The customer magazineof ABB in India,
Middle East & Africa
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contact
ABB to power new steel plant facility in Nigeria 07Automation solutions optimize mining project in Chile 10Minerals Remote Monitoring Center 12Improving plant uptime and productivity 18Turbocharging solutions for better performance 24Breakthrough order for DC technology 26
Process solutions for core industriesCement, Minerals and Mining
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ABB to power new steel plant
Facility in Nigeria
Local News05 Energising Thembelani 2 Shaft at Anglo
Platinum
07 ABB to power new steel plant facility in Nigeria
Global news08 Improving productivity process at Podilsky
Cement, Ukraine
10 Automation solutions optimize mining project
in Chile
Cover feature12 Minerals Remote Monitoring Center
14 MiRMC architecture
In focus 16 Tourah Portland Cement Company gets a
System 800xA upgrade
18 Improving plant uptime and productivity
Events24 Solar takes centre stage at WETEX 2012
exhibition in Dubai
25 Flagship technology showcased at major
trade show held in Doha
For a better world26 Breakthrough order for DC technology
27 Turning electronic scrap into gold
Glimpses of ABB28 Building a nation – ABB congratulates UAE for
40 years of success
Table of contents
07 12 Minerals Remote Monitoring Center
High-end integral service offering for mineral
industry
Contact, customer news magazine from ABB, © 2012, web: www.abb.co.in, email: [emailprotected], Publisher: ABB Group, Layout: Adsync, Bangalore, India, Cover picture: Overview of Podilsky cement plant, Ukraine.
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25
28Building a nation
ABB congratulates UAE
for 40 years of success
turned a deaf ear to the protests of local
communities about resource extraction
activities in the “second scramble for
“Africa”, with nationalisation and a neo-
colonial practices as common cause.
A common thread among these
scenarios is the assumption that
developing countries will be the source
of much of the world’s supply of
minerals. While the reaction of global
leaders varied, the impact of climate
change could not be escaped.
This issue of CONTACT, features
glimpses of some the solutions that
have been used across these sectors.
From optimization solutions in some
of the world’s biggest cement plants
to enhancing customer experience
through service contracts, ABB is well
positioned in South Africa to support
the industry.
We have illustrated some of these
successes and hope that you fi nd this
issue of the magazine an interesting read.
Best regards,
Carlos Poñe
Dear friends,
The World Economic Forum recently
launched a scenario planning project
with the objective of answering the
question “How will the environment for
the global mining and metals sector
look in 2030?” The report produced by
more than 200 leaders from business,
government, academia and non-
governmental organisations – makes for
fascinating reading.
The three scenarios the group
focused on, were selected because,
based on the critical uncertainties
identified by the group, they were not
only very divergent, but all three were
highly relevant.
One scenario, called the Green
Trade Alliance, was based on an alliance
of countries united by the common
vision of “environmental sustainability
without compromising competitiveness”.
A second scenario was built on a 2030
where the geo-political and -economic
influence of Europe and North America
have shifted towards a global landscape
defined by the influences from a wider
range of political and economic centers
of power. The third scenario explored an
environment where governments have
Carlos Poñe
Country Manager
South Africa
Flagship technology showcased at major trade show held in Doha
Olympian event of the oil and gas Industry
From the country manager
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Local News
Anglo American Platinum Limited is a
member of the Anglo American plc Group
and is the world’s leading primary producer
of platinum group metals. The company
is listed on the Johannesburg Securities
Exchange (JSE). Its mining, smelting and
refining operations are based in South
Africa. Elsewhere in the world, the Group
owns Unki Platinum Mine in Zimbabwe
and is actively exploring in Brazil. Anglo
American Platinum has a number of
joint ventures with several South African
consortia as part of its commitment to
the transformation of the mining industry.
Switchgear for Styldrift
In September 2008, Anglo American
Platinum established in partnership with
community-based investment group Royal
Bafokeng Holdings, a new South African
Rand (ZAR) 10 billion mine at Styldrift, in
the North West Province. Bulk earthworks
started in March 2009 and extended over a
Driving new levels of performance at Anglo Platinum
17-hectare footprint. Styldrift is processing
230,000 tonnes of Merensky reef a month,
utilising a new twin shaft system, sunk to
a depth of 740m, and a new concentrator.
In January this year, ABB was awarded a
10 million ZAR order for double bus bar Air
Insulated Switchgear (AIS) for the Styldrift
Shaft. “We have been part of the Styldrift
project since its inception as we tendered
for and were awarded the contract for the
supply of Unigear Switchgear for the first
phase of the project in 2009,” said Per
Wanland, ABB’s Key Account Manager
for Anglo American. “The new contract for
the supply of air insulated switchgear is a
critical part of a new development at the
main consumer substation of the Styldrift
shaft. While this will be the first time we
supply AIS at this shaft, I am proud of
the fact that ABB is the sole supplier of
switchgear at this critical Anglo American
Platinum operation.”
For more information: www.abb.com/mining
Sole supplier of switchgear to world’s leading producer of platinum group metals (PGMs)
Styldrift: Double Drum Service Winder
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Local News
Energising Thembelani 2 Shaft at Anglo Platinum
ABB was awarded an order valued
3 million ZAR for a new 33kV substation
at Anglo American Platinum’s Thembelani
2 shaft project in Rustenburg in South
Africa’s North West province.
The original substation installation at the
Thembelani 2 Shaft was successfully
completed by ABB and, based on
their satisfaction with its performance;
the customers continued the project
by extending the substation with ABB
equipment. “We enjoy working with Anglo
American Platinum, their expansion plans
are visible, enabling us to do forward
planning to deliver against their project
timelines” said Per Wanland, ABB’s Key
Account Manager for Anglo American.” The
medium-term mining profile for Rustenburg
is predicated on a series of phased decline
extension projects to existing shafts.
Between 2014 and 2020, the production
profile will be maintained by using either
two or three intermediate vertical shafts.
The Thembelani No 2 shaft is the first of
these vertical shafts.
The first blast for construction of the
ventilation shaft took place in September
2006, while construction of the men-and-
materials shaft began in September 2007.
The Thembelani 2 project includes a
downcast vertical men-and-materials shaft,
and an adjacent matching vertical upcast
ventilation shaft, which will intersect the
existing horizontal connections. It also
involves the extension of the existing
declines at the Thembelani 1 shaft project.
For more information: www.abb.com/mining
Customer satisfaction leads to 33kV substation order
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Mine hoists to improve efficiency in new mine
South Africa currently accounts
for about 75% of the world’s
identified manganese
resources, mostly found
in the Northern Cape Province near
Hotazel. The country was the world‘s
largest producer of manganese in 2011,
producing 3.4 million tons.
Steelmaking, including its ironmaking
component, has accounted for most
manganese demand, presently in
the range of 85% to 90% of the total
demand.
Kalagadi Manganese (Pty) Ltd, a
company held by ArcelorMittal (50%),
Kalahari Resources (40%) and the
Industrial Development Corporation
(10%) is involved in the exploration for
Manganese in the Kalahari Basin, in
South Africa’s Northern Cape Province.
The company holds new order mining
rights on three farms believed to home
to some 960 million tons of manganese
ore and about 100 million tons of mineral
resources.
Full commissioning of the mine is
scheduled for the third quarter of 2012.
