The deployment of Flir acoustic imaging cameras in cement plants has significantly improved operational efficiency by identifying concealed leaks and potential inefficiencies.
These advanced tools facilitate reduced downtime, lower energy costs, and enhanced performance through their user-friendly operation, precise leak detection capabilities, and efficient reporting methods.
Challenges in the cement industry
The global cement market, valued at $361 billion in 2024, is anticipated to grow at a compound annual growth rate (CAGR) of 5.1% from 2025 to 2032. The demand for residential construction, especially across Asia, has spurred production from 600 million metric tons at the turn of the century to over 2 billion metric tons by 2023.
Previously perceived as costly, care is emerging as a critical strategy for boosting profitability
This remarkable increase brings challenges where unscheduled downtime in quarrying and cement production necessitates a shift from reactive to proactive maintenance approaches.
Previously perceived as costly, maintenance is emerging as a critical strategy for boosting profitability. For large plants with an annual throughput of 1 million metric tons, a single day of unplanned downtime can result in financial losses of up to $300,000.
Precision tools for maintenance
Beyond preventing major failures, regular maintenance helps unearth efficiency flaws that, if unnoticed, might degrade profit margins and competitiveness.
Especially in high-energy operations involving compressed air and industrial gases, pinpointing small or hidden leaks presents a hurdle.
To address this, Flir introduced the Si2-LD handheld acoustic camera. This device, featuring sensitive MEMS microphones, is adept at identifying leaks within compressed air systems. It presents findings on a 12 MP image displayed on a 5-inch, 1280 x 720 colour screen, providing clarity even in complex operational environments.
Inspection in challenging conditions
The camera's bandpass filtering truly isolates leak sounds by letting users select clear frequency ranges
In noisy settings, the camera's bandpass filtering effectively isolates leak sounds by allowing users to select specific frequency ranges.
Capable of detecting sounds from 2 to 130 kHz, the Si2-LD identifies leaks as small as 0.007 litres per minute from distances up to 2.5 metres, and larger leaks from afar.
This facilitates safe inspections in challenging or hazardous areas, including high-temperature zones, safeguarding personnel welfare in the process.
Efficient operation and analysis
Upon completing inspections, the onboard software of the camera efficiently quantifies leak sizes, assisting in prioritising repairs based on energy loss potential, ensuring high-impact issues are dealt with promptly.
Considering potential restrictions on external drives or Wi-Fi access in plant settings, Flir offers a data cable accessory for secure image file transfers without network dependency.
The Si2-LD's intuitive design accommodates the busy schedules of engineers who may lack the expertise to master every new tool. Its "point and shoot" functionality simplifies detection, quantification, and analysis with minimal training. The device includes a durable carrying case, making it suitable for demanding environments like quarries and cement facilities.
Flir acoustic imaging cameras uncover hidden leaks and inefficiencies in cement plants, helping teams reduce downtime, cut energy costs, and boost performance.
With intuitive operation, precise leak detection even in noisy or hard-to-reach areas and smart reporting, maintenance becomes faster, safer, and more cost-effective than ever.
Concern in the quarrying and cement industry
The global cement market was valued at $361 billion in 2024 and is forecast to grow at a CAGR of 5.1% through 2025–2032. Rising demand for residential construction, particularly in Asia, has driven production from 600 million metric tons at the turn of the century to over 2 billion metric tons in 2023 a staggering increase in global demand.
With such rapid growth, unscheduled downtime is a major concern in the quarrying and cement industry. Maintenance was once viewed as a cost centre, often limited to annual shutdowns and reactive repairs.
Now, however, pioneering operators recognise that regular scheduled maintenance is essential for boosting profit margins. In a typical 1 million metric ton-per-year plant, a single day of unplanned shutdown can cost up to $300,000.
Precision leak detection for cement plants
Regular maintenance does more than prevent catastrophic failure. Hidden inefficiencies in plant and machinery can persist for months or even years, quietly eroding profits and competitiveness.
The challenge is identifying these issues—especially in high-energy systems like compressed air and industrial gases, where leaks are often small, hidden, or obscured for operational reasons.
It is for this reason that Flir has developed the Si2-LD handheld acoustic camera. Equipped with highly sensitive MEMS microphones, the camera pinpoints leaks in compressed air systems while displaying a 12 MP image on a 5-inch, 1280 x 720 colour screen.
Safely inspect hard-to-access areas
For noisy environments, the camera’s bandpass filtering allows users to isolate leaks with precision by manually selecting the frequency range, even in challenging industrial settings.
The Si2-LD detects sounds from 2–130 kHz, identifying even the smallest leaks. For example, a leak as tiny as 0.007 litres per minute can be detected from 2.5 metres away, and larger leaks can be located from up to 130 metres.
This allows maintenance teams to safely inspect hard-to-access areas, including high-temperature zones, without risking personnel safety.
Fast, user-friendly operation and reporting
Once an inspection is complete, the camera’s onboard leak size quantification software helps prioritise repairs by potential energy loss, ensuring the most significant leaks are addressed first.
Recognizing that plant environments often restrict external drives and Wi-Fi access, Flir provides a data cable accessory that connects the camera directly to a PC or laptop, allowing easy transfer of image files without network or security issues.
Engineers have also emphasised ease of use, noting that they often lack the time to become experts on every new piece of analytical equipment. Flir has designed the Si2-LD to be intuitive: a simple "point and shoot" operation handles detection, quantification, and analysis with minimal training required. The handheld device comes with a rugged carrying case to protect it in harsh environments such as quarries and cement works.
