ABB has announced that its ABB Ability™ Expert Optimizer advanced process control solution has helped Nippon Steel Blast Furnace Slag Cement Company Ltd improve energy efficiency, product quality and operational performance at its Muroran cement plant in Hokkaido, Japan. The digital process optimization system has enabled the cement manufacturer to reduce specific heat consumption by 2.2 percent while improving production stability and product consistency. The company also reported a 10 percent reduction in free lime, an important quality indicator in cement manufacturing, resulting in the production of higher-quality clinker.
ABB carried out a comprehensive performance assessment comparing plant operations before and after the implementation of Expert Optimizer. The evaluation confirmed measurable improvements in energy use, process control and production quality following the deployment of the advanced automation system.
After the initial commissioning phase, the plant achieved more than 90 percent automatic operation, significantly reducing the need for manual intervention. Operator actions were cut by nearly 80 percent, while the system continued to maintain stable process control during preheater cleaning and other abnormal operating conditions. The platform also provides operators with real-time process insights that support better decision-making and continuous operational improvement.
Muroran Plant manufactures blast furnace slag cement as part of Nippon Steel’s steelmaking operations. The product is recognized as a lower-carbon alternative to conventional Ordinary Portland Cement because replacing clinker with blast furnace slag reduces overall carbon dioxide emissions by around 40 percent.
ABB Ability Expert Optimizer combines Model Predictive Control (MPC) and artificial intelligence technologies to monitor critical operating parameters such as temperature, pressure and exhaust gas composition. The system predicts process variations and automatically adjusts operating conditions to improve efficiency, reduce fuel consumption and maintain consistent product quality. The Muroran facility has an annual cement production capacity of 1.6 million tonnes, making operational improvements highly significant in terms of energy savings, production performance and environmental impact.
Commenting on the project, Hiroyuki Abe, Plant Manager of Muroran Plant at Nippon Steel Blast Furnace Slag Cement Company, said, “Reducing manual operation and lowering fossil fuel consumption are important priorities as we work toward carbon neutrality. ABB Ability Expert Optimizer has helped improve process stability, clinker quality and overall operating consistency while reducing manual control. We look forward to further advancing plant automation in the future.”
Hiromichi Yoda, Local Division Manager for Japan, ABB Process Industries, said the project demonstrates how advanced digital technologies can improve productivity while addressing skilled labour shortages and supporting industrial decarbonisation. He added that ABB will continue working closely with Nippon Steel to further refine the process model and deliver additional improvements in efficiency, quality and operational performance.
ABB is a global technology company specializing in electrification and automation solutions that improve productivity, efficiency and sustainability across industries. The company combines engineering expertise with digital technologies to help customers optimize operations, reduce energy consumption and lower emissions.
ABB serves a wide range of industries, including process industries, utilities, manufacturing, transportation and infrastructure, with innovative products, software and services designed to support the transition to smarter and more sustainable operations. With more than 140 years of engineering heritage and operations in over 100 countries, ABB continues to drive industrial innovation worldwide.