In February this year, the final blast for
a 300m underground mine shaft was
completed, keeping the company on
track to achieving its mid-2012 three-
million-ton run-of-mine production target.
ABB has been awarded a 28.4 million
ZAR order by Kalagadi manganese mine
at Hotazel in the Northern Cape province
of South Africa, to supply two double
drum hoists and other mechanicals.
“We will supply a new 3.6m double
drum hoist and refurbish a 5m double
drum hoist. Our scope for the new hoist
entails full mechanical engineering for
the drums, shaft bearings, basplates,
brake units and clutches, as well as
bearing lubrication and hydraulic braking
systems,” said ABB’s Mike Davis, Mining
and Minerals Business Development
Manager.
The refurbishment project will
involve the upgrade of the mechanical
equipment including re-metalling of the
bearing, conversion of the brakes to disc
brakes and installation of a new bearing
lubrication system and a new hydraulic
brake system.The hoist project is
planned to commence in the final quarter
of 2012, while the mine itself will begin
commissioning in the third quarter.
The 3.6m hoist will serve as
the mine’s men-and-material hoist,
which will be used to transport mine
personnel and material underground.
The larger 5m refurbished hoist will
Mine hoist to serve as men-and-material hoist
be the production hoist, used to hoist
ore from underground. The 5m hoist
served in another significant project in
Switzerland, where ABB supplied the
hoisting, electrical and control equipment
for the great St Goddard railway tunnel,
commissioned in 1999.
“We are proud to be associated with
this model project, supporting the mine
with our technical expertise in hoisting
solutions. Our contribution will ensure
safe and efficient transportation of
people and material,” said Carlos Poñe,
CEO of ABB South Africa.
Kalagadi Manganese founder and
chairperson Daphne Mashile-Nkosi
recently emphasised in a public address
the importance of government support
for development projects such as the
Kalagadi Manganese project, and the
need for the internalisation of South
Africa’s resource wealth.
“I am glad to see that government
realises the importance of partnering with
various stakeholders in the economy to
drive the developmental agenda. This is
a role that government is well positioned
to play to ensure the mobilisation of our
resources,” she said.
For more information: www.abb.com/mining
Local News
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Local News
ABB to power new steel plant facility in Nigeria
ABB is to provide a Static Var
Compensator (SVC) for Sagamu
Steel Nigeria Limited, part of the
Sunflag group, an Indian multinational
specializing in Automobile grade Steel.
The scope of work involves providing
an SVC along with the Electric Arc
Furnace (AEF). A steel plant based on
Electric Arc Furnace (EAF) metallurgy
requires a stable and steady voltage
supply for optimum performance.
Simultaneously, an EAF is a heavy load
on the grid, injecting disturbances back
into the grid, unless proper mitigating
measures are taken. By installing an
SVC, it is possible to instantaneously
compensate the random load variations
characteristic of an arc furnace
operation. The outcome is an overall
improvement of the utilization of the
furnace, and hence improved process
economy.
ABB has a unique knowledge of
Electrical Arc Furnaces compensated
by an (SVC). The company has more
than 30 years of satisfactory operation
of Static Var Compensators. In the early
70’s the first SVC was commissioned for
an electric arc furnace, which has been
followed by a number of successful
installations. Over the past decades
ABB has supplied more than 400 SVCs
in more than forty countries. The supply
to Sagamu Steel would be the first in
Nigeria.
For more information: www.abb.com/metals
Static Var Compensator along with the Electric Arc Furnace to be supplied for optimum performance
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Global news
Enhancing industrial productivity at gas plant in Abu Dhabi
ABB has won an order from Saipem
S.p.A. and Samsung Engineering Co.
Ltd., to provide a range of power and
automation equipment for a natural gas
processing plant in Abu Dhabi, United
Arab Emirates.
The plant is located in the Shah
natural gas field, southwest of Abu
Key technology to ensure operational safety and reliability
Dhabi city, and has a daily production
target of one billion cubic feet of sour
gas or high sulfur gas. Abu Dhabi is
developing its sour gas reserves as
domestic power consumption soars.
The hydrogen sulfide content of the gas
must be reduced to acceptable levels
before it can be used.
ABB in Italy and ABB in South Korea
will supply low voltage switchgear,
intelligent motor control units and
variable frequency drives (VFDs).
“This order is the end result of a
successful ‘One ABB’ collaboration
between different local teams,”
said Tarak Mehta, head of ABB’s
Low Voltage Products division.
“ABB technology for remote control
systems is crucial in order to ensure
the functionality and the integration
of low-voltage switchgear in modern
production plants.”
The safety of personnel and
equipment reliability are key issues
for this plant and played a significant
role in the awarding of this contract.
ABB’s MNS low-voltage switchgear
uses remote control systems and
multifunction protection relays that
make it the benchmark for operational
safety, reliability and quality.
For more information: www.abb.com/oilandgas
An overview of Podilsky plant, Ukraine
Improving productivity process at Podilsky Cement, Ukraine
ABB has successfully commissioned
its integrated electrical, control and
automation systems at the largest
cement production line in the Ukraine.
Owned by international building
materials group CRH, the plant is
located in Kamyanets-Podilsky,
approximately 420 kilometers southwest
of Kiev and started operation in the
1970s. The new production line
No. 7 is part of a plant modernization
that replaces the existing production
lines while maintaining the plant’s 7,500
tonnes daily capacity, making it the
largest cement production line in the
Ukraine.
The modernization project helped
the plant decrease the emissions from
fossil fuel combustion by changing the
technology of cement production from
a wet production process to a state-of-
the-art dry production process. The new
process uses considerably less fuel,
with lower emissions of particulates and
CO2.
For this project, ABB delivered
integrated electrical and automation
systems that include medium-voltage
switchgear, intelligent low-voltage
motor control centers,variable speed
drives, instrumentation, gas analyzers,
collaborative production management
systems, and a plant-wide 800xA
automation system to control, connect,
and optimize the performance of all
processes, systems and equipment.
ABB also provided design, engineering
and site services, training, and
procurement of third-party equipment.
For more information: www.abb.com/cement
New production line to achieve high energy effi ciency, product quality, while reducing environmental impact
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Electrical equipment contract awarded by Masan Resources’ Nui Phao mine in Vietnam
ABB has been awarded a contract
to supply the majority of the electrical
equipment for Masan Resources’ Nui
Phao mine. The Nui Phao mine is located
approximately 80km northwest of Hanoi
in the Dai Tu District of Thai Nguyen
Province in Northern Vietnam.
Masan Resources, a division of the
Masan Group, one of the largest private
companies in Vietnam, is developing
the Nui Phao mine, which is a unique
polymetallic mine with reserves of
tungsten, fluorspar, bismuth, copper and
gold. The mine is positioned to be one
of the most cost-effective producers of
tungsten in the world.
ABB will supply and provide
commissioning for a comprehensive
scope of electrical equipment, including
automation and drives systems for the
mine. The equipment and system design
for the project will minimize impact on
the surrounding power network, and
increase both efficiency and productivity.
Reliable performance of the system
is critical to the safety and financial
success of the mine‘s operation. ABB‘s
proven maintenance, lifecycle support
service and expertise in delivering
systems were important factors in
securing this contract.
For more information: www.abb.com/mining
A panoramic view of the Nui Phao mining site
Rio Tinto mines in Australia to boost production via power infrastructure
ABB has won orders worth around
$100 million from Rio Tinto for 17
distribution substations to support
increased production at iron ore mines
in Western Australia.
