ABB has been awarded contracts to supply electrical equipment and automation systems for several mining and cement projects globally: 1) ABB will provide a static var compensator and electric arc furnace for a new steel plant in Nigeria to optimize performance. 2) In Ukraine, ABB successfully commissioned electrical and automation systems for the largest cement production line, helping to improve energy efficiency and reduce emissions. 3) ABB has also won a contract to supply electrical equipment for Masan Resources' Nui Phao mine in Vietnam.

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The customer magazine
contact
of ABB in India,
Middle East & Africa
Process solutions for core industries
Cement, Minerals and Mining
ABB to power new steel plant facility in Nigeria 07
Automation solutions optimize mining project in Chile 10
Minerals Remote Monitoring Center 12
Improving plant uptime and productivity 18
Turbocharging solutions for better performance 24
Breakthrough order for DC technology 26

2. Table of contents
07 ABB to power new steel plant
Facility in Nigeria 12 Minerals Remote Monitoring Center
High-end integral service offering for mineral
industry
Local News Events
05 Energising Thembelani 2 Shaft at Anglo 24 Solar takes centre stage at WETEX 2012
Platinum exhibition in Dubai
07 ABB to power new steel plant facility in Nigeria 25 Flagship technology showcased at major
trade show held in Doha
Global news
08 Improving productivity process at Podilsky
For a better world
Cement, Ukraine 26 Breakthrough order for DC technology
10 Automation solutions optimize mining project 27 Turning electronic scrap into gold
in Chile
Glimpses of ABB
Cover feature 28 Building a nation – ABB congratulates UAE for
12 Minerals Remote Monitoring Center 40 years of success
14 MiRMC architecture
In focus
16 Tourah Portland Cement Company gets a
System 800xA upgrade
18 Improving plant uptime and productivity
Contact, customer news magazine from ABB, © 2012, web: www.abb.co.in, email: contactmagazine@in.abb.com, Publisher: ABB Group,
Layout: Adsync, Bangalore, India, Cover picture: Overview of Podilsky cement plant, Ukraine.
2 contact 1 | 12

3. From the country manager
28
Building a nation
ABB congratulates UAE
for 40 years of success
25 Flagship technology showcased at major trade show held in Doha
Olympian event of the oil and gas Industry
contact 1|12 Dear friends,
The World Economic Forum recently turned a deaf ear to the protests of local
launched a scenario planning project communities about resource extraction
with the objective of answering the activities in the “second scramble for
question “How will the environment for “Africa”, with nationalisation and a neo-
the global mining and metals sector colonial practices as common cause.
look in 2030?” The report produced by A common thread among these
more than 200 leaders from business, scenarios is the assumption that
government, academia and non- developing countries will be the source
governmental organisations – makes for of much of the world’s supply of
fascinating reading. minerals. While the reaction of global
The three scenarios the group leaders varied, the impact of climate
focused on, were selected because, change could not be escaped.
based on the critical uncertainties This issue of CONTACT, features
identified by the group, they were not glimpses of some the solutions that
Carlos Poñe
only very divergent, but all three were have been used across these sectors.
Country Manager
highly relevant. From optimization solutions in some
South Africa
One scenario, called the Green of the world’s biggest cement plants
Trade Alliance, was based on an alliance to enhancing customer experience
of countries united by the common through service contracts, ABB is well
vision of “environmental sustainability positioned in South Africa to support
without compromising competitiveness”. the industry.
A second scenario was built on a 2030 We have illustrated some of these
where the geo-political and -economic successes and hope that you find this
influence of Europe and North America issue of the magazine an interesting read.
have shifted towards a global landscape
defined by the influences from a wider Best regards,
range of political and economic centers
of power. The third scenario explored an
environment where governments have Carlos Poñe
contact 1 | 12 3

