Case Studies

1) Expert Optimizer Boosts Kiln Output 8% for Holcim Group (pdf)

An ABB OptimizeIT Expert Optimizer was implemented on the kiln and cooler at the Ternate cement plant of Holcim Italy located in northern Italy. Online times of more than 95% have been achieved. Moreover, production increases of 8% plus reduction of quality variability by as much as 40% have been measured by these satisfi ed customers. Operators at Holcim's Ternate plant in northern Italy were involved in the project from an early stage. Project goals were communicated to them and they were given training both before and during commissioning. As a result they soon felt able to take ownership of the system and treated it as a labor saving tool. Their confi dence is shown by online times of more than 95% in the fi rst months of operation.

2) Lone Star Industries (now Buzzi Unichem) Doubles Capacity via Electrical Refit (pdf)

Demand-beyond-capacity created the need to nearly double the facility's production – from 750,000 TPY to 1.3 million TPY – maximize uptime, and introduce a new cement-making process to the U.S. A decade of upgrades leading to the massive '99-'00, $75 million expansion included the addition of new motors and the installation of 40 ABB Variable Frequency Drives on new and existing motors throughout the entire plant.

3): Glenn o'Hawbaker (pdf)

Hawbaker was challenged with constructing the new limestone mining and production plant to fulfill a 10- year contract to supply a local power plant with high-calcium carbonate pulverized limestone. The limestone is part of a clean-coal technology the power plant uses to neutralize the sulfur dioxide emissions as part of the burning process of waste coal. The limestone will contribute to a 75% reduction in smokestack emissions. Reliability and up-time were the key concerns for Hawbaker. It is required to meet the power plant's contract of 750,000 tpy (tons per year) of pulverized limestone to avoid fines and penalties. In addition, the plant is located near a residential area, where production is limited by restricted operation of 12 hours per day, five days per week. Consistent, reliable production is crucial, as there is no opportunity to make up production on eekends.

4): Taiwan Cement (pdf)

In the past, cement manufacturers, including TCC, have used DCS solutions Rockwell Automation's Logix technology based solution for cement roduction process offers 60% faster reaction time, 30% less program time and 50% less cost than the previous DCS alternative. to control the cement production process in their facilities. But TCC came to realize it needed a steadier, more flexible, more cost effective system for one part of the process in particular.

TCC also determined that DCS reaction time – the responsiveness between the operation console and the control system – was too long and low for its purposes. Further, the company was vigilant to prevent any flaw in production quality – which could potentially affect its cement market share. In order to maximize throughput and consistency, and maintain the highest quality of cement, TCC needed a new control system.