The upgrades and installation of
new power infrastructure will raise the
voltage level of the existing distribution
substations and increase the power
supply to support the expansion of
existing iron ore mines in the Pilbara
region.
Urbanization and economic
development in emerging markets is
fueling demand for steel, for which
iron ore is the main component. Steel
is widely used in the construction of
bridges, railways, ships, cars, buildings,
Global news
Power and automation equipment will help increase mine effi ciency and minimize impact on the surrounding power network
and other infrastructure and industries.
ABB’s scope of supply includes
electrical switch rooms, switchgear,
cables, power transformers and
ring main units. ABB will also deliver
a range of components including
SCADA (Supervisory Control and
Data Acquisition), and protection and
communication equipment compliant
with the IEC 61850 global standard.
This will enable remote monitoring and
control of power assets located at
multiple sites, from Rio Tinto’s Remote
Operations Centre situated in Perth,
more than 1,000 kilometers away.
As part of the contracts, ABB is
responsible for the design, engineering
and supply of equipment needed
for the upgrade and installation of
new electrical infrastructure for the
substations. The projects are scheduled
for completion by 2013 and form
part of the customer’s multi-stage
Electrical Infrastructure Replacement
(EIR) project. ABB has successfully
completed several similar projects for
Rio Tinto in the past.
Rio Tinto is a global leader in the
exploration, mining and processing
of minerals and metals, including
aluminum, copper, diamonds, energy
products, gold, industrial minerals and
iron ore.
For more information: www.abb.com/mining
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Automation solutions optimize mining project in Chile
ABB won an order worth $43 million
to deliver three gearless mill drive
systems, plus related automation and
power infrastructure equipment for a
new copper mine to be operated by
Minera Quadra Ltd., in Sierra Gorda,
Chile.
Minera Quadra is a Chilean
subsidiary of Vancouver-based Quadra
FNX Mining Ltd.
Located in the Atacama Desert
region of northern Chile, the new open-
pit mine will produce 111,000 tonnes
of copper per day, with significant
molybdenum by-products, for the next
20 years.
ABB’s delivery will help the mine
to optimize its overall efficiency and
productivity. Its gearless ore-crushing
mill drives are more reliable and
energy efficient than traditional mill
drive systems, providing increased
productivity.
The scope of supply for the project
consists of three 17 megawatt gearless
mill drive systems, related automation
equipment and systems, as well as
remote and diagnostic monitoring
systems that include earthquake
detection, and related engineering
and installation services. ABB will also
provide power infrastructure equipment
such as transformers, containerized
electrical-rooms to house electrical
systems, auxiliary distribution, and other
electrical equipment.
For more information: www.abb.com/mining
Gearless mill drive systems to optimize production at Minera Quadra’s new copper mine
Global news
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Turning Lisbon’s waste into energy
One-fifth of Portugal’s waste is processed and converted into electricity at the Valorsul waste-to-energy plant, Portugal
Located on the outskirts of
Lisbon, the plant recovers the
solid waste of 19 municipalities
in the capital and western
Portugal, and turns it into 50 megawatts
of electricity – enough to meet the
needs of a large city.
Looking for ways to reduce the
energy consumption and CO2 emissions
of the plant, Valorsul identified six fans
with a high energy saving potential:
three induced draft (ID) fans and three
secondary air fans.
In waste-to-energy plants, ID fans
and secondary air fans are an important
part of the combustion process. The
latter supply secondary air to the
boiler to combust the fuel, and ID
fans remove the flue gases as exhaust
during combustion. ID fans in particular
consume large amounts of electrical
energy. The method by which the fans
are speed-controlled has, therefore, a
major effect on energy consumption and
operating costs. Prior to the installation
of the ABB solution, the fans were
controlled by dampers, which is the
least energy-efficient control method
available.
By replacing the dampers with an
ABB variable speed drive solution,
Valorsul considerably reduced fan
energy consumption and carbon dioxide
emissions, and gained a number of
other significant benefits as well.
The ABB solution comprises three
ACS 2000 medium voltage drives, three
ACS800 low voltage drives, and UniMix
medium voltage switchgear for line
supply connection and backup bypass
for the variable speed drives. The ACS
2000 variable speed drives - rated
at 700 kW, 6.4 kV - can be directly
connected to the line supply and do not
require an input isolation transformer.
Prior to the installation of the ABB
solution, the average daily energy
consumption of the fans with damper
control was 153.6 megawatt-hours. The
variable speed drives have reduced this
by 9 MWh to 144 MWh, which equates
to €240,000 ($320,000) a year at a tariff
of €0.80 ($1) per kWh.
Lower energy consumption means
lower carbon dioxide emissions. The
drive solution has reduced the plant’s
CO2 emissions by about 4.5 tonnes
a day – a significant reduction to the
plant’s carbon footprint.
The ABB variable speed drives
have also improved process control.
The air flow can be controlled more
accurately, faster and reliably than
with dampers. Other benefits of the
drive solution include lower investment
and maintenance costs, reduced
footprint in the electrical room, and
smooth integration with existing plant
infrastructure.
For more information: www.abb.com/betterworld
www.abb.com/drives
Global news
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Minerals Remote Monitoring CenterHigh-end integral service offering for mineral industry
Cover feature
Minerals Remote Monitoring
Center (MiRMC) is an
offering from ABB for the
minerals industry to provide
remote monitoring, periodic patch,
release updates and modification of
the plant operating systems. MiRMC
integrates process consultancy service
with remote diagnostic services for
processes and systems.
MiRMC facilitates customers to
collaborate with ABB experts to achieve
improved quality and cost effectiveness.
A step-wise process in which the key
data is monitored by ABB experts
remotely, thereby predicts potential
problems and resolves errors. MiRMC
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offering includes system upgrades and
maintenance, periodic patch and release
updates, system status monitoring,
system modification and enhancements,
loop performance monitoring and
tuning, process consultancy (Cement
Performance FingerPrint), access to
global knowledge repository, 24x7
service support and training.
The remote service offering reduces
redundant maintenance, improves
production efficiency, tracks causes
of failures, provides fault diagnosis
and recommends specific actions for
smooth work flow. It also notifies about
impending failures which in turn helps
in initiating proactive corrective actions.
The benefits of MiRMC include, but
are not limited to lower operating cost
enhanced plant availability, maximized
production and improved quality.
ABB experts will have access
to plant distributed control system
(DCS) through a secured network,
this ensures security. The system
will be managed by competent and
certified resources through a secured
environment with SSL encrypted
connection to plant system. Actricity
tool based case tracking and unique
service ID generation are some other
features of MiRMC. MiRMC also has
well defined automated workflow, plant
access through approved work permit,
audit trail for complete traceability and
knowledge management for re-use.
Across the globe ABB has an
installed base of more than $100
billion of automation products and
systems, hence is constantly working
on achieving flawless product support
for ABB customers. Remote service
developments are directly proportional
to clients’ ever changing demands.
MiRMC plays a significant role in cost
saving and offering an exhaustive
review of procedures and process
implementation.
For more information: www.abb.com/minerals
Cover feature
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Cover feature
MiRMC architecture
ABB’s customer
Internet
Virtual support engineer (Local application)
Centralized server
ABB solutions for the Industry
SpectraFlow
SpectraFlow is an online bulk
material analyzer for belt conveyors
powered by ABB’s SOLBAS™
technology. SOLBAS™ technology is
the innovative application of the well
known Near Infra Red (NIR) concept
to the analysis of bulk material online.
