ABB in Cement

Cement Industry Solutions...

The Challenge to the Industry
Producing consistent, high-quality cement, meeting
environmental responsibilities, improving process
control, and managing information effectively to
reduce capital employed thats what cement
manufacturing is all about at the dawn of a new
century.
ABB helps you meet these business challenges
by providing automation and power systems that
improve operating procedures and integrate existing
plant equipment. Our experience is unmatched,
with a track record of supplying complete electrication for more than 130 cement plants worldwide.
So, whether you need a single critical component
or a complete turnkey electrication system, look
to ABB as your single source.

Raising Production Standards

ABBs tailored products and services improve

processes and help you achieve optimum
production standards. The automation system
minimizes material and energy use in complex
processes.
Besides improving klinker quality, results
measured in over 170 production lines show an
average of 3% decreased fuel consumption and of
5% increased production.
Protecting the Environment

Each year, environmental regulations get tougher.

And the more stringent the regulations become,
the more money is spent on waste processing and
disposal.
As emissions from cement production decrease
to all-time lows, cement kilns are recognized as
excellent incinerators of waste materials. But
product and operating standards must remain high.
Proactive, exible and adaptive systems are key.
Providing Environmental Safety

High Quality Look

to ABB for process optimization
and control as quality tolerances
get tighter and product diversity
increases.

ABBs Solutions
Boosting Quality

There can be no aws or failures in cement composition, or entire structures could disintegrate.
Advanced information and optimization systems
are needed as never before to monitor and correct
any deviations in quality standards from quarry
to dispatch.

Quarry

For more than 40 years, ABBs environmental

services have helped companies comply with
evolving environmental standards. These services
are being combined with ABB technologies
in process control and optimization, enabling
companies to increase operational efciency as well
as environmental safety.
ABB is working closely with manufacturers to help
them utilize waste products as an energy source
through incineration. The incineration can take
place in the kiln or preheater as a supplementary
fuel. This reduces the cost and consumption of
primary fuel. ABBs expertise and experience helps
manufacturers to maintain stable combustion
conditions while burning a huge variety of waste
products. In partnership with manufacturers we
help in moving them towards their goal of zero
fuel costs.

Raw Mill

for Today and Tomorrow

Process Automation and Control

Cement plants need integrated process control

systems that can increase plant-wide efciency and
productivity. Plants must also manage vital process
and business information if management objectives
are to be met. Investments in automation and
control technology, therefore, must be able to pay
dividends as well as help you meet stringent quality
and consistency requirements.
A Comprehensive Approach

ABB, dedicated to excellence in cement, develops a

customer-specic approach. A full range of p roven
automation and power modules takes you from an
automation island to a complete process optimization and management information system that
drives plant-wide efciency. As pressure builds to
reduce capital employed, ABBs ne process control
and immediate data retrieval capabilities become
the essential tools for reducing silo reserves and
minimizing spare parts inventory. And through
our supply and maintenance contracts, you can be
assured of a long-term partnership with ABB.

Companies utilize
ABBs extensive laboratory
integration systems for
a exible approach to
automated modern sample
preparation and analysis.
Samples are taken at predened intervals and pneumatically dispatched to
the laboratory where they are prepared for analysis.
An ABB robot automatically feeds the individual
preparatory and analysis stations, achieving
handling rates of hundreds of samples per day for
the complete cement plant.
Managing Information

Accurate and timely information for your staff is

critical to achieving greater productivity. Whats
more, the time available to make critical business
decisions continues to shrink. The key is to bridge
the gap between process control and business
control systems.
Information at Your Service

ABB is a leader in providing you with immediate

access to essential information. This is where
our advanced cement information management
solutions help in proactive decision-making. You
have the capacity to access thousands of data points
instantly, when and where it is needed, including
business, nancial, production, environmental,
technical, and quality management information.
With complete access to plant and operating data
from a single window, you can deploy personnel
and resources decisively and effectively.
Customer-Specic Approach Empower the experience in your cement operations with ABBs eld proven
solutions.

Kiln

Cement Mill

Technology Solutions
ABB offers the most extensive
range of products and services
available from any single company serving the cement industry
today.