4. Local News
Driving new levels of performance at
Anglo Platinum
Styldrift: Double Drum Service Winder
Sole supplier of Anglo American Platinum Limited is a
member of the Anglo American plc Group
17-hectare footprint. Styldrift is processing
230,000 tonnes of Merensky reef a month,
switchgear to world’s and is the world’s leading primary producer utilising a new twin shaft system, sunk to
of platinum group metals. The company a depth of 740m, and a new concentrator.
leading producer is listed on the Johannesburg Securities In January this year, ABB was awarded a
of platinum group Exchange (JSE). Its mining, smelting and
refining operations are based in South
10 million ZAR order for double bus bar Air
Insulated Switchgear (AIS) for the Styldrift
metals (PGMs) Africa. Elsewhere in the world, the Group Shaft. “We have been part of the Styldrift
owns Unki Platinum Mine in Zimbabwe project since its inception as we tendered
and is actively exploring in Brazil. Anglo for and were awarded the contract for the
American Platinum has a number of supply of Unigear Switchgear for the first
joint ventures with several South African phase of the project in 2009,” said Per
consortia as part of its commitment to Wanland, ABB’s Key Account Manager
the transformation of the mining industry. for Anglo American. “The new contract for
the supply of air insulated switchgear is a
Switchgear for Styldrift critical part of a new development at the
In September 2008, Anglo American main consumer substation of the Styldrift
Platinum established in partnership with shaft. While this will be the first time we
community-based investment group Royal supply AIS at this shaft, I am proud of
Bafokeng Holdings, a new South African the fact that ABB is the sole supplier of
Rand (ZAR) 10 billion mine at Styldrift, in switchgear at this critical Anglo American
the North West Province. Bulk earthworks Platinum operation.”
started in March 2009 and extended over a For more information: www.abb.com/mining
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5. Local News
Energising Thembelani 2 Shaft at
Anglo Platinum
ABB was awarded an order valued extension projects to existing shafts.
Customer 3 million ZAR for a new 33kV substation Between 2014 and 2020, the production
satisfaction leads at Anglo American Platinum’s Thembelani
2 shaft project in Rustenburg in South
profile will be maintained by using either
two or three intermediate vertical shafts.
to 33kV substation Africa’s North West province. The Thembelani No 2 shaft is the first of
The original substation installation at the these vertical shafts.
order Thembelani 2 Shaft was successfully The first blast for construction of the
completed by ABB and, based on ventilation shaft took place in September
their satisfaction with its performance; 2006, while construction of the men-and-
the customers continued the project materials shaft began in September 2007.
by extending the substation with ABB The Thembelani 2 project includes a
equipment. “We enjoy working with Anglo downcast vertical men-and-materials shaft,
American Platinum, their expansion plans and an adjacent matching vertical upcast
are visible, enabling us to do forward ventilation shaft, which will intersect the
planning to deliver against their project existing horizontal connections. It also
timelines” said Per Wanland, ABB’s Key involves the extension of the existing
Account Manager for Anglo American.” The declines at the Thembelani 1 shaft project.
medium-term mining profile for Rustenburg For more information: www.abb.com/mining
is predicated on a series of phased decline
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6. Local News
Mine hoists to improve
efficiency in new mine
S
outh Africa currently accounts million-ton run-of-mine production target. be the production hoist, used to hoist
for about 75% of the world’s ABB has been awarded a 28.4 million ore from underground. The 5m hoist
identified manganese ZAR order by Kalagadi manganese mine served in another significant project in
resources, mostly found at Hotazel in the Northern Cape province Switzerland, where ABB supplied the
in the Northern Cape Province near of South Africa, to supply two double hoisting, electrical and control equipment
Hotazel. The country was the world‘s drum hoists and other mechanicals. for the great St Goddard railway tunnel,
largest producer of manganese in 2011, “We will supply a new 3.6m double commissioned in 1999.
producing 3.4 million tons. drum hoist and refurbish a 5m double “We are proud to be associated with
Steelmaking, including its ironmaking drum hoist. Our scope for the new hoist this model project, supporting the mine
component, has accounted for most entails full mechanical engineering for with our technical expertise in hoisting
manganese demand, presently in the drums, shaft bearings, basplates, solutions. Our contribution will ensure
the range of 85% to 90% of the total brake units and clutches, as well as safe and efficient transportation of
demand. bearing lubrication and hydraulic braking people and material,” said Carlos Poñe,
Kalagadi Manganese (Pty) Ltd, a systems,” said ABB’s Mike Davis, Mining CEO of ABB South Africa.
company held by ArcelorMittal (50%), and Minerals Business Development Kalagadi Manganese founder and
Kalahari Resources (40%) and the Manager. chairperson Daphne Mashile-Nkosi
Industrial Development Corporation The refurbishment project will recently emphasised in a public address
(10%) is involved in the exploration for involve the upgrade of the mechanical the importance of government support
Manganese in the Kalahari Basin, in equipment including re-metalling of the for development projects such as the
South Africa’s Northern Cape Province. bearing, conversion of the brakes to disc Kalagadi Manganese project, and the
The company holds new order mining brakes and installation of a new bearing need for the internalisation of South
rights on three farms believed to home lubrication system and a new hydraulic Africa’s resource wealth.
to some 960 million tons of manganese brake system.The hoist project is “I am glad to see that government
ore and about 100 million tons of mineral planned to commence in the final quarter realises the importance of partnering with
resources. of 2012, while the mine itself will begin various stakeholders in the economy to
Full commissioning of the mine is commissioning in the third quarter. drive the developmental agenda. This is
scheduled for the third quarter of 2012. The 3.6m hoist will serve as a role that government is well positioned
In February this year, the final blast for the mine’s men-and-material hoist, to play to ensure the mobilisation of our
a 300m underground mine shaft was which will be used to transport mine resources,” she said.
completed, keeping the company on personnel and material underground. For more information: www.abb.com/mining
track to achieving its mid-2012 three- The larger 5m refurbished hoist will
Mine hoist to serve as men-and-material hoist
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7. Local News
ABB to power new steel plant
facility in Nigeria
ABB is to provide a Static Var operation. The outcome is an overall
Static Var Compensator (SVC) for Sagamu improvement of the utilization of the
Compensator Steel Nigeria Limited, part of the furnace, and hence improved process
Sunflag group, an Indian multinational economy.
along with the specializing in Automobile grade Steel. ABB has a unique knowledge of
The scope of work involves providing Electrical Arc Furnaces compensated
Electric Arc Furnace an SVC along with the Electric Arc by an (SVC). The company has more
to be supplied Furnace (AEF). A steel plant based on than 30 years of satisfactory operation
Electric Arc Furnace (EAF) metallurgy of Static Var Compensators. In the early
for optimum requires a stable and steady voltage 70’s the first SVC was commissioned for
supply for optimum performance. an electric arc furnace, which has been
performance Simultaneously, an EAF is a heavy load followed by a number of successful
on the grid, injecting disturbances back installations. Over the past decades
into the grid, unless proper mitigating ABB has supplied more than 400 SVCs
measures are taken. By installing an in more than forty countries. The supply
SVC, it is possible to instantaneously to Sagamu Steel would be the first in
compensate the random load variations Nigeria.
characteristic of an arc furnace For more information: www.abb.com/metals
contact 1 | 12 7