Fast and accurate chemical analysis
using Near Infra Red (NIR) i. e. the
wavelength range from 700 to 2500
nanometers is a well established
method in the petrochemical, food and
pharmaceutical industry.
The SpectraFlow analyzer helps
plants in better and longer use of the
quarry, less variation in the raw material
feed, reduced need for corrective
material and smoother mill operation.
Its benefits in the analyzer operation
include online analysis of secondary
materials, long lifetime of the source
because the lamps are operated at
80 % of their rating, high stability of the
FTIR, low cost of ownership and low
analyzer maintenance.
Cement Performance FingerPrint
Cement Performance FingerPrint
is a process optimization and energy
consulting service designed to capture,
analyze and improve operational
performance and energy efficiency
of cement making process. This
process ensures tuning of plant control
system efficiently, benchmarked to
industry best practices. It also offers
a systematic approach in capturing
the process sensitivity using plant
step tests, building a dynamic process
model, analyzing site constraints and
identifying improvement opportunities.
Cement Performance FingerPrint
provides plant benchmarking with
industry standards, plant variability
study, control loop performance report,
process performance analysis, energy
efficiency potential and access to best
practices.
Knowledge Manager Cement basic
report package
The Knowledge Manager cement
basic report package is an entry
level production reporting system
which is cost-efficient and fast to
implement. Knowledge Manager
enables to achieve operational
objectives by monitoring and managing
manufacturing processes. It also
provides analytical insight to identify
best practices that will improve overall
operation.
The highlights of this report
package are fast implementation and
startup, cost-efficient installation,
basic calculations that fit the cement
industry, standard reports across all
plant sections, minimal customization
requirements, extendable with more
cement report package.
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Cover feature
EMS Overview screenshot
Energy Management Solution (EMS)
EMS is a set of software solutions
for the cement and minerals Industry,
where ABB has extensive experience
in developing and supplying energy
management solutions. EMS aims to
reduce energy use and costs, while
improving the company’s overall
carbon footprint. Energy Management
solutions can achieve an overall cost
reduction of 2 to 5 percent of the total
electrical energy bill.
In EMS customer sites are
modeled as an Economic Flow
Network with a number of balancing
areas interconnected by connection
points that model the transfer and
conversion of energy and material. The
total consumption or outbound flows
of the utility in the balancing area is
balanced with other supply resources,
or inbound flows. Depending on the
objectives of a specific case, the
resources are selected to minimize
the total energy cost or to maximize
the total profit of the operation
over a specified time range. Energy
Management Solution helps in lowering
electricity purchase prices due to
Loop Performance Manager (LPM)
LPM provides a powerful, yet
extremely easy-to-use, collection of
software tools that control engineers
and process operators will find
useful to start-up, diagnose and
maintain control loops. LPM supports
a wide variety of commercial PID
(proportional–integral–derivative)
control block algorithms, as well as
various configuration options available
for those PID algorithms. By combining
data collection, model identification,
feedback tuning, feed forward
tuning and controller simulation in a
single user interface, ABB delivers a
complete tool and removes the barriers
preventing optimization of regulatory
layer.
The benefits include extended
equipment lifetime, improved energy
efficiency, increased process capacity,
fewer plant trips and higher as well as
more consistent product quality.
cpmPlus Expert Optimizer
cpmPlus Expert Optimizer helps
improve productivity, energy efficiency
and profitability by stabilizing and
optimizing the process involved.
cpmPlus Expert Optimizer extends
the capabilities of control system
by coordinating actions on the
process, such as rotational speed,
fuels, valves or chemical additives.
It maximizes efficiency by looking at
the interactions among variables and
deciding according to the plant goals.
It collects real-time data, processes
it with mathematical algorithms and
coordinates the plant actuators for
accurate consumption plans, avoiding
price peaks and penalty charges and
in employing optimal resources in the
supply of electric power.
optimal performance.
The features of cpmPlus Expert
Optimizer include advanced process
optimization techniques, such as
Model Predictive Control (MPC), Fuzzy
Logic and Neural Networks Flexibility
to handle the process requirements
of different industries with different
business objectives, user-friendly
modeling environment in which the
process engineer does not have to
get in to the mathematical complexity
of the optimizer along with a modular,
reusable and scalable design to reduce
deployment time.
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In focus
Tourah Portland Cement Company gets a System 800xA upgradeProven technology in control systems coupled with training help customer in improved plant continuity and productivity
System 800xA is ABB’s flagship automation solution
A complete Cement Mill Control
System modernization was
commissioned by ABB at
the Tourah Portland Cement
Company Plant # 2 with high level of
plant modernization solutions like Lock
Out Tag Out System (LOTO System)
which took the safety to higher level
and SMS functionality which increased
plant availability via keeping the plant
managers updated on time with any
stoppages / alarms for immediate
corrective actions.
The Tourah Portland Cement
Company is Egypt’s first cement
company with 66.12% owned by Suez
Cement Company. Suez Cement owns
approximately 30% of grey cement
market share and 50% of white cement
market share in Egypt making it one
of the largest cement producers. The
solutions were implemented in its
mill no. 11. Prior to the upgrade, the
company was using obsolete BBC
control systems.
ABB provided complete engineering
solutions on turnkey basis which were
incorporated during the shutdown
window at the facility. The scope of
solutions include System 800xA with
AC800M, work stations and screens,
LOTO System, LCD, Padlocks Holder,
Padlocks and Bar Code Scanner
System, SMS functionality engineering,
activation and communication modems.
The company is familiar with ABB
control systems and was pleased with
the level of detailing and involvement
by ABB engineers including hands-
on training and safety procedures and
operational training. In addition to the
supply and commissioning which was
implemented on time, the customer will
stand to benefit from long-term technical
support for their assets as well as ready
availability of spares.
For more information: www.abb.com/cement
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In focus
Unique mining solution brings out the best results
Key benefits
- reduced wear and tear of the
buckets
- energy saving
- avoidance of overload trippings
- optimum use of the BWE
- increase in machine availability
time
The excavation component itself is
a large rotating wheel mounted on a
boom. On the outer edge of the wheel
are a series of buckets. As the wheel
turns, the buckets remove soil or strata
from the target area and carry it around
to the rear of the wheel, where it falls
onto a conveyor, which carries it up
the arm toward the main body of the
excavator.
Discharge conveyor carries it further
and discharges it on the overland
conveyor. The most favourable soil and
strata conditions for BWE operation
are soft, unconsolidated overburden
materials without large boulders.
ABB partnered with ThyssenKrupp
Industries India Limited, the original
equipment manufacturer (OEM) for
the project, to develop the unique
ABB has used its global expertise
in automation solutions for open
pit mining and material handling
to provide a unique, custom-built
automation system for a bucket wheel
excavator (BWE) for Neyveli Lignite
Corporation Limited, in Tamil Nadu.
ABB Cottbus, Germany is the MTC
(Main Technology Center) for open pit
mining. ABB Cottbus supported for
this bucket wheel excavator project, by
providing the Continuous Mining Motion
Control program, which is used in the
Variable Frequency drives. Also ABB
Cottbus has deputed their experts for
commissioning of the various drives.
