ABB has delivered the advanced process control solution ABB Ability Expert Optimiser system to control, stabilise and optimize industrial processes at the Tokuyama Nanyo cement plant in Japan. The equipment enables Tokuyama to reduce about 3% of thermal energy consumption in the kiln as well as maintain operational quality at the Nanyo plant, one of the largest single factories in Japan.

Tokuyama manufactures high-quality cement at the Nanyo plant which has a clinker production capacity of 4,5-million tons per year and supplies customers in Asia and Oceania as well as Japan. The company has invested in an efficient and sustainable factory that manufactures cement, incorporating by-products in the Nanyo plant, as well as raw material waste and fuel substitutes mainly from neighboring areas. All materials are treated in the cement kiln to ensure they are harmless ahead of cement manufacturing.

The device controls and optimises the calciner, kiln, and cooler processes, and will further stabilise production at the Nanyo plant by properly controlling equipment and functions such as induced draft fans, burners, grade speeds, etc., in each process.

It is an industrial software based advanced process control solution that enables and automates the best operational decisions accurately and consistently at all times drawing on linear and non-linear model predictive control, fuzzy logic and neural networks. By coordinating the setpoints of the different stages of the process and immediately detecting deviations among the various operation procedures, the unit helps plant managers to reach set profitability and sustainability goals within significant payback time and typically provides a return on investment of less than six months.

Since commissioning, production has been maintained and thermal energy consumption in the kiln has reduced by 3%. Over the same time, the company has seen a near 70% reduction of operator manual operations and has benefits when cleaning the kiln.

ABB provides tailored automation and industrial software solutions that use real-time data enabling constant monitoring and analysis of process and assets. The ABB Ability portfolio delivers additional value with integrated digital applications for unmatched operation, maintenance, as well as process and production optimization in the cement industry.

Contact Ofentse Dijoe, ABB, Phone 010 202-5105, Ofentse.dijoe@za.abb.com, www.abb.com/processautomation