ABB today introduces its tried and trusted ABB Ability™ Advanced Process Control solution to the metals industry, promising accurate modeling of process behaviors to achieve greater process stability, bringing improved product quality, output and cost savings. The solution uses straightforward design and deployment of model predictive control (MPC) and analytics to enable a high level of automation and optimization.
ABB Ability™ Advanced Process Control for metals employs Model Predictive Control (MPC) to create digital twins of many key steel production processes, using process data to predict behavior over time. Acting as an ‘autopilot’, the solution drives the process towards more profitable operation via modeling and optimization techniques. In addition to increased output, improved quality and reduced input costs, the solution also reduces the need for operators to continuously monitor and modify processes around the clock.
“The introduction of ABB Ability™ Advanced Process Control for metals is a momentous development for steel producers, but also a well-established solution demonstrating value for over 20 years in other process industries such as mining, cement, oil and gas,” said Tarun Mathur, Global Product Manager, Metals Digital at ABB. “As one of the very few companies currently providing MPC-based modeling and optimization solutions to the steel industry, we look forward to bringing the benefits of improved resource efficiency, output and quality to our metals customers.”
Part of the ABB Ability™ digitalization portfolio, Advanced Process Control for metals utilizes real-time data from control systems such as ABB Ability™ System 800xA or third-party alternatives using open communications protocols such as OPC (OLE for Process Control).
The solution offers metals producers a customizable toolbox that can be applied to a variety of process applications, which can be developed in line with customer needs. At launch, three powerful APC applications are currently available for metals customers aimed at optimizing performance of:
- Pellet plant indurating machine burners
- Pellet plant dryer
- Raw material grinding mills
Two of these applications have already been deployed at a steel plant in India, demonstrating significant benefits. At the pellet plant indurating machine burner, the customer reports a 15 percent reduction in standard deviation for indurating machine temperature profile, resulting in improved pellet quality and reduced fuel consumption. At the pellet plant dryer, the customer is able to control the outlet temperature more precisely even with large process delays and disturbances in feed rate.
Customers using ABB’s APC solutions in other process industries such as mining and cement, report significant advantages, with data from more than 300 installations indicating typical benefits of 2-3 percent increased output; 1-2 percent decreased fuel consumption; 2-3 percent reduced electricity consumption and reduction in quality variability of between 10- and 20 percent.
For further information about ABB Ability™ Advanced Process Control for metals, please visit https://new.abb.com/metals/digital/abb-ability-advanced-process-control-for-metals
ABB is a trusted partner and leading supplier to the metals industry, offering a complete range of products, services and end-to-end solutions that improve productivity, quality, safety and cost-efficiency in iron, steel, aluminium and other metals production processes. With over a century of experience, ABB’s offerings are expertly tailored and highly process-specific, serving the entire industry from material yard and primary manufacturing to casting, rolling and processing lines. Across the whole metals value chain ABB demonstrates a commitment to optimizing operations with high performance products and digital solutions. www.new.abb.com/metals
ABB (ABBN: SIX Swiss Ex) is a technology leader that is driving the digital transformation of industries. With a history of innovation spanning more than 130 years, ABB has four customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by the ABB Ability™ digital platform. ABB’s Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 144,000 employees. www.abb.com
