cpmPlus Expert OptimizerDesigned by process experts, customized to your needs

Global Product Group Cement, CPM Cement

ABB’s CPM portfolio for cement industries

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Economic Process Optimization

Thermal Energy Electrical Energy

-Performance Indicators-Production Performance-Costs

SAP

QMPMPP-PIMM/SD

Control

Knowledge Manager

Production Information Mngt.

Production Accounting

Production Scheduling

Enterprise Connectivity

Information

Process Data Mngt.

Process Control

LaboratoryAutomation

Quality

Robotics

LIMS

Downtime Mngt.

Expert Optimizer

Kilns, Calciner & Cooler

Mills Optimization

Alternative Fuels

Stockpile Blending

Raw Mix Preparation

Cement Blending

Your challenges

Need for optimal productivity

Need for reduced energy consumption

Shift-to-shift variations

Variable raw material and fuel quality

cpmPlus Expert OptimizerABB’s advanced process control solution for your cement plant

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Our solution

Advanced Process Control solution providing you with modern tools, such as Model Predictive Control, graphical program editor etc.

Pre-defined modules covering the entire cement process

Your benefitStabilize then optimize

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Prod

uctio

n R

ate

Manual setpoint

Manual

Optimized setpoint

Optimize

Stabilize

Automatic using Expert Optimizer

Benefitsdue to

optimization

Time

Fuzzy algorithms to create multivariable controllers

Soft sensors to estimate hidden variables or create back-up signals

Linear and non-linear Model Predictive Control (MPC) capabilities

Graphical and empirical modelling

Easy to use graphical configuration

General calculations: arithmetic, Boolean, text etc.

State Machines

Windows-based HMIs: Drag & drop configuration

Technology in cpmPlus Expert Optimizer

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Expert Optimizer toolsAPC model builderGraphical control builder

Fuzzy algorithms MPC engine

Arithmetic and logic operations Soft sensors

Graphical MPC models (linear and non-linear)

Empirical models from data sets

Data processing

Soft sensor models

cpmPlus Expert Optimizer Cement applications

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Kiln, calciner and cooler control

Stockpile blendingRaw material

blendingRaw mill control

Cement mill control

Cement blending

Coal mill control

Features

Burning zone temperature optimization

Combustion optimization

Alternative fuel maximization

Output optimization

Kiln, calciner and cooler optimizationFeatures and benefits

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Return to overviewBZT

Operator

Outputor Freelime

Freelime vs BZTOutput vs BZT

Output

EO

Benefits

Reduced number of mill stops

Increased output

Reduced specific power

Reduced quality variability

Features

Mill load and throughput optimization

Fineness control

Automatic product type switching

Supports vertical mills, ball mills and hybrid circuits

Material grindingFeatures and benefits

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Return to overview

Mill fill

Mill output

Output

EOOperator

Benefits

Reduced number of mill stops

Increased output

Reduced specific power

Reduced quality variability

Features

Mix control with laboratory samples and/or online analyzers

Optimization of material costs

Maximization of additives in finished cement

Material blendingFeature and benefits

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Kiln

Middle termfluctuations

Short termfluctuations

Short termfluctuations

"Zero"

Quality

Long termfluctuations

Quarry

Pre-blending bed Feeders Raw Mill Continuous homogenization silo

Benefits

Reduced fluctuations in blended material composition

Reduced material costs

Improved kiln operation due more homogeneous raw material

Return to overview

Typical values we deliver to customer

Increased output1% to 5%

Reduced fuel consumption1% to 5%

Reduced emission levels3% to 5%

Reduced electricity consumption1% to 5%

Reduced quality variability10% to 20%

Reduced refractory consumption10% to 20%

cpmPlus Expert OptimizerA reliable solution for increased productivity

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