ABB technology helps Wonder Cement to save over 1.8GWh energy annually

ABB technology helps Wonder Cement to save over 1.8GWh energy annually

  • ABB’s Slip Power Recovery System (SPRS) helps Wonder Cement to save up to 15% energy annually, equivalent to the power consumed by over 9,000 households per month
  • ABB Ability™ Condition Monitoring solution tracks the overall energy consumption of the cement plant in real-time
  • The automatic alerts feature enables Wonder Cement to take corrective actions before any downtime issues occur

Wonder Cement, one of the leading cement manufacturing companies in India, installed ABB’s ACS880-based SPRS solution for saving energy, at its manufacturing plant in Chittorgarh, Rajasthan. The plant has three production lines, with a capacity of producing 8 Million Tons Per Annum (MTPA) of clinker.

Slip Power Recovery System guarantees energy savings

The cement manufacturing process is complex, and companies usually opt for big slip ring induction motors to get high starting torque and to meet process requirements. The traditional method uses external rotor resistors and leads to heavy energy loss in the form of resistive heat dissipation. ABB’s ACS880 based SPRS solution plays a very important role in controlling the speed of slip ring motors and helps in achieving significant energy savings. The built-in energy calculators including used and saved kilowatt-hours, CO2 reduction, and money saved, help the customer to optimize manufacturing processes to ensure efficient energy use. The energy optimizer mode ensures maximum torque per ampere, reducing energy drawn from the supply.

“This project is indeed a great example of how we are one of the most trusted partners for customers when it comes to energy efficiency. From the cement sector to food & beverages, and pharmaceuticals, we have constantly promoted technologies that help in driving our carbon-neutral future. Our solutions are helping businesses across India to cut energy expenses and decarbonize their operations, “said Sanjeev Arora, President, Motion Business Area, ABB India.

With the help of SPRS, Wonder Cement saved 1.8 GWh - 2.0 GWh energy annually, which is equivalent to the energy consumed by over 9,000 houses per month.

Digital monitoring for easy maintenance

The SPRS is equipped with the ABB Ability™ Condition Monitoring solution, which helps Wonder Cement to monitor and measure key parameters like humidity, temperature, pressure, current, and fault events. The automatic alerts feature helps the customer to take corrective actions in the early stage to avoid possible tripping. The Bluetooth panel facilitates easy connectivity to mobile devices and helps the manufacturer to have a simple, easy-to-use approach for monitoring historical trends, control speed, and start-stop operation, and access drive information to support commissioning, servicing, and reporting.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation, and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 105,000 talented employees in over 100 countries.

ABB Motion keeps the world turning - while saving energy every day. We innovate and push the boundaries of technology to enable a low-carbon future for customers, industries, and societies. With our digitally enabled drives, motors, and services our customers and partners achieve better performance, safety, and reliability. We offer a combination of domain expertise and technology to deliver the optimum drive and motor solution for a wide range of applications in all industrial segments. Through our global presence, we are always close to serve our customers. Building on over 130 years of cumulative experience in electric powertrains, we learn and improve every day.


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