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Great Lakes cement producer selects ABB Ability™ Expert Optimizer to increase production and reduce fuel consumption through digital optimization

Major cement producer serving Canadian and US customers acknowledges ABB expertise in decision to deploy ABB Ability™ Expert Optimizer to increase production throughout region

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ABB, the technology leader in digital industries will deliver the ABB Ability™ Expert Optimizer solution to a major producer of cementitious materials in the Great Lakes region in 2019.

Key facts

Customer: 

Great Lakes cement producer

Country:

USA

Customer need: 

  • Improve the production and energy efficiency of six cement plants with a production capacity of over five million metric tons
Application
  • The most critical operations in a plant: kilns, mills, coolers and calciners
ABB solutions
Customer benefits:
  • Increased production
  • Reduced fuel consumption
  • Meeting energy usage goals
  • Return on investment in the first year

Good experience with advanced process control strategy

With six plants strategically located to serve Canadian and US customers, and a production capacity of over five million metric tons, the company manufactures a variety of cement for different purposes, as well as other supplementary cementitious products, in bulk and as bagged product.

With this new order, the cement producer seeks to duplicate the success of its parent company which saw significant returns following the installation of ABB solutions.

The cement producer seeks to duplicate the success of its parent company which saw significant returns following the installation of ABB solutions

ABB approach to process optimisation in cement kilns & mills

ABB Ability™ Expert Optimizer, part of the ABB Ability™ digital solutions portfolio, is a computer-based system for controlling, stabilizing and optimizing industrial processes. The solution uses linear and non-linear model predictive control, fuzzy logic and neural networks to find the best operating conditions to maximize output, and can immediately detect deviations among various processes in cement production. This will allow the cement producer to both increase production and reduce fuel consumption to meet energy usage goals.

 

“With our range of Expert Optimizer modules, ABB covers the most critical operations in a plant: kilns, mills, coolers and calciners. For this installation, we have to determine where the customer will see the best performance increase,” remarked Bulent Kolanci, Business Development Manager for the cement industry, ABB in North America. “Once ABB Ability™ Expert Optimizer is installed and operating, the customer should see an immediate impact, and can expect a return on investment in the first year.”

Bulent Kolanci, Business Development Manager for the cement industry, ABB in North America
“Once ABB Ability™ Expert Optimizer is installed and operating, the customer should see an immediate impact, and can expect a return on investment in the first year.”

ABB’s leading portfolio of digital solutions, ABB Ability™, combines ABB’s deep domain expertise with network connectivity and the latest digital technologies to help customers develop new processes and advance existing ones by providing insights and optimizing planning and controls for real-time operations.

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