#Japan #Nippon Steel #ABB #Muroran #Expert Optimizer

Boosting Energy Efficiency and Quality in Cement Production

Nippon Steel’s Muroran plant has achieved impressive results with the introduction of ABB Ability™ Expert Optimizer, a sophisticated process control solution. This innovative technology has enabled the reduction of energy consumption by over 2% while simultaneously enhancing product quality by approximately 10%. This transformation highlights the significant advantages that automation and digital solutions bring to the manufacturing sector.

Automation Through Expert Optimizer

The ABB Ability™ Expert Optimizer automates and optimizes the calcination process, which includes crucial stages like preheating, kiln firing, and cooling. Using Model Predictive Control (MPC), it stabilizes the operational processes effectively, significantly decreasing the need for manual operator intervention. As a result, the automatic operation rate surpassed 90%, leading to an impressive 80% reduction in manual inputs.

This improvement not only streamlines operations but also ensures continuous process control, even during routine maintenance and unexpected operating conditions.

Quality-Driven Results

One of the most notable outcomes of implementing the Expert Optimizer is its impact on product quality. By focusing on critical indicators, such as reducing free lime, Nippon Steel has been able to enhance the production of high-quality cement. Their approach also emphasizes sustainability; they have introduced low-carbon cement that reduces CO₂ emissions by around 40% compared to ordinary Portland cement by substituting a portion of the clinker with blast furnace slag.

A Testament to Innovation

The company’s commitment to advanced automation and reliable technology was further emphasized by Hiroyuki Abe, Plant Manager at Nippon Steel Muroran. He stated, “In our pursuit of carbon neutrality, reducing manual operations and fossil fuel consumption are essential challenges. We determined that ABB Ability™ Expert Optimizer was the optimal solution to achieve these goals, resulting in significant improvements in process stability, clinker quality, and overall operational consistency.”

This narrative of innovation extends beyond immediate operational gains; both Nippon Steel and ABB aim to further develop these advancements to elevate operational excellence even higher.

Supporting Continued Growth

Yasumichi Yoda, Division Manager of ABB's Process Industries Division, remarked on the flexibility and precision of the Expert Optimizer, which allows for advanced process control while alleviating multiple challenges like cost reduction, quality enhancement, and the push for digital transformation.

“Our collaboration to develop effective process models tailored to operational conditions is vital. The ability to improve and update models recurrently adds enormous value,” he emphasized. ABB is committed to supporting Nippon Steel in achieving further efficiency and performance improvement through their ongoing partnership.

ABB’s Global Impact

ABB stands as a global technology leader in electrification and automation, focused on creating a sustainable, resource-efficient future. By marrying engineering with digital expertise, they enhance industrial performance while boosting efficiency, productivity, and sustainability. With a legacy spanning over 140 years and more than 110,000 employees globally, ABB is listed on the SIX Swiss Exchange (ABBN) and Nasdaq Stockholm (ABB).

This partnership is not just a leap for Nippon Steel and the cement industry; it exemplifies how intelligent automation and digital solutions can reshape manufacturing into a more sustainable and efficient endeavor for the future. www.abb.com