Cemex, a prominent global supplier of building materials, has undertaken significant modernisation efforts at its Rudniki plant in Poland, aimed at enhancing the safety and reliability of its electrical infrastructure. The plant, one of the largest cement suppliers in the country, is renowned for its production of various types of cement, as well as road binder and limestone flour. Given the complexity of the production processes, which include a furnace that can take up to 36 hours to ignite, even brief interruptions in power supply can halt operations, underscoring the necessity for continuous power.
The company's collaboration with ABB, a longstanding partner for over a decade, has focused on retrofitting the electrical switchgear responsible for powering the vital furnace. This approach allowed Cemex to update only the obsolete components rather than undertaking a costly complete overhaul of the switchgear system. The retrofit not only promises to bolster reliability and sustainability but also meets the plant's operational demands for a seamless transition.
Cemex maintenance specialist Paweł Małolepszy remarked, “We were looking for reliable and compact technology. The risk of unplanned power outages has been minimized, and the use of a pull-out solution has improved our safety. This significantly extends the continuity of operation of the furnace, which is key to our business.”
To optimise operations, the upgrade includes ABB’s Emax2 circuit breakers, which are now equipped with Ekip Touch technology. This modern system offers comprehensive protection functions and is designed to be modular, allowing easy interchangeability. Furthermore, the plant has transitioned to digital monitoring systems; ABB's advanced digital analyzers, which serve as both multimeters and network analyzers, facilitate precise measurements with remarkable accuracy.
Operational efficiency has significantly benefitted from these upgrades. Data gathered can be uploaded to the ABB Ability™ Energy & Asset Manager, allowing for the monitoring of energy usage and other critical parameters, including power and load, through a cloud-based platform. This capability enhances the plant's ability to manage energy consumption effectively.
The retrofitting measures have also allowed Cemex operators to isolate specific breakers safely, enabling maintenance tasks without needing to disconnect the furnace, a step that would have otherwise necessitated a production halt. Moreover, by improving the thermal energy efficiency of the furnace, the plant is positioned to use less clinker, thus contributing to a decrease in CO2 emissions associated with cement production.
Kamil Schabiński, Project Manager for ABB Electrification Service, stated, “This is a perfect example of a comprehensive retrofit, tailored to our customer’s specific needs. ABB products have transformed the plant’s operating conditions and the reliability and safety of its power supply. Their new circuit breakers can be connected to the cloud at any time, which will further increase their digital functionality and energy management.”
Cemex's initiatives at the Rudniki plant reflect broader trends in the construction and building materials sector, where the integration of advanced technologies is becoming pivotal for enhancing operational performance and sustainability.
Source: Noah Wire Services