ABB in Cement
Financial Advisory
Services

Quarry
Gas Insulated
Switchgear
and Industrial
Substations

Primary
Crusher

Transformers,
Switchgear, Static Var
Compensators, and
Harmonic Filters

Motor Control
Centers
Emergency
Power Generation
and UPS

Secondary
Crusher

At ABB, we see your plant and its requirements as a single,

fully integrated entity. We excel at merging equipment,
skills, and services to develop a complete, customized
solution to strengthen your entire operation regardless
of project size. A case in point is our Knowledge Manager,
which provides and condenses huge quantities of relevant
information throughout your business for effective decision

making. You specify the requirements just once, and we

take the responsibility for creating a solution that works
smoothly and efciently. Above all, it is a solution based on
our solid, worldwide eld experience in the cement industry,
bringing you the skills of an engineering team with an extensive commissioning track record.

Environmental
Services for Pollution
Prevention, Hazardous
Waste Investigation,
and Remediation

Infrastructure:
Grounding Lightning
Protection,
Lighting, Cabling,
Communications
Systems, and
Fire Protection

Additives
Limestone / Clay
Filter

Raw Material
Preblending

Raw Mill

Clay

AC Motors and
AC Single Drives

Automated
Robot Supported
Laboratory Systems

Homogenizing
Silos

Process Control and Optimization

Power Distribution

ABB has the depth of industry specic and technological knowledge

and experience to do the job right, the rst time. We offer products and
services that overcome the difculty of combining complex automation
and information systems. With ABB, the process control, optimization
functions, and business information systems are integrated. Solutions
include on-line auto pilots, helping operating personnel meet the
higher quality standards created by plant optimization and information
technology. And with ABBs multi-industry experience, you can be sure
of cutting-edge technology that is proven and effective.

When you need efcient and reliable power distribution in your cement
plant, look to ABB. We offer the broadest range of high, medium, and
low voltage equipment for switching and distributing electrical power
to the cement plant. Solutions are engineered for safety, exibility, and
security to keep operations running day and night, including emergency
power generation and UPS, industrial sub-stations, harmonic correction
equipment, switchgear, and transformers. ABB provides you with stateof-the-art technology to exceed todays rigorous power demands.

AC Multidrives

Coal Mill
Clinker

Coal

Waste Material
and Substitute
Fuels

Cooler
Vent

Exhaust Fan
Clinker Silos

Raw
Material Feed

Kiln I.D. Fan

Kiln

Process Control
Systems and
Advanced
Applications
Software for
Plant Automation

Cooler
Fans

Process Optimization
Systems for Maximizing
Production, Optimizing
Quality and Minimizing
Production Costs

Automated Integration
of Process Data with
Business Systems for
Effective Management

Drives Applications

Services

Selecting the right motor specication for a particular application

requires knowledge of and experience with the process environment.
ABB manufactures motors worldwide, from the sub-kilowatt to the
multi-megawatt ratings of the gearless mill drive. And as the worlds
largest producer of variable frequency and DC drivesvital to modern cement production ABB draws on its extensive cement industry
knowledge to select the best drives to increase the throughput, reliability,
and energy efciency of your operations.

When it comes to service, we focus on helping your company succeed.

After-Sales Services: ABB has an extensive network of service centers to
support your local facilities. Our expert eld engineers are available day or
night to diagnose, repair, upgrade, install, or perform on-site maintenance
for ABB systems and for many other manufacturers products.
Financial Services: Our nancial services organization helps you nd
the most competitive nancing to purchase the equipment you need.
Environmental Services: We offer the broadest spectrum of services for
environmental compliance.

Gearless Mill Drive

Project Management
and Engineering for
Complete Electrical
System Integration
Training, Maintenance,
Repair, Parts, and
Installation Service

Dynamic Air
Separator

Gypsum

Filter

Cement
Silos

Distribution

Cement
Mill

Process
Instrumentation

Gas and Emissions

Monitoring System

ABBs Strength
ABB is a global leader in providing state-of-the-art
technology to cement producers.
While ABB can access the best technology from
anywhere in the world, its strong local presence
provides complete support through the life-cycle
of an installation including engineering, training,
commissioning, service, and support every day of
the year. As a technological leader, ABB optimizes
processes wherever cement is made.
Because of its vast global resources, ABB can
provide you with many advantages, from supplying
a single product to delivering large turnkey electrication for all stages of cement-making, including
such components as distributed control systems,
sensors and instrumentation, drives, and environmental products.