ABB introduced a variable frequency
drive (VFD) ACS 8004Q for the bucket
wheel application, which significantly
reduced the wear and tear of buckets
and optimizes energy consumption
in the operation of the machine. The
indigenously developed solution was
implemented in record time and helped
boost the performance of the bucket
wheel. Bucket-wheel excavators are
pieces of heavy equipment used in open
pit/ surface mining, especially for lignite.
It is a continuous excavation machine
capable of removing up to 3430 cubic
meters of soil / strata per hour.
Bucket wheel excavator at Neyveli Lignite Corporation Limited
automation solution. ABB’s scope
included composite solutions spanning
engineering, manufacturing, supply,
erection supervision, testing and
commissioning of machine electrics,
drives, motors, automation system and
field instruments.
Electrics comprised HT switchboard,
transformer, motor control centers
(MCC) and cables for the complete
machine.
The automation system included
AC800M controller, S800 IO’s and
process panel. Communication with the
remote IO’s, process panels and field
devices is through Profibus network.
The solution was designed
after detailed studies, analysis and
simulations. The objective of the
application software designed to
operate the system was to ensure even
loading of the conveyor belt, minimize
idle operation and form stable slopes.
ABB’s application engineering team
developed the application programme
including the automation of the entire
process of soil excavation. This software
seamlessly directs the bucket wheel to
follow the optimal track, thereby helping
the operator to enhance its productivity.
For more information: www.abb.com/mining
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In focus
Improving plant uptime and productivity
ABB has recently provided Cement
Mill Control System for Shah Cement
Industries Limited, Bangladesh. This
includes high level of plant modernization
solutions like 33kV indoor substation,
switch boards, distribution and convertor
duty transformers, LT PCC and MCC,
variable frequency drives, LT and VFD duty
motors, HT capacitor, automatic power
factor control and 800xA based AC800M
distributed control system.
Comprehensive design, engineering,
supply and commissioning solutions
on turnkey basis were done by ABB in
line with customer requirements. The
scope of solutions include 800xA DCS
with AC800M, servers, workstations
and screens along with all electrical
equipment. ABB has also provided hands-
on training in safety procedures and
operational training. In addition to the
supply and commissioning, the customer
Shah Cement Industries Limited, Dhaka, Bangladesh
will benefit from long-term technical
support for their assets and ready
availability of spare parts.
Shah Cement, located at Dhaka, is
one of the pioneer cement companies
in Bangladesh. Shah Cement has a total
plant capacity of 6 MTPA and has about
16% market share.
For more information: www.abb.com/cement
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In focus
Tapping into Oman’s sturdy construction sector
The Annual Oman Construction
Summit held in Muscat saw key players
in the construction sector gather together
to discuss the major construction and
infrastructure projects in the Sultanate.
Executives from all over the region were
able to interact with executives from ABB
and understand how the company can
contribute to the sustainable future of
Oman with leading edge, energy effi cient
technology solutions.
With a strong focus on climate
change and relative energy challenges,
a sustainable and effi cient future was
seen as the need of the hour. For ABB,
the challenge is to reduce energy
consumption while always maintaining
capacity where it’s needed.
ABB is well-equipped to improve
on tomorrow’s infrastructure. An
infrastructure that encompasses all the
key elements of a dynamic society:
airports, ports, roads, water supply and
sewage disposal, track-bound systems,
tunnels and public buildings such as
hospitals, sports arenas, shopping malls
and residential housing.
At the summit Tarek Zakaria, ABB
regional manager for KNX Building
Technology in Middle East and Africa,
shared insights on the modern green
building technology at a panel discussion
on ‘Reviewing Oman’s Regulations,
Standards, and Specifi cations Summit’.
“With greater demand of dependable,
energy effi cient solutions for infrastructure,
green building has become to focus
globally and also in Oman. ABB systems
and products are designed to save energy
the easy way; for example our intelligent
building control system KNX system, is
one of the most energy-effi cient building
automation systems on the market.
The ability to control energy-intensive
functions, such as air conditioning
and lighting in each room, is reducing
signifi cantly power consumption and
carbon dioxide emissions in buildings “,
explained Zakaria. KNX system improves
comfort, energy effi ciency and security
for example in hotels, public buildings or
skyscrapers where energy consumption is
traditionally very high.
The Construction Summit and joint
exhibition saw over 300 visitors consist of
Omani government offi cials and industry
professionals across the region.
For more information: www.abb.com/industries
Gulf’s premier event on construction and investment opportunities
KNX system improves comfort, energy efficiency and security in hotels, public buildings or skyscrapers
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In focus
For more information: www.abb.com/metals
Enabling JSW Steel to manufacture steel at competitive price
JSW cold rolling mill facility, Bellary
Visit ABB YouTube channel to watch
the video
www.youtube.com/abb
ABB has equipped the JSW cold
rolling mill, the most modern CRM
plant in the world at Bellary, with its
latest technology. The CRM plant is
equipped with modern automation,
drives and control systems. ABB in India
was the sole supplier for automation
and drives for this green-field project
which consists of continuous pickling
line (CPL), compact cold mill (CCM),
electrolytic cleaning line (ECL), skin pass
mill (SPM) and two recoiling lines cum
tension leveling lines (RCL).
ABB solutions helped the CRM
plant to improve yield and productivity
of processing lines, improved surface
quality and finishing, better roughness
transfer reducing turnaround time,
accurate tension control, enhanced
strip defect inspection to log surface
defects and production planning and
management through modern MES
system.
JSW Steel Ltd., with a capacity
of 10 million tonnes per annum is
a major player. It is India’s second
largest steelmaker and boasts of
the most modern, eco-friendly steel
plants with the latest technologies
for both upstream and downstream
processes. It is also one of the lowest
cost steel producers in the world. ABB
has prepared the CRM with advanced
drive and automation technology. The
drives control is based on the patented
Direct Torque Control or DTC concept,
providing dynamic performance in terms
of torque and speed accuracy. The
high torque accuracy and dynamics
of the drives used in combination with
mass flow control leads to extremely
fast correction times of process
disturbances and exceptional thickness
quality. ABB power system and
drives consist of ACS 6000 family of
medium voltage drives based on IGCT
technology, coupled with synchronous
machines for accurate torque control for
the compact cold mill. Medium Voltage
switchgear system, LV distribution, and
UPS system were also supplied in this
project.
ABB has standard software modules
for rolling mills, consisting of total
integration of automation functions
based on ABB 800xA control system.
ABB has also provided the Level 1 and
Level 2 automation system to integrate
the plant. Level 1 control system for
mills is based on 800xA which is highly
flexible and scalable ABB DCS solution
and level 2 consists of production
management and process control.
In close collaboration with JSW
Steel Ltd. and other suppliers, ABB
in India ensured a rapid plant start-
up by supporting it with the advanced
automation systems. Ensuring that the
CRM plant was commissioned within
a record period of 24 months, it has
presently a capacity of producing 10
MT per year cold rolled coils. On an
average 350 coils are manufactured per
day. The consistent cold rolled quality
has enabled JSW to produce steel at a
very competitive price catering to the
automotive and process industries.
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In focus
ABB will manage, develop, implement and execute the entire maintenance function at the plant
Full Service contract for Oman aluminum rolling mill
Agreement will ensure best practice maintenance and increase plant reliability
ABB won a contract worth $9 million
from Oman Aluminum Rolling Company
(OARC) to develop, implement and
execute all maintenance activities at the
company’s rolling mill plant in Sohar,
Oman.
