The collaboration was started with a site audit in October 2014. An ABB engineer visited the Bursa Cimento plant to study the process and evaluate the potential of applying Expert Optimiser to clinker line 1 and two cement mills. In the pyro processing area it was identified that Expert Optimiser would be able to improve the stability of the calciner temperature and the cooler operation with subsequent optimisation of the kiln production and energy consumption.
The potential improvements indicated by ABB convinced Bursa Cimento and the contract to implement Expert Optimiser digital application was signed in September 2015.
In early 2016, two engineers from Bursa Cimento attended an Expert Optimiser training course
to learn the essentials about the technology used in Expert Optimiser and ABB’s approach to control and optimise a cement factory.
Commissioning of the system started end of February 2016. The resistance of the operators was minimal as the system quickly showed benefits, including improving little things that made the operators' life easier. Utilisation factors higher than 90% were already achieved at the beginning of commissioning. ABB implemented Model Predictive Control (MPC) for the kiln 1 and the mills. The MPC approach and results from the practical implementation of MPC application for the cement kiln at Bursa Cement plant will be explained in more detail in the next chapters, with focus on the pyro processing section.