Customer story: Cement plant implements MPC platform

Buzzi Unicem USA has deployed ABB’s MPC based Expert Optimizer platform at their Signal Mountain cement plant near Chattanooga, TN.


Buzzi Unicem USA has deployed ABB’s MPC based Expert Optimizer platform at their Signal Mountain cement plant near Chattanooga, TN. This new system now controls the vertical raw mill and cement mill, helping alleviate production bottlenecks in both of these process steps.

Part of a larger plant upgrade project, Buzzi began the installation in September, 2007 and had the system fully commissioned about a month later. ABB reports that both the raw mill and cement mill increased production after the installation, helping improve areas that had historically caused a drag on production. This has translated into an increase in clinker production. Expert Optimizer has also improved process stability by providing a more consistent feed to the kiln.

Both the raw mill and cement mill increased production after the Expert Optimizer installation. Expert Optimizer’s MPC technology helped reduce restrictions by improving the mills’ performance. Scott Henninger, production manager at Signal Mountain reports, “We’ve been really pleased with how the installation went and, of course, with the outcome. Having Expert Optimizer installed with its MPC has been a real improvement to production and the business.”

ABB’s Expert Optimizer advanced process control software helps customers achieve continuous process optimization. Part of ABB’s collaborative production management suite, it coordinates the setpoints of the different parts of the process and immediately detects deviations across an entire operation. By expertly applying MPC, Expert Optimizer is able to stabilize and then optimize the process, which helps plant management to reach profitability and sustainability goals.

—Edited by Peter Welander, process industries editor, ,
Process & Advanced Control Monthly
Register here and scroll down to select your choice of free eNewsletters.

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Choosing controllers: PLCs, PACs, IPCs, DCS? What's best for your application?; Wireless trends; Design, integration; Manufacturing Day; Product Exclusive
Variable speed drives: Smooth, efficient, electrically quite motion control; Process control upgrades; Mobile intelligence; Product finalists: Vote now; Product Exclusives
Machine design tips: Pneumatic or electric; Software upgrades; Ethernet advantages; Additive manufacturing; Engineering Leaders; Product exclusives: PLC, HMI, IO
This article collection contains the 5 most referenced articles on improving the use of PID.
Learn how Industry 4.0 adds supply chain efficiency, optimizes pricing, improves quality, and more.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security