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News

ABB boosts output at Holcim cement plant

ABB Automation Technologies : 28 June, 2006  (Company News)
ABB increased production at a Holcim cement plant in Italy by an exceptional 8 percent and improved key quality indicators by between 25 and 40 percent, enabling Holcim to recoup its investment in only four months.
The solution, based on ABB's industry-leading Expert Optimizer process optimization system, was installed in the kiln and cooler sections of Holcim's Ternate cement plant in northern Italy. The plant has a capacity of 2,600 tons of clinker a day.

The project goals were to increase production, achieve a more consistent product quality, and raise the plant's consumption of alternative and subsidized fuels like chemical and animal waste products while simultaneously improving process stability.

C3S and free lime are critical for the strength and durability of concrete. A significant reduction in the standard deviation of both substances is proof of process stability and consistent product quality, while lower plant operating costs from using Expert Optimizer result in a payback time of just four months.

Measurements taken after the installation of Expert Optimizer reveal an increase in clinker output of 8 percent, and a reduction in the standard deviation of C3S (tricalcium silicate) and free lime of 40 and 25 percent respectively, indicating improved process stability and more consistent product quality.

By increasing in process stability and consistent product quality, Expert Optimizer lowers the plant's operating costs for a payback time of just four months.

C3S and free lime are critical for the strength and durability (free lime) of concrete. A significant reduction in the standard deviation of both substances is proof of process stability and consistent product quality, factors which lower the plant's operating costs and enable Holcim to consistently meet customer demands for reliable quality.

Expert Optimizer is installed in some 170 clinker kilns worldwide producing more than 100 million tons of cement a year. It is the only optimization system to include expert systems and model predictive control in the same system, thereby providing cement manufacturers with a choice of technologies most appropriate to their needs.
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