8. Global news
Enhancing industrial productivity at gas plant
in Abu Dhabi
Key technology to Dhabi city, and has a daily production
target of one billion cubic feet of sour
Low Voltage Products division.
“ABB technology for remote control
ensure operational gas or high sulfur gas. Abu Dhabi is systems is crucial in order to ensure
developing its sour gas reserves as the functionality and the integration
safety and reliability domestic power consumption soars. of low-voltage switchgear in modern
The hydrogen sulfide content of the gas production plants.”
must be reduced to acceptable levels The safety of personnel and
before it can be used. equipment reliability are key issues
ABB has won an order from Saipem ABB in Italy and ABB in South Korea for this plant and played a significant
S.p.A. and Samsung Engineering Co. will supply low voltage switchgear, role in the awarding of this contract.
Ltd., to provide a range of power and intelligent motor control units and ABB’s MNS low-voltage switchgear
automation equipment for a natural gas variable frequency drives (VFDs). uses remote control systems and
processing plant in Abu Dhabi, United “This order is the end result of a multifunction protection relays that
Arab Emirates. successful ‘One ABB’ collaboration make it the benchmark for operational
The plant is located in the Shah between different local teams,” safety, reliability and quality.
natural gas field, southwest of Abu said Tarak Mehta, head of ABB’s For more information: www.abb.com/oilandgas
Improving productivity process at Podilsky
Cement, Ukraine
New production
line to achieve high
energy efficiency,
product quality,
while reducing
environmental impact
An overview of Podilsky plant, Ukraine
ABB has successfully commissioned largest cement production line in the switchgear, intelligent low-voltage
its integrated electrical, control and Ukraine. motor control centers,variable speed
automation systems at the largest The modernization project helped drives, instrumentation, gas analyzers,
cement production line in the Ukraine. the plant decrease the emissions from collaborative production management
Owned by international building fossil fuel combustion by changing the systems, and a plant-wide 800xA
materials group CRH, the plant is technology of cement production from automation system to control, connect,
located in Kamyanets-Podilsky, a wet production process to a state-of- and optimize the performance of all
approximately 420 kilometers southwest the-art dry production process. The new processes, systems and equipment.
of Kiev and started operation in the process uses considerably less fuel, ABB also provided design, engineering
1970s. The new production line with lower emissions of particulates and and site services, training, and
No. 7 is part of a plant modernization CO 2. procurement of third-party equipment.
that replaces the existing production For this project, ABB delivered For more information: www.abb.com/cement
lines while maintaining the plant’s 7,500 integrated electrical and automation
tonnes daily capacity, making it the systems that include medium-voltage
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9. Global news
Electrical equipment contract awarded
by Masan Resources’ Nui Phao mine in
Vietnam
A panoramic view of the Nui Phao mining site
Power and ABB has been awarded a contract
to supply the majority of the electrical
ABB will supply and provide
commissioning for a comprehensive
automation equipment for Masan Resources’ Nui scope of electrical equipment, including
Phao mine. The Nui Phao mine is located automation and drives systems for the
equipment will approximately 80km northwest of Hanoi mine. The equipment and system design
help increase mine in the Dai Tu District of Thai Nguyen
Province in Northern Vietnam.
for the project will minimize impact on
the surrounding power network, and
efficiency and Masan Resources, a division of the increase both efficiency and productivity.
Masan Group, one of the largest private Reliable performance of the system
minimize impact companies in Vietnam, is developing is critical to the safety and financial
the Nui Phao mine, which is a unique success of the mine‘s operation. ABB‘s
on the surrounding polymetallic mine with reserves of proven maintenance, lifecycle support
power network tungsten, fluorspar, bismuth, copper and service and expertise in delivering
gold. The mine is positioned to be one systems were important factors in
of the most cost-effective producers of securing this contract.
tungsten in the world. For more information: www.abb.com/mining
Rio Tinto mines in Australia to boost
production via power infrastructure
ABB has won orders worth around and other infrastructure and industries. for the upgrade and installation of
$100 million from Rio Tinto for 17 ABB’s scope of supply includes new electrical infrastructure for the
distribution substations to support electrical switch rooms, switchgear, substations. The projects are scheduled
increased production at iron ore mines cables, power transformers and for completion by 2013 and form
in Western Australia. ring main units. ABB will also deliver part of the customer’s multi-stage
The upgrades and installation of a range of components including Electrical Infrastructure Replacement
new power infrastructure will raise the SCADA (Supervisory Control and (EIR) project. ABB has successfully
voltage level of the existing distribution Data Acquisition), and protection and completed several similar projects for
substations and increase the power communication equipment compliant Rio Tinto in the past.
supply to support the expansion of with the IEC 61850 global standard. Rio Tinto is a global leader in the
existing iron ore mines in the Pilbara This will enable remote monitoring and exploration, mining and processing
region. control of power assets located at of minerals and metals, including
Urbanization and economic multiple sites, from Rio Tinto’s Remote aluminum, copper, diamonds, energy
development in emerging markets is Operations Centre situated in Perth, products, gold, industrial minerals and
fueling demand for steel, for which more than 1,000 kilometers away. iron ore.
iron ore is the main component. Steel As part of the contracts, ABB is For more information: www.abb.com/mining
is widely used in the construction of responsible for the design, engineering
bridges, railways, ships, cars, buildings, and supply of equipment needed
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10. Global news
Automation solutions optimize
mining project in Chile
Gearless mill drive ABB won an order worth $43 million
to deliver three gearless mill drive
mill drives are more reliable and
energy efficient than traditional mill
systems to optimize systems, plus related automation and drive systems, providing increased
power infrastructure equipment for a productivity.
production at Minera new copper mine to be operated by The scope of supply for the project
Minera Quadra Ltd., in Sierra Gorda, consists of three 17 megawatt gearless
Quadra’s new copper Chile. mill drive systems, related automation
mine Minera Quadra is a Chilean equipment and systems, as well as
subsidiary of Vancouver-based Quadra remote and diagnostic monitoring
FNX Mining Ltd. systems that include earthquake
Located in the Atacama Desert detection, and related engineering
region of northern Chile, the new open- and installation services. ABB will also
pit mine will produce 111,000 tonnes provide power infrastructure equipment
of copper per day, with significant such as transformers, containerized
molybdenum by-products, for the next electrical-rooms to house electrical
20 years. systems, auxiliary distribution, and other
ABB’s delivery will help the mine electrical equipment.
to optimize its overall efficiency and For more information: www.abb.com/mining
productivity. Its gearless ore-crushing
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11. Global news
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
L
ocated on the outskirts of operating costs. Prior to the installation control was 153.6 megawatt-hours. The
Lisbon, the plant recovers the of the ABB solution, the fans were variable speed drives have reduced this
solid waste of 19 municipalities controlled by dampers, which is the by 9 MWh to 144 MWh, which equates
in the capital and western least energy-efficient control method to €240,000 ($320,000) a year at a tariff
Portugal, and turns it into 50 megawatts available. of €0.80 ($1) per kWh.
of electricity – enough to meet the By replacing the dampers with an Lower energy consumption means
needs of a large city. ABB variable speed drive solution, lower carbon dioxide emissions. The
Looking for ways to reduce the Valorsul considerably reduced fan drive solution has reduced the plant’s
energy consumption and CO2 emissions energy consumption and carbon dioxide CO 2 emissions by about 4.5 tonnes
of the plant, Valorsul identified six fans emissions, and gained a number of a day – a significant reduction to the
with a high energy saving potential: other significant benefits as well. plant’s carbon footprint.
three induced draft (ID) fans and three The ABB solution comprises three The ABB variable speed drives
secondary air fans. ACS 2000 medium voltage drives, three have also improved process control.
In waste-to-energy plants, ID fans ACS800 low voltage drives, and UniMix The air flow can be controlled more
and secondary air fans are an important medium voltage switchgear for line accurately, faster and reliably than
part of the combustion process. The supply connection and backup bypass with dampers. Other benefits of the
latter supply secondary air to the for the variable speed drives. The ACS drive solution include lower investment
boiler to combust the fuel, and ID 2000 variable speed drives - rated and maintenance costs, reduced
fans remove the flue gases as exhaust at 700 kW, 6.4 kV - can be directly footprint in the electrical room, and
during combustion. ID fans in particular connected to the line supply and do not smooth integration with existing plant
consume large amounts of electrical require an input isolation transformer. infrastructure.
energy. The method by which the fans Prior to the installation of the ABB For more information: www.abb.com/betterworld
are speed-controlled has, therefore, a solution, the average daily energy www.abb.com/drives
major effect on energy consumption and consumption of the fans with damper
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12. Cover feature
Minerals Remote
Monitoring Center
High-end integral service
offering for mineral industry
M
inerals 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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13. Cover feature
offering includes system upgrades and The benefits of MiRMC include, but audit trail for complete traceability and
maintenance, periodic patch and release are not limited to lower operating cost knowledge management for re-use.
updates, system status monitoring, enhanced plant availability, maximized Across the globe ABB has an
system modification and enhancements, production and improved quality. installed base of more than $100
loop performance monitoring and ABB experts will have access billion of automation products and
tuning, process consultancy (Cement to plant distributed control system systems, hence is constantly working
Performance FingerPrint), access to (DCS) through a secured network, on achieving flawless product support
global knowledge repository, 24x7 this ensures security. The system for ABB customers. Remote service
service support and training. will be managed by competent and developments are directly proportional
The remote service offering reduces certified resources through a secured to clients’ ever changing demands.
redundant maintenance, improves environment with SSL encrypted MiRMC plays a significant role in cost
production efficiency, tracks causes connection to plant system. Actricity saving and offering an exhaustive
of failures, provides fault diagnosis tool based case tracking and unique review of procedures and process
and recommends specific actions for service ID generation are some other implementation.
smooth work flow. It also notifies about features of MiRMC. MiRMC also has For more information: www.abb.com/minerals
impending failures which in turn helps well defined automated workflow, plant
in initiating proactive corrective actions. access through approved work permit,
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14. Cover feature
MiRMC architecture
Centralized server
Virtual support engineer
(Local application) Internet
ABB’s customer
ABB solutions for the Industry
Cement Performance FingerPrint Knowledge Manager Cement basic SpectraFlow
Cement Performance FingerPrint report package SpectraFlow is an online bulk
is a process optimization and energy The Knowledge Manager cement material analyzer for belt conveyors
consulting service designed to capture, basic report package is an entry powered by ABB’s SOLBAS™
analyze and improve operational level production reporting system technology. SOLBAS™ technology is
performance and energy efficiency which is cost-efficient and fast to the innovative application of the well
of cement making process. This implement. Knowledge Manager known Near Infra Red (NIR) concept
process ensures tuning of plant control enables to achieve operational to the analysis of bulk material online.
system efficiently, benchmarked to objectives by monitoring and managing Fast and accurate chemical analysis
industry best practices. It also offers manufacturing processes. It also using Near Infra Red (NIR) i. e. the
a systematic approach in capturing provides analytical insight to identify wavelength range from 700 to 2500
the process sensitivity using plant best practices that will improve overall nanometers is a well established
step tests, building a dynamic process operation. method in the petrochemical, food and
model, analyzing site constraints and pharmaceutical industry.
identifying improvement opportunities. The SpectraFlow analyzer helps
Cement Performance FingerPrint plants in better and longer use of the
provides plant benchmarking with quarry, less variation in the raw material
industry standards, plant variability feed, reduced need for corrective
study, control loop performance report, material and smoother mill operation.
process performance analysis, energy Its benefits in the analyzer operation
efficiency potential and access to best include online analysis of secondary
practices. 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
The highlights of this report analyzer maintenance.
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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15. Cover feature
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 EMS Overview screenshot
over a specified time range. Energy
Management Solution helps in lowering accurate consumption plans, avoiding in employing optimal resources in the
electricity purchase prices due to price peaks and penalty charges and supply of electric power.
Loop Performance Manager (LPM) cpmPlus Expert Optimizer optimal performance.
LPM provides a powerful, yet cpmPlus Expert Optimizer helps The features of cpmPlus Expert
extremely easy-to-use, collection of improve productivity, energy efficiency Optimizer include advanced process
software tools that control engineers and profitability by stabilizing and optimization techniques, such as
and process operators will find optimizing the process involved. Model Predictive Control (MPC), Fuzzy
useful to start-up, diagnose and cpmPlus Expert Optimizer extends Logic and Neural Networks Flexibility
maintain control loops. LPM supports the capabilities of control system to handle the process requirements
a wide variety of commercial PID by coordinating actions on the of different industries with different
(proportional–integral–derivative) process, such as rotational speed, business objectives, user-friendly
control block algorithms, as well as fuels, valves or chemical additives. modeling environment in which the
various configuration options available It maximizes efficiency by looking at process engineer does not have to
for those PID algorithms. By combining the interactions among variables and get in to the mathematical complexity
data collection, model identification, deciding according to the plant goals. of the optimizer along with a modular,
feedback tuning, feed forward It collects real-time data, processes reusable and scalable design to reduce
tuning and controller simulation in a it with mathematical algorithms and deployment time.
single user interface, ABB delivers a coordinates the plant actuators for
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.
contact 1 | 12 15