ABB Switzerland Ltd

CH-5405 Baden 5 Dttwil
Switzerland
Phone: + 41 (0)58 586 84 44
Fax:
+ 41 (0)58 586 73 33
E-Mail: process.industries@ch.abb.com
www.abb.com/cement

3 BHT 490 292R0001 REVB (03.06 1500) Pomcanys

ABB is well-positioned to help you achieve industrial efciency and environmental compliance with
products, systems, and services that ensure product
quality, minimize environmental impact, and
reduce production costs.

ABB in Cement

At ABB, we see your plant and its requirements as a single,

fully integrated entity. We excel at merging equipment,
skills, and services to develop a complete, customized
solution to strengthen your entire operation regardless
of project size. A case in point is our Knowledge Manager,
which provides and condenses huge quantities of relevant
information throughout your business for effective decision

making. You specify the requirements just once, and we

take the responsibility for creating a solution that works
smoothly and efficiently. Above all, it is a solution based on
our solid, worldwide field experience in the cement industry,
bringing you the skills of an engineering team with an extensive commissioning track record.

Environmental
Services for Pollution
Prevention, Hazardous
Waste Investigation,
and Remediation

Infrastructure:
Grounding Lightning
Protection,
Lighting, Cabling,
Communications
Systems, and
Fire Protection

Financial Advisory
Services

Process Control and Optimization

Drives Applications

Power Distribution

ABB has the depth of industry specific and technological knowledge

and experience to do the job right, the first time. We offer products and
services that overcome the difficulty of combining complex automation
and information systems. With ABB, the process control, optimization
functions, and business information systems are integrated. Solutions
include on-line auto pilots, helping operating personnel meet the
higher quality standards created by plant optimization and information
technology. And with ABBs multi-industry experience, you can be sure
of cutting-edge technology that is proven and effective.

When you need efficient and reliable power distribution in your cement
plant, look to ABB. We offer the broadest range of high, medium, and
low voltage equipment for switching and distributing electrical power
to the cement plant. Solutions are engineered for safety, flexibility, and
security to keep operations running day and night, including emergency
power generation and UPS, industrial sub-stations, harmonic correction
equipment, switchgear, and transformers. ABB provides you with stateof-the-art technology to exceed todays rigorous power demands.

Services

Selecting the right motor specification for a particular application

requires knowledge of and experience with the process environment.
ABB manufactures motors worldwide, from the sub-kilowatt to the
multi-megawatt ratings of the gearless mill drive. And as the worlds
largest producer of variable frequency and DC drivesvital to modern cement production ABB draws on its extensive cement industry
knowledge to select the best drives to increase the throughput, reliability,
and energy efficiency of your operations.

When it comes to service, we focus on helping your company succeed.

After-Sales Services: ABB has an extensive network of service centers to
support your local facilities. Our expert field engineers are available day or
night to diagnose, repair, upgrade, install, or perform on-site maintenance
for ABB systems and for many other manufacturers products.
Financial Services: Our financial services organization helps you find
the most competitive financing to purchase the equipment you need.
Environmental Services: We offer the broadest spectrum of services for
environmental compliance.

Gearless Mill Drive

AC Multidrives
Project Management
and Engineering for
Complete Electrical
System Integration

Additives
Training, Maintenance,
Repair, Parts, and
Installation Service

Limestone/Clay
Filter
Quarry
Gas Insulated
Switchgear
and Industrial
Substations

Primary
Crusher

Secondary
Crusher

Homogenizing
Silos

Dynamic Air
Separator

Gypsum

Raw Material
Preblending

Filter

Coal Mill
Clinker

Raw Mill
Coal

Waste Material
and Substitute
Fuels

Cement
Silos

Cooler
Vent
Distribution

Clay

Exhaust Fan
Clinker Silos

Transformers,
Switchgear, Static Var
Compensators, and
Harmonic Filters

Raw
Material Feed

Cement
Mill

Kiln I.D. Fan

Kiln

Cooler

Fans

Process
Instrumentation
Motor Control
Centers
Emergency
Power Generation
and UPS

AC Motors and
AC Single Drives

Automated
Robot Supported
Laboratory Systems

Process Control
Systems and
Advanced
Applications
Software for
Plant Automation

Process Optimization
Systems for Maximizing
Production, Optimizing
Quality and Minimizing
Production Costs

Automated Integration
of Process Data with
Business Systems for
Effective Management

Gas and Emissions

Monitoring System