The greenfield aluminum rolling mill
will produce flat sheet and aluminum
foil with a capacity of 140,000 tonnes
per annum and will primarily serve the
Middle East and European markets.
The projected completion of the plant
is expected during Q3 2013 when the
plant will commence operations.
“We look forward to having ABB
as a partner in the new rolling facility.
ABB brings experience in Oman and
gives us access to their global rolling
capabilities of ABB for maintenance
services and rolling technology support.
The agreement is performance based
and provides both parties incentives
for success. OARC and ABB will
work jointly to provide a high rate of
Omanization within the maintenance
work force which is in the interest
of our shareholders,” says Buddy
Stemple, chief executive officer of Oman
Aluminum Rolling Company.
Through the ABB Full Service
concept, ABB will manage, develop,
implement and execute the entire
maintenance function at the plant
including all mechanical and electrical
maintenance regimes, shutdown
management, planning and scheduling
and reliability maintenance.
“Our innovative approach to
performance-based services ensures
improved production and equipment
performance, energy efficiency and
reliability for the entire facility,” says
Saeed Fahim, country manager for ABB
in Oman.
ABB’s renowned global expertise,
tools and methodologies will assist
OARC in allowing a successful start up
of the plant. The agreement involves 55
ABB employees directly and will start in
June 2012 and continue for a minimum
5 year period.
For more information: www.abb.com/service
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Bringing increased effi ciency to the Southern Hemisphere’s largest coal project
Industrial IT System 800xA Extended Operator Workplace
Through its electrification and automation contract, ABB is making a huge contribution towards coal projects commissioned by Vale, the world’s largest iron-ore producer
Vale - the world’s largest iron
ore producer - significantly
raised its initial production
target for its Moatize coal mine
in Mozambique, expecting to quadruple
initial targets by the end of this year.
Ships emptied of iron ore in Asia are
now filled with coal in Mozambique
for return journeys to Brazil and other
steelmaking markets.
It is believed that some of the
world’s richest coal deposits are located
in Moatize in the Tete Province of
Mozambique – 2000 kilometers (1,250
miles) north of the capital Maputo. With
a targeted production volume of 12
MTPA of hard export co*king coal and 2
MTPA of export thermal coal, the mine
brings much needed economic growth
to the region, as does the upgrade of
rail and port facilities. Moatize, which
employs 7,500 workers, transports
its coal along a 600-kilometer railway
line to the port of Beira in central
Mozambique.
In 2008 Vale awarded ABB the
contract for Moatize’s electrification
and automation. ABB collaborated
internally with members of the Centre
for Excellence for Mineral Processing
in Switzerland, and formed an external
consortium with B&W Electrical and
Instrumentation.
ABB has made a huge contribution
towards the cost-efficiency of the
project through its multi-drive solution
in variable speed drives. Compact and
movable substations known as Mini
subs have been designed for a part of
the 22kV distribution in the plant. These
are built on steel baseframes with a
distribution transformer up to 800 kVA
and an LV distribution board. Ring main
units (RMUs) used in the distribution
system are SF6 insulated compact
switchgear units with a short circuit
current of 25 kA.
For more information: www.abb.com/mining
In focus
ABB scope of works at Moatize
includes
- Extending the existing substation
at Matambo with a new 220/66 kV
bay including a 45 MVA 220/66 kV
transformer and extension to the
existing double busbar system
- Installing a 44km, 66 kV overhead
line from the Matambo substation
to the Moatize site
- Building a new switchyard
equipped with SCADA system at
the proposed Moatize site with a
45 MVA 66/22 kV transformer
- 22 kV GIS switchgear and DC
power supply units, plus 22 kV
power factor and harmonic filter
system
- Control system equipment,
complete with workstations and
furniture. DCS equipment and
software packages
- Plant lighting and earthing
protection system. Plant lighting
and small power system within
substation area
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One of the largest System 800xAinstallations in the world
Clockwise, from back row: Robert Markic (ABB), Murray Aird (ABB), Tony Antonecchia (ABB), Glen Evans
(Vale), Mark Fletcher (ABB), Arun Duraisamy (ABB), John Leger (ABB), Mats Pahls (Vale), Anthony Klip
(Vale) and Rejish Kandy (ABB)
ABB’s solutions for Vale in
Mozambique is not a standalone
project. Vale Nouvelle Calédonie, part
of the Vale group, has a plant in the
French-territory South Pacific island of
New Caledonia. This site ranks as one
of the richest undeveloped laterite ore
bodies in the world, with an estimated
55 million tonnes of measured and
indicated mineral reserves.
In 2005 Vale Nouvelle Calédonie
awarded ABB the electrification and
automation of this new nickel refinery.
Vale Nouvelle Calédonie selected ABB’s
flagship automation solution, System
800xA, for the facility’s automation
system – making it one of the largest
System 800xA installations in the world.
Beyond the breadth and scope of
the mining site and plant, as well as
the client expectation of continuous
installation and commissioning support,
there was a unique challenge posed:
for the first time, ABB needed to abide
by French standards. All drawings
and documents produced had to be
submitted in both French and English.
In focus
ABB solutions for the System 800xA
open pit mine’s refinery comprised of
the following:
- 48 operator workplaces
- 15 Quad screen and 20 Dual screen
Rich clients
- 10 engineering workstations and 10
temporary engineering workstations
- Integration of approximately 8,000
HART-capable instruments
- Approximately 1,100 DOL and 450
VSD Profibus devices
- 2 OPC clients (connecting to
OSI PI)
- 2 IM servers
- 33,000 History logs
- 23,000 (redundant) 800xA tags
- 56,000 (non-HI) CLPs
- 15,000 (HI) CLPs
- 1 PC network monitoring system
- 50 AC800M (redundant, PM 864)
controllers
- 4 AC800M (redundant, PM 866)
controllers
- 8 AC800M (redundant, PM 865)
controllers
Vale Nouvelle Calédonie, part of the Vale group has ABB installations as well as has a long-term service contract
Based on customer feedback and
continued collaboration, Vale awarded
ABB a three-year service contract to
provide onsite process control systems
service and maintenance of the process
plants installed System 800xA process
automation system in 2009. The service
contract formed part of an overall
solution package offered to Vale.
“Good planning and preparation
resulted in a successful execution
(of the upgrade).” shared Ghislain
Belmonte, Technical Services Manager
at Vale.
ABB leverages its more than 20
years’ knowledge of mineral processing.
As the original equipment manufacturer
of the control system, ABB had the
added capacity to provide expertise to
support, maintain and train the local
Vale New Caledonie teams.
For more information: www.abb.com/mining
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Events
Turbocharging solutions for better operational and environmental performance
The turbocharging business of
ABB in India showcased its products
and solutions in the 7th International
Maritime Exhibition and Conference
(INMEX 2011) held at Mumbai.
Advanced turbocharging solutions
and service, resulting in maximized fuel
efficiency and reduced emissions, were
displayed at ABB’s stall. The business
showcased its expertise as a solution
provider through Power2 Technology
along with latest A series Turbochargers.
The highlight of the stall was the cut
section of the TPL series turbocharger.
