Introduction
ABB Ability™ Expert Optimizer (EO) is an advanced process control application that controls, stabilizes, and optimizes various cement processes, helping plant managers achieve profitability and sustainability targets, often with payback in less than six months.
EO utilizes model predictive control, fuzzy logic, and neural networks to optimize cement plants. By coordinating setpoints across different process stages and detecting deviations promptly, EO makes accurate and consistent system decisions. This approach avoids the variations inherent in manual control, minimizing shift-to-shift inconsistencies and reducing operator workload, allowing them to focus on other critical tasks.
- Up to 5% output improvement
- Fuel consumption reduced by up to 5%
- Electricity use reduced by up to 5%
ABB Ability™ CementOptimize Framework
ABB Ability™ CementOptimize is a comprehensive 4-pillar framework designed to deeply analyze all aspects of a cement plant for fine-tuning and optimization. The pillars are: Optimized Solutions, Optimized Engineering, Digital Applications, and Collaborative Services.
With digitalization at its core, CementOptimize employs advanced application libraries, software solutions, and digital platforms to simplify process complexity while ensuring safe and secure production. It provides the right information to the right people at the right time, maximizing reliability, productivity, and energy efficiency across the entire enterprise.
Within the Digital Applications pillar lies ABB Ability™ Expert Optimizer for cement, an advanced process control technology that helps the cement industry reduce costs and increase yields. It optimizes the cement process from material blending to the final product, minimizing consumables and maximizing the use of alternative fuels and throughput.
Applications
The software modules within EO cover kiln optimization, alternative fuel management, mill optimization, and material blending.
Kiln Optimization
The kiln process is inherently unstable due to long time delays and large perturbations. EO stabilizes the process before pushing key controlled variables to their limits. It operates the kiln 24/7, matching the performance of the company's best operator. Depending on the kiln type, EO offers:
- Kiln control module
- Calciner control module
- Cooler control module
| Metric | EO Off | EO On |
|---|---|---|
| Throughput [t/h] | 152.0 | 155.8 (+2.5%) |
| Specific energy consumption [kcal/kg] | 870–880 | 850–860 |
| EO utilization | – | > 95% |
Features
- Burning zone temperature optimization
- Combustion optimization
- Alternative fuel maximization
Benefits
- Reduced number of kiln stops
- Increased yield
- Reduced specific thermal energy consumption
- Reduced quality variability
| Unit | EO on Reduction |
|---|---|
| Temperature variation (Pre-Calciner) | 31% |
| Coal over alternative fuels (Pre-Calciner) | 58% |
| Litric variation (Kiln) | 41% |
| UGP1 variation (Cooler) | 43% |
| UGP2 variation (Cooler) | 30% |
Alternative Fuel Management
Burning alternative fuels can introduce instability into the clinker manufacturing process. EO controls, mixes, and monitors rates of various alternative fuel types to achieve consistent burning, ensuring the kiln remains stable despite changes in fuel calorific value.
Features
- Handling of numerous and complex alternative fuel lines
- Uncontrolled and controlled fuels management
- Ratio or maximize functionality
Benefits
- Maximum utilization of alternative fuels
- Steady energy input
Mill Optimization
Grinding is an energy-intensive process. Optimizing its efficiency significantly impacts a plant's energy costs. EO optimizes coal, raw material, and finished cement grinding by increasing throughput, ensuring consistent output quality, and lowering energy consumption.
Features
- Mill load and throughput optimization
- Fineness control
- Temperature control
- Handling of mill start-up
- Automatic product type switching
Benefits
- Reduced number of mill stops
- Increased output
- Reduced specific power consumption
- Reduced quality variability
Material Blending
Stable and correctly proportioned raw meal is crucial for energy-efficient clinker production. Correctly blended cement ensures customers receive a quality end-product. EO assists in controlling raw material and cement blending.
Features
- Mix control with laboratory samples and/or online analyzers
- Additives control
Benefits
- Reduced fluctuations in blended material composition
- Optimized material costs
- Improved kiln operation due to more homogeneous raw material
Integration with ABB Ability™ System 800xA
EO can be integrated directly into the ABB Ability™ System 800xA distributed control system (DCS) or function as a standalone application, connecting to any third-party PLC or DCS. Integration with System 800xA offers consistent usability and interface with the rest of the control system. Cyber security is enhanced, requiring less hardware for maintenance, and establishing a common historian and information management system.
Model Builder Functionality
The major tools and technologies used are contained within ABB's advanced process control model builder:
- Neural networks
- Analytics
- Model predictive control
- Open/close loop simulation
- Controller diagnostics
- Fuzzy logic
- Soft sensors
- First principle model construction
Other ABB technologies, such as the secure remote access platform (RAP) and KPI monitoring, enhance collaboration between users and ABB, simplifying application maintenance during process and optimization strategy alterations.
Customer-Oriented Delivery
Every plant's advanced process control system must be tailored to its specific production needs. EO provides the flexibility to adapt to each plant, meaning end-users only pay for what they require.
Delivery Options:
- Turnkey Solution: Receive EO integrated with selected ABB applications, including engineering and commissioning, leveraging ABB's proven cement industry applications.
- Software Only: Purchase EO software licenses if you prefer to build your own application.
Users can opt for a single license or a software license subscription, which provides automatic access to the latest functionalities and software improvements at a fixed annual fee.
A Road Map for Successful Installation
- Cement Performance Fingerprint: ABB gathers on-site information to ensure smooth engineering and implementation. Potential applications are identified based on current performance, base level health, and plant economics. A baseline and roadmap for digital applications are then defined, forming the business case for implementation, prioritizing applications with the fastest return on investment.
- Implementation: ABB engineers model the process using plant knowledge, historical data, and step-test data to construct the multivariable controller. The controller is then tuned to exploit plant constraints, maximizing profit and minimizing cost. Commissioning is performed on-site with operators and process engineers to ensure successful change management.
Collaborative Service Offering
With over 20 years of experience in the cement industry and EO deployed in over 200 cement plants worldwide, ABB has a proven track record in sustaining benefits throughout a plant's lifecycle. In today's complex cement production environment, comprehensive expertise is challenging. Therefore, ABB offers several support packages to maximize the long-term performance of your EO installation.
Support Packages:
- System Support: Assistance with hardware faults to minimize shutdown frequency.
- Strategy Support: Maintenance of EO applications for optimal performance, including onsite visits and remote support.
- Full Product Support: Encompasses all above packages, offering subscribers reduced labor day rates.
- Subscription Services (SaaS): Minimizes initial capital expenditure and sustains benefits through ongoing controller maintenance, ensuring a rapid return on investment.
Contact Information
ABB Switzerland Ltd
Local business line Process Industries
Segelhofstrasse 1K
5405 Baden-Dättwil
Switzerland
Phone: +41 58 586 8444
E-Mail: minerals@ch.abb.com
For contact details, please visit our website: www.abb.com/cement
© Copyright 2019 ABB. All rights reserved. Specifications subject to change without notice.
