2013-02-18 - ABB has supplied an integrated electrical, control and instrumentation solution for the largest cement production line and biggest single cement investment in Ukraine. Compared to the six mothballed production lines it replaces, the new line reduces fuel and power consumption by more than 50 and 15 percent respectively.
By ABB Communications
Owned by Ireland-based building materials group CRH, the JSC Podilsky Cement plant is located at Kamyanets-Podilsky in western Ukraine.
The plant’s new dry process production line (Line 7) is the largest cement production line ever built in Ukraine and the biggest single investment ever made in the country’s cement industry. It was commissioned in August 2011 and has a production capacity of 7,500 tons per day.
Line 7 replaces six wet process lines at the plant that are now mothballed. What is remarkable is that Line 7 has almost the same production capacity as the six lines it replaces. It achieves this production feat while reducing fuel consumption by more than 50 percent, power consumption by more than 15 percent, and carbon dioxide emissions by similarly substantial amounts.
Following the successful completion of several other projects at the plant, ABB was selected by CRH in 2009 to design and deliver an integrated electrical, control and instrumentation solution for the new production line.
The solution comprises a vast range of ABB power and automation products and systems, including medium-voltage switchgear, intelligent low-voltage motor control centers, variable speed drives, a plant-wide process control system, manufacturing execution system, instrumentation, gas analyzers, engineering and technical services, and onsite and offsite training.
The Extended Automation System 800xA has proven particularly beneficial to Podilsky Cement’s operations. It seamlessly integrates all the plant subsystems, including those of third-party suppliers, into a fully integrated plant automation system.
Advanced functionality is provided by System 800xA Minerals Library, which delivers operations and maintenance information from all over the plant and real-time visibility into the process. Plant optimization and information management is provided by ABB’s Knowledge Manager.
“From the first steps of the detailed project design through to the intensive commissioning phase, the ABB project team provided professional and dedicated support to Podilsky Cement.”Nigel Reape, Production Director, Podilsky Cement
“Due to the clear structure of the ABB control system and the well-arranged process graphics and faceplates, our operators easily and efficiently learnt to operate our new plant. For us, the new control system is the perfect combination of most modern design and ultimate functionality,” said Aleksey Lavrenyuk, control system manager at Podilsky Cement.
During project execution ABB twice agreed to requests from the customer to accelerate its engineering schedule and delivery times, thereby cutting three months off the contracted delivery time.
Despite the challenging new schedule, ABB’s project team reached all the new milestones and delivered all the equipment and engineering documentation on time, while maintaining ABB’s high quality standards.
“This flexibility in meeting tight deadlines coupled with the ability to provide truly professional installation and commissioning engineers were critical in achieving our project deadlines,” said Nigel Reape, Podilsky Cement’s production director. “It was a pleasure to work with ABB on this project and we look forward to future collaborations.”
to read an article in World Cement on the ABB solution for Podilsky Cement.
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