This turbocharger provides a robust and
reliable platform for engine applications
Solar takes centre stage at WETEX 2012 exhibition in Dubai
ABB’s cutting-edge solar power
generation systems were showcased
at the WETEX 2012 (Water, Energy,
Technology and Environment) exhibition
in Dubai, UAE. The show provided
an opportunity for professionals in
the energy, water and environment
management industries to exchange
ideas with the potential to transform the
future of communities, economies and
nations.
For the first time, customers
and visitors were able to try ABB’s
interactive augmented reality demo pod.
The hands on tool allowed visitors to
be given an interactive virtual tour of a
solar plant via a large screen. The 3D
visualization of a photovoltaic (PV) plant
on the screen explained ABB’s turnkey
solution for a power plant, touching
on product details like the megawatt
station.
ABB’s solar solutions maximize
plant performance and provide owners
with a rapid return on investment and a
long plant operating life. The solutions
include trackers, inverters, transformers,
electrical and control equipment which
are delivered in pre-tested 1 MW
modules for scalability, cost efficiency
and rapid installation.
The scope of supply covers
the entire project from site and
project assessment to plant design,
engineering, installation, commissioning,
service and maintenance. In partnership
with contracted manufacturers, ABB
also supplies a complete range of solar
trackers.
The show came hot on the heels
of an announcement to build the
Mohammad Bin Rashid Al Maktoum
Solar Park which will be operated by
Dubai Electricity and Water Authority
with the first phase of the project,
10MW of solar power, slated to be
completed by 2013.
Other key ABB technology and
features highlighted included energy
efficiency, solutions for the water
industry and the Smart Home and
Intelligent Building Control (KNX) that
meets the highest requirements for
applications in modern home and
building control.
At the exhibition Ventyx, an ABB
ABB stall at INMEX 2011
company, introduced FocalPoint
solution suite that offers advanced
business analytics solutions. The
business intelligence captures and
aggregates rich data in a plant held
across disparate software systems.
The solution can be easily tailored for
individual users or user groups.
Asset management tools such as
Symphony Plus software compile the
industry’s best business practices
into pre-packaged solutions to enable
companies to more effectively monitor
and manage their distributed assets
on a real-time, near real-time and
event driven basis. The software leads
operators to greater awareness, faster
response and better decisions.
The exhibition provided visitors an
excellent platform for a discussion on
how ABB can help improve productivity
in various processes while saving
energy and lowering environmental
impact.
For more information: www.abb.com/solar
www.abb.com/water
with outputs ranging from 2,500 KW
to the highest in the industry. The TPL
series have features designed to satisfy
strict environmental requirements and
typically need overhauls after long time
durations.
Visitors to the ABB stall included
officials from Wartsila India Ltd.,
Chidambaram Shipcare Pvt. Ltd.,
GMMCO Ltd, Pipavav Shipyard
Ltd,Kirloskar Oil engines Ltd, Shipping
Corporation of India, Great Eastern
Shipping, Indian Navy and Indian Coast
Guard.
For more information: www.abb.com/turbocharging
www.abb.com/marine
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Flagship technology showcased at major trade show held in Doha
ABB’s pioneering technology in the oil
and gas industry drew major attention at
the 20th World Petroleum Congress (WPC)
held in Qatar.
The power of the integrated solutions
and System 800xA – the company’s
flagship distributed control system, the
IRB 120 robot and asset management
solutions from Ventyx, an ABB company,
took center stage at the event.
Focus on energy efficiency
System 800xA extends the reach of
traditional automation systems - beyond
control of the process - to increase energy
efficiency, asset utilization, energy savings
and operator effectiveness.
At a plant, in order to be competitive,
various plant entities, departments and
personnel have to work as one flexible,
integrated, collaborative team. For this to
be accomplished, an automation platform
with incredible connectivity capabilities
is necessary. Integration of systems and
applications where all actionable information
is available for use in the system can be
provided to users in a variety of roles.
Robots increase productivity
A special feature at the ABB stand was
the IRB 120 multi-purpose industrial robot
that visitors were able to try operating.
The robot consumes 50 per cent less
power compared to even the lowest
power consuming robot and allows easy
transportation and hassle-free installation.
The robot is capable of handling a payload
of three kilos (four kilos for vertical wrist)
with a reach of 580mm.
Visitors to the exhibition were given an
interactive and hands on demonstration of
ABB’s flagship technology which improves
productivity and energy efficiency across
a number of different industries.
For more information: www.abb.com/oilandgas
Visitors at ABB stall at World Petroleum Congress
Events
‘Olympian event of the oil and gas industry’, the WPC was attended by a global oil and gas audience and outside stakeholders
26 contact 1|12
For a better world
Breakthrough order for DC technology
ABB has won an order from ship
owner Myklebusthaug Management
to supply the first ever direct current
(DC) power grid on board a ship. The
equipment will allow a new offshore
platform support vessel, under
construction in Norway, to operate at
the highest energy efficiency level to
minimize emissions.
In traditional electrical propulsion
vessels, multiple DC connections are
made to thrusters and propulsion drives
from an alternating current (AC) circuit,
accounting for more than 80 percent of
electrical power consumption. ABB’s
Onboard DC Grid represents a step
forward in optimized propulsion by
ABB wins order to install the first ever DC-based electric solution for a vessel. The Onboard DC Grid will allow vessels to cut fuel consumption and emissions by up to 20 percent
distributing power through a single
DC circuit providing significant power
savings.
Launched in May 2011, ABB’s
Onboard DC Grid is part of a revival
of power solutions using DC, and
will provide highly efficient power
distribution and electric propulsion for a
wide range of vessels. It is designed for
ships with low-voltage onboard circuits,
such as offshore support vessels, tug
boats, ferries and yachts, and can
reduce fuel consumption and emissions
by up to 20 percent.
ABB will provide its full onboard DC
system, including all power, propulsion
and automation systems for the 93
meter long, 5,000 tonnes multi-purpose
oil field supply and construction vessel,
which is scheduled for delivery in the
first quarter of 2013.
A key advantage of ABB’s Onboard
DC Grid is that the ship’s engines
no longer have to run at a fixed
speed and engine’s speed can be
adjusted to optimize fuel consumption.
By eliminating the need for bulky
transformers and switchboards, the
footprint and weight of the electrical
system can be reduced by up to 30
percent, leaving more space on the
vessels for passengers or cargo while
also providing greater flexibility in the
positioning of system components in the
vessel.
For more information: www.abb.com/marine
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For a better world
Turning electronic scrap into gold
ABB power and automation
technologies are helping metals
company Boliden create the world’s
largest electronic scrap recycling facility
– recovering copper and precious metals
from electronic scrap using only a
fraction of the energy required to extract
metals from ore.
Boliden is currently ramping up a new
plant adjacent to its existing electronic
scrap recycling facility at the Rönnskär
copper smelter in northern Sweden. The
expansion will almost triple the recycling
capacity from 45,000 metric tonnes to
120,000 metric tonnes a year, making
it the largest e-scrap recycling facility in
the world.
Rönnskär is an integrated
metallurgical complex, which smelts
and refines metals from mined copper
concentrates and from recyclable
materials like metal shred and electronic
scrap. E-scrap comes from computers,
mobile phones, circuit boards and other
electronic equipment and contains
metals such as copper, gold and silver.
The pre-sorted and pre-shredded
e-scrap is smelted at Rönnskär using
Boliden’s proprietary Kaldo furnace
technology. After smelting, the molten
metals are transferred to the adjoining
production lines for processing into high-
grade products.
