Japan-based Tokuyama Corp has reported productivity and energy efficiency improvements following the deployment of ABB Ability™ Expert Optimizer at its Nanyo cement plant.
The advanced process control system has been commissioned across seven finish mills, comprising four cement ball mills and two vertical mills for pre-grinding and slag, following an initial trial on one finish mill in 2024. Tokuyama said the system has achieved an automatic operation rate of more than 90 per cent.
ABB reported that the technology has increased grinding throughput by three per cent while reducing specific power consumption by three per cent.
Expert Optimizer has also been used for kiln optimisation at the plant since 2022. This application resulted in a three per cent reduction in specific heat consumption and a 70 per cent reduction in manual operator interventions, according to ABB.
The system uses model predictive control and AI to predict process behaviour and automatically adjust operating parameters, including feed rates and mill power.
