ABB Retrofits Enhance Energy Efficiency at Cemex Plant

Automation machinery powerhouse ABB has significantly enhanced operations at Cemex’s facility in Poland through bespoke retrofit solutions.

The global building materials provider Cemex has observed not only greater safety and reliability in their processes but also a significant reduction in energy consumption following upgrades to its electrical infrastructure.

By retrofitting, Cemex is not only future-proofing its operations but also boosting asset monitoring through the integration of digital technology in place of outdated analogue systems.

Rising to the challenge

Cemex is “committed to providing innovative and sustainable products for the construction industry” and when its own sites require solutions, it “prioritise sustainable development".

With an unwavering commitment to sustainable innovation as a cornerstone of its business philosophy, Cemex often looks towards long-term, environmentally friendly solutions when dealing with challenges at its operational sites.

Cemex’s Rudniki plant, one of Poland’s primary cement suppliers, exemplifies this approach.

The plant, famed for producing diverse cement variants and other materials, hinges its productivity on the efficient functioning of its massive furnace — which can take up to 36 hours to light.

This means that even brief power disruptions pose severe operational setbacks.

Paweł Małolepszy, a maintenance expert at Cemex, points out the crucial needs that prompted the upgrades.

“We were looking for reliable and compact technology.," he says.

“The risk of unplanned power outages has been minimised 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.”

Technological Innovation at Play

For more than a decade, ABB and Cemex have cultivated a strong collaborative relationship.

During this time, ABB has provided dependable service support throughout.

When it came to upgrading the electrical switchgear powering the furnace at the Rudniki plant, ABB tailored a retrofit solution, updating obsolete elements and enabling access to ABB’s digital portfolio.

ABB curated a specifically tailored retrofit solution that not only updated obsolete elements but also facilitated integration into ABB’s advanced digital portfolio.

This included the upgrade to ABB’s Emax2 circuit breakers enhanced with Ekip Touch, known for their robust protection features and modular, interchangeable design.

This approach significantly cuts down the costs that come with replacing entire switchgear systems while ensuring seamless transition and sustainability.

The plant’s control and monitoring systems have also been upgraded to encompass ABB's digital analysers, enabling precision measurements accurate to 1%.

This critical data feeds into ABB Ability Energy & Asset Manager, permitting real-time monitoring of energy usage, power and load via the cloud.

A tailored solution for Cemex

Cemex’s operational flexibility has markedly improved following these upgrades.

Operators at the plant now have the capability to isolate and test specific breakers without disrupting the power supply to vital components like the furnace, preventing unnecessary production halts.

Moreover, these enhancements have optimised the thermal energy efficiency of the furnace, contributing significantly towards reduced CO₂ emissions — a testament to the plant’s commitment to environmental sustainability.

“This is a perfect example of a comprehensive retrofit, tailored to our customer’s specific needs,” says Kamil Schabiński, Project Manager for ABB Electrification Service.

“ABB products have transformed the plant’s operating conditions and the reliability and safety of its power supply.

“The new circuit breakers can be connected to the cloud at any time, which will further increase their digital functionality and energy management.”

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