16. In focus
System 800xA is ABB’s flagship automation solution
Tourah Portland Cement Company gets
a System 800xA upgrade
Proven technology in control systems coupled with training help
customer in improved plant continuity and productivity
A
complete Cement Mill Control Cement Company. Suez Cement owns Padlocks and Bar Code Scanner
System modernization was approximately 30% of grey cement System, SMS functionality engineering,
commissioned by ABB at market share and 50% of white cement activation and communication modems.
the Tourah Portland Cement market share in Egypt making it one The company is familiar with ABB
Company Plant # 2 with high level of of the largest cement producers. The control systems and was pleased with
plant modernization solutions like Lock solutions were implemented in its the level of detailing and involvement
Out Tag Out System (LOTO System) mill no. 11. Prior to the upgrade, the by ABB engineers including hands-
which took the safety to higher level company was using obsolete BBC on training and safety procedures and
and SMS functionality which increased control systems. operational training. In addition to the
plant availability via keeping the plant ABB provided complete engineering supply and commissioning which was
managers updated on time with any solutions on turnkey basis which were implemented on time, the customer will
stoppages / alarms for immediate incorporated during the shutdown stand to benefit from long-term technical
corrective actions. window at the facility. The scope of support for their assets as well as ready
The Tourah Portland Cement solutions include System 800xA with availability of spares.
Company is Egypt’s first cement AC800M, work stations and screens, For more information: www.abb.com/cement
company with 66.12% owned by Suez LOTO System, LCD, Padlocks Holder,
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17. In focus
Unique mining solution brings out the
best results
ABB has used its global expertise The excavation component itself is automation solution. ABB’s scope
in automation solutions for open a large rotating wheel mounted on a included composite solutions spanning
pit mining and material handling boom. On the outer edge of the wheel engineering, manufacturing, supply,
to provide a unique, custom-built are a series of buckets. As the wheel erection supervision, testing and
automation system for a bucket wheel turns, the buckets remove soil or strata commissioning of machine electrics,
excavator (BWE) for Neyveli Lignite from the target area and carry it around drives, motors, automation system and
Corporation Limited, in Tamil Nadu. to the rear of the wheel, where it falls field instruments.
ABB Cottbus, Germany is the MTC onto a conveyor, which carries it up Electrics comprised HT switchboard,
(Main Technology Center) for open pit the arm toward the main body of the transformer, motor control centers
mining. ABB Cottbus supported for excavator. (MCC) and cables for the complete
this bucket wheel excavator project, by Discharge conveyor carries it further machine.
providing the Continuous Mining Motion and discharges it on the overland The automation system included
Control program, which is used in the conveyor. The most favourable soil and AC800M controller, S800 IO’s and
Variable Frequency drives. Also ABB strata conditions for BWE operation process panel. Communication with the
Cottbus has deputed their experts for are soft, unconsolidated overburden remote IO’s, process panels and field
commissioning of the various drives. materials without large boulders. devices is through Profibus network.
ABB introduced a variable frequency ABB partnered with ThyssenKrupp The solution was designed
drive (VFD) ACS 8004Q for the bucket Industries India Limited, the original after detailed studies, analysis and
wheel application, which significantly equipment manufacturer (OEM) for simulations. The objective of the
reduced the wear and tear of buckets the project, to develop the unique application software designed to
and optimizes energy consumption operate the system was to ensure even
in the operation of the machine. The loading of the conveyor belt, minimize
indigenously developed solution was Key benefits idle operation and form stable slopes.
implemented in record time and helped - reduced wear and tear of the ABB’s application engineering team
boost the performance of the bucket buckets developed the application programme
wheel. Bucket-wheel excavators are - energy saving including the automation of the entire
pieces of heavy equipment used in open - avoidance of overload trippings process of soil excavation. This software
pit/ surface mining, especially for lignite. - optimum use of the BWE seamlessly directs the bucket wheel to
It is a continuous excavation machine - increase in machine availability follow the optimal track, thereby helping
capable of removing up to 3430 cubic time the operator to enhance its productivity.
meters of soil / strata per hour. For more information: www.abb.com/mining
Bucket wheel excavator at Neyveli Lignite Corporation Limited
contact 1 | 12 17

