on the same targets
- Knowledge kept at the plant: your best operators' handling recorded as scenarios
Simple to run
- Standard Windows PCs, fully offline, with no link to the live DCS
- Annual subscription, with software updates and remote support included
- Plant data kept in a separate, access-controlled package, never shared
From your data to your simulator
10 weeks for the whole plant, 4 for one mill
Flow sheets, best-day data, interlocks and DCS screenshots.
Screens redrawn, logic configured, models matched to plant data.
Plant scenarios reviewed with your supervisors, then factory acceptance.
Installed, site-accepted and handed over to your trainers.
Take it to your team
MACSIM at work
Case studies for MACSIM are on the way. Ask us in a demo about results at plants like yours.
Ask about results →