In 2010, e-scrap accounted for
6 percent of Rönnskär’s feed, with
recyclable materials as a whole
contributing 24 percent. When the new
plant reaches full capacity in the second
quarter of 2012, these figures will rise
to 14 and 31 percent respectively, thus
enabling Rönnskär to become less
dependent on copper concentrates and
more energy efficient.
Recovering metals from electronic
scrap requires only 10-15 percent of
the energy required to extract metals
from ore. The process also supports
the European Union’s Waste Electrical
and Electronic Equipment (WEEE)
Directive, which requires 4 kg of e-scrap
to be collected and sorted per head of
population in the EU. This is expected to
rise to 13-16 kg per person by 2016.
ABB has played a significant role in
the Kaldo plant expansion and at the
Rönnskär complex as a whole. For the
new Kaldo plant, ABB has supplied a
comprehensive range of process-critical
power and automation technologies,
including the process control system.
On the electrical side, the ABB
solutions include low- and medium-
voltage switchgear to ensure safe and
reliable power distribution throughout
the plant; low-voltage industrial drives
to speed-control the motor applications
and reduce energy consumption
and RESIBLOC dry-type distribution
transformers, which are explosion-proof
and environmentally friendly, and can
withstand extreme loads and very high
levels of mechanical stress and thermal
shock.
The entire e-scrap recycling process
is controlled by ABB’s 800xA Extended
Automation System, and includes
customized features such as remote
operation of the process and an exact
positioning system to prevent spilling of
molten metal from the furnace.
The System 800xA solution for the
Kaldo plant expansion is integrated
with Rönnskär’s existing System
800xA distributed control system,
which controls the entire site and all
its production processes. When ABB
first installed the Rönnskär automation
system in 1999, it was one of the largest
plant control systems of all time, with
more 50,000 input/output (I/O) points.
For more information: www.abb.com
Electronic scrap. Images courtesy of Boliden
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Building a nation – ABB congratulates UAE for 40 years of success
Glimpses of ABB
Power and automation solutions increase energy efficiency and industrial productivity in UAE
A view of Burj Khalifa, Dubai which houses ABB technology
ABB has played a pivotal role in the
UAE’s development over the past four
decades. Since the unification of the
seven Emirates in 1971 – celebrated
as National Day – the country has
transformed into one of the world’s
leading regions of which ABB technology
has been instrumental. The 40th National
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Glimpses of ABB
Day was celebrated on December 2
2011. Over the past 40 years, ABB has
helped increase grid reliability, energy
efficiency and industrial productivity
across many elementary sectors such as
utilities, transportation and the economy,
while ensuring sustainable growth for the
nation.
“ABB technology is everywhere.
Our solutions enable reliable power
and energy efficient automation from
the world’s tallest tower, palm islands
or driverless metro system right down
to utilities and industrial sector; our
presence in the UAE has been far-
reaching. ABB will continue to play
a vital role in driving the country’s
infrastructure, projects and economy
forwards, for many years to come,” said
Frank Duggan, country manager for ABB
in the UAE.” We take this opportunity to
congratulate the lead of the nation and
its people for the 40th National Day of
UAE.”
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Behind the scenes of the noble
landmarks
Burj Khalifa, the world’s tallest
tower, houses ABB technology that
enables reliable power, water supply
and energy efficient cooling throughout
the 5-million square-foot building. The
world’s highest distribution substation
and control equipment that ABB
custom-engineered are on the top
floors ensuring power to lighting,
elevators, ventilation, heating and the air
conditioning system.
Additionally, ABB is the driving
force behind the Dubai Fountain, the
world’s largest dancing fountain. The
company supplied equipment such
as switchgears, transformers and
power monitoring systems to ensure
the feature receives reliable power.
The fountain’s energy efficiency and
power quality was increased with ABB’s
capacitor banks and harmonic filters.
The Dubai Metro, a key part of the
city’s infrastructure, runs smoothly
thanks to ABB’s products, which
ensure reliable, high quality power. Two
substations supply power to all red
line stations, while the third substation
supplies power to the entire green
line. The metro has transported 100
million passengers since it opened in
September 2009.
Leading edge technology for
complete water cycle
To assist the capital’s rising demand
for drinking water, ABB has worked with
Abu Dhabi Transmission & Despatch
Company (TRANSCO) on a major
expansion of a water transmission
system. The project increased the
volume of water supplied by the
Shuweihat power and desalination plant
to Abu Dhabi by expanding the capacity
of two pumping stations.
Meanwhile, ABB’s robots, helped
the Oasis Water Company to automate
a once-hazardous operation and
increased its bottled water production
capacity to become the second biggest
5-gallon water producer in the world.
Powering the nation
Furthermore, ABB has played an
integral part in helping the UAE to meet
its electricity demand and upgraded and
expanded electric power transmission
and distribution through the country.
The contracts, signed with Abu Dhabi
Water and Electricity Authority (ADWEA),
helped meet the growing demand for
energy. ABB also worked with DEWA to
deliver electrical power to Dubai’s two
palm shaped islands.
In addition, ABB successfully
strengthened the power and
transmission network in the north of the
country for the Federal Electricity and
Water Authority (FEWA) in Ajman, UAE.
The substations were part of a wider
project to expand the power supply
network in the northern region.
Glimpses of ABB
Dubai Metro is powered by ABB substations
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Executive editor: Karen Wilds
Editor-in-chief: Sanaj Natarajan
Branding and production team:
Isha Bhalla, Midhun Murali, Rakesh Shastri
Editorial board: Ali Keilani, Claire Hill, Marion Hug,
Midhun Murali, Rakesh Shastri, Riham El Gamal,
Royston Rebello, Tamara Chetty, Tuija Elomaa-
Maenpaa, Vikram V Kanth
Design and layout: Michael Wachter
Contact is published in English for circulation
among ABB customers and stakeholders with
an interest in ABB offerings, products and
technologies.
Partial reprints or reproductions are permitted
subject to full acknowledgement. Complete reprints
require the publisher’s written consent.
Publisher and copyright ©2012
ABB Asea Brown Boveri Ltd.
Disclaimer
The information contained herein reflects the views
of the authors and is for informational purposes
only. Readers should not act upon the information
contained herein without seeking professional
advice. We make publications available with the
understanding that the authors are not rendering
technical or other professional advice or opinions
on specific facts or matters and assume no liability
whatsoever in connection with their use.
The companies of the ABB Group do not make any
warranty or guarantee, or promise, expressed or
implied, concerning the content or accuracy of the
views expressed herein.
Light and heat from the sun is the most abundant energy source on earth.The solar energy that hits our planet’s surface in one hour is about equal to the amount of energy consumed by all human activities in a year. Moreover, electricity generated by solar power is emission-free and can help mitigate climate change as well as reduce our dependence on finite carbon-based energy sources.
ABB offers a range of solutions that not just help capture the sun’s rays in the most effective manner but also help achieve grid parity.
Preview 2|12
SolarGenerating power from the sun
Connect renewable power to the grid?
Naturally.
Electricity generated by water, sun and wind is most abundant in remote areas like mountains, deserts or far out at sea. ABB’s leading power and automation technologies help renewable power reach about 70 million people by integrating it into electrical grids, sometimes over vast distances. Our effort to harness renewable energy is making power networks smarter, and helping to protect the environment and fi ght climate change. www.abb.com/betterworld