18. In focus
Shah Cement Industries Limited, Dhaka, Bangladesh
Improving plant uptime and
productivity
ABB has recently provided Cement Comprehensive design, engineering, will benefit from long-term technical
Mill Control System for Shah Cement supply and commissioning solutions support for their assets and ready
Industries Limited, Bangladesh. This on turnkey basis were done by ABB in availability of spare parts.
includes high level of plant modernization line with customer requirements. The Shah Cement, located at Dhaka, is
solutions like 33kV indoor substation, scope of solutions include 800xA DCS one of the pioneer cement companies
switch boards, distribution and convertor with AC800M, servers, workstations in Bangladesh. Shah Cement has a total
duty transformers, LT PCC and MCC, and screens along with all electrical plant capacity of 6 MTPA and has about
variable frequency drives, LT and VFD duty equipment. ABB has also provided hands- 16% market share.
motors, HT capacitor, automatic power on training in safety procedures and For more information: www.abb.com/cement
factor control and 800xA based AC800M operational training. In addition to the
distributed control system. supply and commissioning, the customer
18 contact 1 | 12

19. In focus
Tapping into Oman’s sturdy
construction sector
KNX system improves comfort, energy efficiency and security in hotels, public buildings or skyscrapers
Gulf’s premier event The Annual Oman Construction Technology in Middle East and Africa,
Summit held in Muscat saw key players shared insights on the modern green
on construction in the construction sector gather together building technology at a panel discussion
and investment to discuss the major construction and
infrastructure projects in the Sultanate.
on ‘Reviewing Oman’s Regulations,
Standards, and Specifications Summit’.
opportunities Executives from all over the region were “With greater demand of dependable,
able to interact with executives from ABB energy efficient solutions for infrastructure,
and understand how the company can green building has become to focus
contribute to the sustainable future of globally and also in Oman. ABB systems
Oman with leading edge, energy efficient and products are designed to save energy
technology solutions. the easy way; for example our intelligent
With a strong focus on climate building control system KNX system, is
change and relative energy challenges, one of the most energy-efficient building
a sustainable and efficient future was automation systems on the market.
seen as the need of the hour. For ABB, The ability to control energy-intensive
the challenge is to reduce energy functions, such as air conditioning
consumption while always maintaining and lighting in each room, is reducing
capacity where it’s needed. significantly power consumption and
ABB is well-equipped to improve carbon dioxide emissions in buildings “,
on tomorrow’s infrastructure. An explained Zakaria. KNX system improves
infrastructure that encompasses all the comfort, energy efficiency and security
key elements of a dynamic society: for example in hotels, public buildings or
airports, ports, roads, water supply and skyscrapers where energy consumption is
sewage disposal, track-bound systems, traditionally very high.
tunnels and public buildings such as The Construction Summit and joint
hospitals, sports arenas, shopping malls exhibition saw over 300 visitors consist of
and residential housing. Omani government officials and industry
At the summit Tarek Zakaria, ABB professionals across the region.
regional manager for KNX Building For more information: www.abb.com/industries
contact 1 | 12 19

20. In focus
Enabling JSW Steel to manufacture steel
at competitive price
JSW cold rolling mill facility, Bellary
ABB has equipped the JSW cold the most modern, eco-friendly steel integration of automation functions
rolling mill, the most modern CRM plants with the latest technologies based on ABB 800xA control system.
plant in the world at Bellary, with its for both upstream and downstream ABB has also provided the Level 1 and
latest technology. The CRM plant is processes. It is also one of the lowest Level 2 automation system to integrate
equipped with modern automation, cost steel producers in the world. ABB the plant. Level 1 control system for
drives and control systems. ABB in India has prepared the CRM with advanced mills is based on 800xA which is highly
was the sole supplier for automation drive and automation technology. The flexible and scalable ABB DCS solution
and drives for this green-field project drives control is based on the patented and level 2 consists of production
which consists of continuous pickling Direct Torque Control or DTC concept, management and process control.
line (CPL), compact cold mill (CCM), providing dynamic performance in terms In close collaboration with JSW
electrolytic cleaning line (ECL), skin pass of torque and speed accuracy. The Steel Ltd. and other suppliers, ABB
mill (SPM) and two recoiling lines cum high torque accuracy and dynamics in India ensured a rapid plant start-
tension leveling lines (RCL). of the drives used in combination with up by supporting it with the advanced
ABB solutions helped the CRM mass flow control leads to extremely automation systems. Ensuring that the
plant to improve yield and productivity fast correction times of process CRM plant was commissioned within
of processing lines, improved surface disturbances and exceptional thickness a record period of 24 months, it has
quality and finishing, better roughness quality. ABB power system and presently a capacity of producing 10
transfer reducing turnaround time, drives consist of ACS 6000 family of MT per year cold rolled coils. On an
accurate tension control, enhanced medium voltage drives based on IGCT average 350 coils are manufactured per
strip defect inspection to log surface technology, coupled with synchronous day. The consistent cold rolled quality
defects and production planning and machines for accurate torque control for has enabled JSW to produce steel at a
management through modern MES the compact cold mill. Medium Voltage very competitive price catering to the
system. switchgear system, LV distribution, and automotive and process industries.
JSW Steel Ltd., with a capacity UPS system were also supplied in this
Visit ABB YouTube channel to watch
of 10 million tonnes per annum is project. the video
a major player. It is India’s second ABB has standard software modules www.youtube.com/abb
largest steelmaker and boasts of for rolling mills, consisting of total For more information: www.abb.com/metals
20 contact 1 | 12

