Optimize IT Expert Optimizer also delivered substantially better and consistent clinker quality
Baden, Switzerland, Juni 14, 2005 – ABB, the world leader in power and automation technology, announces that it has successfully installed and commissioned an Expert Optimizer system for Holcim in Italy. To leverage its assets and increasing profitability, in March 2004 the Expert Optimizer system was implemented on the Kiln and Cooler at the Ternate plant in northern Italy.
The nominal capacity of the kiln line is 2600 t/d, and the thermal energy consumption is around 3'300 kJ/kg clinker. The kiln system is fired with multiple fuels. Petcoke is the main fuel; while heavy fuel oil can also be used. There are also 4 alternative fuels.
The project goals were to achieve more consistent product quality, higher production rates and higher consumption of alternative fuels. The main difficulties to overcome here were the variability of feed chemistry, the high usage of alternative fuels and plant process stability. Expert Optimizer was tuned to maximise production.
The project commenced with a thorough assessment of the process by the project team from Holcim and ABB, to ensure that the process and project objectives were fully understood and that any underlying assumptions were substantiated. A full review of the available sensor information and user requirements was completed before installation. Expert Optimizer was then commissioned in 2 phases during which close collaboration between the ABB project engineer and the Holcim Process engineer ensured the objectives were achieved.
The measurements taken from an average of 4 months before and 6 months with Expert Optimizer and during a kiln optimization program show the following benefits: the clinker output increased by 8%, C3S standard deviation reduced by 40% and the freelime standard deviation reduced by 25%.
This project shows that ABB’s Expert Optimizer continues to produce value for our customers. It depicts Expert Optimizer as a proven but innovative product, which can boost plant productivity and profit while ensuring satisfaction of the process and environmental constraints.
ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 102,000 people.