ABB > Case Studies > System 800xA at Indian Cement Plants

System 800xA at Indian Cement Plants

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 System 800xA at Indian Cement Plants - IoT ONE Case Study
Technology Category
  • Automation & Control - Distributed Control Systems
  • Automation & Control - Human Machine Interface (HMI)
  • Sensors - Gas Sensors
Applicable Industries
  • Cement
Applicable Functions
  • Discrete Manufacturing
Use Cases
  • Process Control & Optimization
The Customer
Chettinad Cement
About The Customer
Chettinad Cement as part of Chettinad Group is a major supplier of cement in southern India.
The Challenge

Chettinad Cement recognized that further efficiencies could be achieved in its cement manufacturing process. It looked to investing in comprehensive operational and control technologies to manage and derive productivity and energy efficiency gains from the assets on Line 2, their second plant in India.

The Solution

Chettinad upgraded Line 2 control system to ABB System 800xA, including the latest human machine interface. Drives, motors and transmitters were also employed to ensure safety operation and optimal performance. ABB gas analyzer was used to monitor product quality and nitrogen oxides (NOx), sulfur oxides (SOx) and other gas components compliance. The Knowledge Manager solution was used to manage production and quality.

Data Collected
Asset Performance, Device Diagnostic Status, Energy Cost Per Unit, Process Procedure, Production Efficiency
Operational Impact
  • [Cost Reduction - Production]
    The energy efficiency of production processes was improved, reducing production costs.
  • [Efficiency Improvement - Installation]
    Technicians are able to query instruments remotely during commissioning to confirm device functionality.
  • [Efficiency Improvement - Maintenance]
    Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Quantitative Benefit
  • Energy consumption was reduced by 10% due to the system upgrade.

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