21. In focus
Full Service contract for Oman aluminum
rolling mill
ABB will manage, develop, implement and execute the entire maintenance function at the plant
ABB won a contract worth $9 million of our shareholders,” says Buddy
Agreement from Oman Aluminum Rolling Company Stemple, chief executive officer of Oman
will ensure (OARC) to develop, implement and
execute all maintenance activities at the
Aluminum Rolling Company.
Through the ABB Full Service
best practice company’s rolling mill plant in Sohar, concept, ABB will manage, develop,
Oman. implement and execute the entire
maintenance and The greenfield aluminum rolling mill maintenance function at the plant
will produce flat sheet and aluminum including all mechanical and electrical
increase plant foil with a capacity of 140,000 tonnes maintenance regimes, shutdown
reliability per annum and will primarily serve the management, planning and scheduling
Middle East and European markets. and reliability maintenance.
The projected completion of the plant “Our innovative approach to
is expected during Q3 2013 when the performance-based services ensures
plant will commence operations. improved production and equipment
“We look forward to having ABB performance, energy efficiency and
as a partner in the new rolling facility. reliability for the entire facility,” says
ABB brings experience in Oman and Saeed Fahim, country manager for ABB
gives us access to their global rolling in Oman.
capabilities of ABB for maintenance ABB’s renowned global expertise,
services and rolling technology support. tools and methodologies will assist
The agreement is performance based OARC in allowing a successful start up
and provides both parties incentives of the plant. The agreement involves 55
for success. OARC and ABB will ABB employees directly and will start in
work jointly to provide a high rate of June 2012 and continue for a minimum
Omanization within the maintenance 5 year period.
work force which is in the interest For more information: www.abb.com/service
contact 1 | 12 21

22. In focus
Bringing increased efficiency to the
Southern Hemisphere’s largest coal project
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 Industrial IT System 800xA Extended Operator Workplace
V
ale - the world’s largest iron In 2008 Vale awarded ABB the
ore producer - significantly contract for Moatize’s electrification ABB scope of works at Moatize
raised its initial production and automation. ABB collaborated includes
target for its Moatize coal mine internally with members of the Centre - Extending the existing substation
in Mozambique, expecting to quadruple for Excellence for Mineral Processing at Matambo with a new 220/66 kV
initial targets by the end of this year. in Switzerland, and formed an external bay including a 45 MVA 220/66 kV
Ships emptied of iron ore in Asia are consortium with B&W Electrical and transformer and extension to the
now filled with coal in Mozambique Instrumentation. existing double busbar system
for return journeys to Brazil and other ABB has made a huge contribution - Installing a 44km, 66 kV overhead
steelmaking markets. towards the cost-efficiency of the line from the Matambo substation
It is believed that some of the project through its multi-drive solution to the Moatize site
world’s richest coal deposits are located in variable speed drives. Compact and - Building a new switchyard
in Moatize in the Tete Province of movable substations known as Mini equipped with SCADA system at
Mozambique – 2000 kilometers (1,250 subs have been designed for a part of the proposed Moatize site with a
miles) north of the capital Maputo. With the 22kV distribution in the plant. These 45 MVA 66/22 kV transformer
a targeted production volume of 12 are built on steel baseframes with a - 22 kV GIS switchgear and DC
MTPA of hard export coking coal and 2 distribution transformer up to 800 kVA power supply units, plus 22 kV
MTPA of export thermal coal, the mine and an LV distribution board. Ring main power factor and harmonic filter
brings much needed economic growth units (RMUs) used in the distribution system
to the region, as does the upgrade of system are SF6 insulated compact - Control system equipment,
rail and port facilities. Moatize, which switchgear units with a short circuit complete with workstations and
employs 7,500 workers, transports current of 25 kA. furniture. DCS equipment and
its coal along a 600-kilometer railway For more information: www.abb.com/mining software packages
line to the port of Beira in central - Plant lighting and earthing
Mozambique. protection system. Plant lighting
and small power system within
substation area
22 contact 1 | 12

23. In focus
One of the largest System 800xA
installations in the world
Vale Nouvelle
Calédonie, part of
the Vale group has
ABB installations
as well as has a
long-term service
contract
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 Based on customer feedback and
Mozambique is not a standalone ABB solutions for the System 800xA continued collaboration, Vale awarded
project. Vale Nouvelle Calédonie, part open pit mine’s refinery comprised of ABB a three-year service contract to
of the Vale group, has a plant in the the following: provide onsite process control systems
French-territory South Pacific island of - 48 operator workplaces service and maintenance of the process
New Caledonia. This site ranks as one - 15 Quad screen and 20 Dual screen plants installed System 800xA process
of the richest undeveloped laterite ore Rich clients automation system in 2009. The service
bodies in the world, with an estimated - 10 engineering workstations and 10 contract formed part of an overall
55 million tonnes of measured and temporary engineering workstations solution package offered to Vale.
indicated mineral reserves. - Integration of approximately 8,000 “Good planning and preparation
In 2005 Vale Nouvelle Calédonie HART-capable instruments resulted in a successful execution
awarded ABB the electrification and - Approximately 1,100 DOL and 450 (of the upgrade).” shared Ghislain
automation of this new nickel refinery. VSD Profibus devices Belmonte, Technical Services Manager
Vale Nouvelle Calédonie selected ABB’s - 2 OPC clients (connecting to at Vale.
flagship automation solution, System OSI PI) ABB leverages its more than 20
800xA, for the facility’s automation - 2 IM servers years’ knowledge of mineral processing.
system – making it one of the largest - 33,000 History logs As the original equipment manufacturer
System 800xA installations in the world. - 23,000 (redundant) 800xA tags of the control system, ABB had the
Beyond the breadth and scope of - 56,000 (non-HI) CLPs added capacity to provide expertise to
the mining site and plant, as well as - 15,000 (HI) CLPs support, maintain and train the local
the client expectation of continuous - 1 PC network monitoring system Vale New Caledonie teams.
installation and commissioning support, - 50 AC800M (redundant, PM 864) For more information: www.abb.com/mining
there was a unique challenge posed: controllers
for the first time, ABB needed to abide - 4 AC800M (redundant, PM 866)
by French standards. All drawings controllers
and documents produced had to be - 8 AC800M (redundant, PM 865)
submitted in both French and English. controllers
contact 1 | 12 23

24. Events
Solar takes centre stage at WETEX 2012
exhibition in Dubai
ABB’s cutting-edge solar power are delivered in pre-tested 1 MW company, introduced FocalPoint
generation systems were showcased modules for scalability, cost efficiency solution suite that offers advanced
at the WETEX 2012 (Water, Energy, and rapid installation. business analytics solutions. The
Technology and Environment) exhibition The scope of supply covers business intelligence captures and
in Dubai, UAE. The show provided the entire project from site and aggregates rich data in a plant held
an opportunity for professionals in project assessment to plant design, across disparate software systems.
the energy, water and environment engineering, installation, commissioning, The solution can be easily tailored for
management industries to exchange service and maintenance. In partnership individual users or user groups.
ideas with the potential to transform the with contracted manufacturers, ABB Asset management tools such as
future of communities, economies and also supplies a complete range of solar Symphony Plus software compile the
nations. trackers. industry’s best business practices
For the first time, customers The show came hot on the heels into pre-packaged solutions to enable
and visitors were able to try ABB’s of an announcement to build the companies to more effectively monitor
interactive augmented reality demo pod. Mohammad Bin Rashid Al Maktoum and manage their distributed assets
The hands on tool allowed visitors to Solar Park which will be operated by on a real-time, near real-time and
be given an interactive virtual tour of a Dubai Electricity and Water Authority event driven basis. The software leads
solar plant via a large screen. The 3D with the first phase of the project, operators to greater awareness, faster
visualization of a photovoltaic (PV) plant 10MW of solar power, slated to be response and better decisions.
on the screen explained ABB’s turnkey completed by 2013. The exhibition provided visitors an
solution for a power plant, touching Other key ABB technology and excellent platform for a discussion on
on product details like the megawatt features highlighted included energy how ABB can help improve productivity
station. efficiency, solutions for the water in various processes while saving
ABB’s solar solutions maximize industry and the Smart Home and energy and lowering environmental
plant performance and provide owners Intelligent Building Control (KNX) that impact.
with a rapid return on investment and a meets the highest requirements for For more information: www.abb.com/solar
long plant operating life. The solutions applications in modern home and www.abb.com/water
include trackers, inverters, transformers, building control.
electrical and control equipment which At the exhibition Ventyx, an ABB
Turbocharging solutions for better
operational and environmental performance
The turbocharging business of with outputs ranging from 2,500 KW
ABB in India showcased its products to the highest in the industry. The TPL
and solutions in the 7th International series have features designed to satisfy
Maritime Exhibition and Conference strict environmental requirements and
(INMEX 2011) held at Mumbai. typically need overhauls after long time
Advanced turbocharging solutions durations.
and service, resulting in maximized fuel Visitors to the ABB stall included
efficiency and reduced emissions, were officials from Wartsila India Ltd.,
displayed at ABB’s stall. The business Chidambaram Shipcare Pvt. Ltd.,
showcased its expertise as a solution GMMCO Ltd, Pipavav Shipyard
provider through Power2 Technology Ltd,Kirloskar Oil engines Ltd, Shipping
along with latest A series Turbochargers. Corporation of India, Great Eastern
The highlight of the stall was the cut Shipping, Indian Navy and Indian Coast
section of the TPL series turbocharger. Guard.
This turbocharger provides a robust and For more information: www.abb.com/turbocharging
reliable platform for engine applications www.abb.com/marine
ABB stall at INMEX 2011
24 contact 1 | 12

25. Events
Flagship technology showcased at major
trade show held in Doha
Visitors at ABB stall at World Petroleum Congress
‘Olympian event ABB’s pioneering technology in the oil
and gas industry drew major attention at
is necessary. Integration of systems and
applications where all actionable information
of the oil and gas the 20th World Petroleum Congress (WPC) is available for use in the system can be
held in Qatar. provided to users in a variety of roles.
industry’, the WPC The power of the integrated solutions
and System 800xA – the company’s Robots increase productivity
was attended by flagship distributed control system, the A special feature at the ABB stand was
a global oil and IRB 120 robot and asset management the IRB 120 multi-purpose industrial robot
solutions from Ventyx, an ABB company, that visitors were able to try operating.
gas audience took center stage at the event. The robot consumes 50 per cent less
power compared to even the lowest
and outside Focus on energy efficiency power consuming robot and allows easy
stakeholders System 800xA extends the reach of
traditional automation systems - beyond
transportation and hassle-free installation.
The robot is capable of handling a payload
control of the process - to increase energy of three kilos (four kilos for vertical wrist)
efficiency, asset utilization, energy savings with a reach of 580mm.
and operator effectiveness. Visitors to the exhibition were given an
At a plant, in order to be competitive, interactive and hands on demonstration of
various plant entities, departments and ABB’s flagship technology which improves
personnel have to work as one flexible, productivity and energy efficiency across
integrated, collaborative team. For this to a number of different industries.
be accomplished, an automation platform For more information: www.abb.com/oilandgas
with incredible connectivity capabilities
contact 1 | 12 25

26. For a better world
Breakthrough order for DC
technology
ABB wins order distributing power through a single
DC circuit providing significant power
to install the first savings.
Launched in May 2011, ABB’s
ever DC-based Onboard DC Grid is part of a revival
of power solutions using DC, and
electric solution will provide highly efficient power
for a vessel. The distribution and electric propulsion for a
wide range of vessels. It is designed for
Onboard DC ships with low-voltage onboard circuits,
such as offshore support vessels, tug
Grid will allow boats, ferries and yachts, and can
vessels to cut fuel reduce fuel consumption and emissions
by up to 20 percent.
consumption and ABB will provide its full onboard DC
system, including all power, propulsion
emissions by up to and automation systems for the 93
20 percent meter long, 5,000 tonnes multi-purpose
oil field supply and construction vessel,
ABB has won an order from ship which is scheduled for delivery in the
owner Myklebusthaug Management first quarter of 2013.
to supply the first ever direct current A key advantage of ABB’s Onboard
(DC) power grid on board a ship. The DC Grid is that the ship’s engines
equipment will allow a new offshore no longer have to run at a fixed
platform support vessel, under speed and engine’s speed can be
construction in Norway, to operate at adjusted to optimize fuel consumption.
the highest energy efficiency level to By eliminating the need for bulky
minimize emissions. transformers and switchboards, the
In traditional electrical propulsion footprint and weight of the electrical
vessels, multiple DC connections are system can be reduced by up to 30
made to thrusters and propulsion drives percent, leaving more space on the
from an alternating current (AC) circuit, vessels for passengers or cargo while
accounting for more than 80 percent of also providing greater flexibility in the
electrical power consumption. ABB’s positioning of system components in the
Onboard DC Grid represents a step vessel.
forward in optimized propulsion by For more information: www.abb.com/marine
26 contact 1 | 12

27. For a better world
Turning electronic scrap
into gold
Electronic scrap. Images courtesy of Boliden
ABB power and automation production lines for processing into high- voltage switchgear to ensure safe and
technologies are helping metals grade products. reliable power distribution throughout
company Boliden create the world’s In 2010, e-scrap accounted for the plant; low-voltage industrial drives
largest electronic scrap recycling facility 6 percent of Rönnskär’s feed, with to speed-control the motor applications
– recovering copper and precious metals recyclable materials as a whole and reduce energy consumption
from electronic scrap using only a contributing 24 percent. When the new and RESIBLOC dry-type distribution
fraction of the energy required to extract plant reaches full capacity in the second transformers, which are explosion-proof
metals from ore. quarter of 2012, these figures will rise and environmentally friendly, and can
Boliden is currently ramping up a new to 14 and 31 percent respectively, thus withstand extreme loads and very high
plant adjacent to its existing electronic enabling Rönnskär to become less levels of mechanical stress and thermal
scrap recycling facility at the Rönnskär dependent on copper concentrates and shock.
copper smelter in northern Sweden. The more energy efficient. The entire e-scrap recycling process
expansion will almost triple the recycling Recovering metals from electronic is controlled by ABB’s 800xA Extended
capacity from 45,000 metric tonnes to scrap requires only 10-15 percent of Automation System, and includes
120,000 metric tonnes a year, making the energy required to extract metals customized features such as remote
it the largest e-scrap recycling facility in from ore. The process also supports operation of the process and an exact
the world. the European Union’s Waste Electrical positioning system to prevent spilling of
Rönnskär is an integrated and Electronic Equipment (WEEE) molten metal from the furnace.
metallurgical complex, which smelts Directive, which requires 4 kg of e-scrap The System 800xA solution for the
and refines metals from mined copper to be collected and sorted per head of Kaldo plant expansion is integrated
concentrates and from recyclable population in the EU. This is expected to with Rönnskär’s existing System
materials like metal shred and electronic rise to 13-16 kg per person by 2016. 800xA distributed control system,
scrap. E-scrap comes from computers, ABB has played a significant role in which controls the entire site and all
mobile phones, circuit boards and other the Kaldo plant expansion and at the its production processes. When ABB
electronic equipment and contains Rönnskär complex as a whole. For the first installed the Rönnskär automation
metals such as copper, gold and silver. new Kaldo plant, ABB has supplied a system in 1999, it was one of the largest
The pre-sorted and pre-shredded comprehensive range of process-critical plant control systems of all time, with
e-scrap is smelted at Rönnskär using power and automation technologies, more 50,000 input/output (I/O) points.
Boliden’s proprietary Kaldo furnace including the process control system. For more information: www.abb.com
technology. After smelting, the molten On the electrical side, the ABB
metals are transferred to the adjoining solutions include low- and medium-
contact 1 | 12 27

28. Glimpses of ABB
Building a nation –
ABB congratulates
UAE for 40 years of
success
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
28 contact 1 | 12

29. Glimpses of ABB
Day was celebrated on December 2 “ABB technology is everywhere. a vital role in driving the country’s
2011. Over the past 40 years, ABB has Our solutions enable reliable power infrastructure, projects and economy
helped increase grid reliability, energy and energy efficient automation from forwards, for many years to come,” said
efficiency and industrial productivity the world’s tallest tower, palm islands Frank Duggan, country manager for ABB
across many elementary sectors such as or driverless metro system right down in the UAE.” We take this opportunity to
utilities, transportation and the economy, to utilities and industrial sector; our congratulate the lead of the nation and
while ensuring sustainable growth for the presence in the UAE has been far- its people for the 40th National Day of
nation. reaching. ABB will continue to play UAE.”
contact 1 | 12 29

30. Glimpses of ABB
Dubai Metro is powered by ABB substations
Behind the scenes of the noble thanks to ABB’s products, which capacity to become the second biggest
landmarks ensure reliable, high quality power. Two 5-gallon water producer in the world.
Burj Khalifa, the world’s tallest substations supply power to all red
tower, houses ABB technology that line stations, while the third substation Powering the nation
enables reliable power, water supply supplies power to the entire green Furthermore, ABB has played an
and energy efficient cooling throughout line. The metro has transported 100 integral part in helping the UAE to meet
the 5-million square-foot building. The million passengers since it opened in its electricity demand and upgraded and
world’s highest distribution substation September 2009. expanded electric power transmission
and control equipment that ABB and distribution through the country.
custom-engineered are on the top Leading edge technology for The contracts, signed with Abu Dhabi
floors ensuring power to lighting, complete water cycle Water and Electricity Authority (ADWEA),
elevators, ventilation, heating and the air To assist the capital’s rising demand helped meet the growing demand for
conditioning system. for drinking water, ABB has worked with energy. ABB also worked with DEWA to
Additionally, ABB is the driving Abu Dhabi Transmission & Despatch deliver electrical power to Dubai’s two
force behind the Dubai Fountain, the Company (TRANSCO) on a major palm shaped islands.
world’s largest dancing fountain. The expansion of a water transmission In addition, ABB successfully
company supplied equipment such system. The project increased the strengthened the power and
as switchgears, transformers and volume of water supplied by the transmission network in the north of the
power monitoring systems to ensure Shuweihat power and desalination plant country for the Federal Electricity and
the feature receives reliable power. to Abu Dhabi by expanding the capacity Water Authority (FEWA) in Ajman, UAE.
The fountain’s energy efficiency and of two pumping stations. The substations were part of a wider
power quality was increased with ABB’s Meanwhile, ABB’s robots, helped project to expand the power supply
capacitor banks and harmonic filters. the Oasis Water Company to automate network in the northern region.
The Dubai Metro, a key part of the a once-hazardous operation and
city’s infrastructure, runs smoothly increased its bottled water production
30 contact 1 | 12

31. 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 Preview 2|12
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
Solar
whatsoever in connection with their use. Generating power from the sun
The companies of the ABB Group do not make any
warranty or guarantee, or promise, expressed or Light and heat from the sun is the most abundant energy
implied, concerning the content or accuracy of the source on earth.The solar energy that hits our planet’s surface in
views expressed herein. 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.
contact 1 | 12 31

32. Connect renewable power to the grid?
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 fight
climate change. www.abb.com/betterworld Naturally.