Call for action to accelerate global sustainability

Real Progress campaign begins with automation, electrification and digitalization in mining, metals and pulp and paper industries

ABB has launched a new global sustainability initiative, showcasing the power of technology and expertise to accelerate sustainability while enhancing productivity has been launched by ABB. Their Real Progress campaign is a rallying call to customers, partners and suppliers, inspiring them to harness technology leadership and the solutions that exist today to amplify their own impact across process industries such as mining, metals and pulp and paper.

For more than 130 years, the technology leader has been embedded in industries where emissions are hard to abate and where alternative solutions are either unavailable or difficult to practically implement. Today, ABB is combatting many changes happening in the world, such as rising emissions, water and energy scarcity and workforce skills challenges. The company is showing that the power of bold ideas and pioneering technologies can overcome these challenges, step by step, together with the wider industrial and societal ecosystem.

The decarbonization challenge unites the mining, metals and pulp and paper industries with leadership teams striving to meet increasing market demand with a more rapid increase in energy and resource efficiency to reach their committed sustainability targets such as more carbon-neutral operations. Across these vital process industries, there is a growing recognition that automation, electrification and digitalization are essential components of their journey towards meeting climate targets set out by businesses, legislation, governments and international agreements over the next 25 years and beyond.

“The journey toward sustainability isn't a gradual progression; it's a bold transformation. The actions and decisions we take today, together with every innovation we embrace, are powerful steps towards a sustainable future, and we're unapologetically leading the charge,” said Joachim Braun, Division President, ABB Process Industries. “Every day, ABB is working side by side with customers in their mines, their mills and their plants, to provide complete technology solutions with automation, electrification and digitalization to radically reduce emissions and energy use. Together with our great network of partners, we are proud of driving real progress in sustainability, but we know that more can and must be done. We’re part of the journey and commit to making real progress always.”

In the metals industries, ABB is committed to enabling customers to use less energy and raw materials when producing steel and aluminum through advanced automation and electrification systems, combined with industry-specific equipment and digitalization, across plants. One solution that brings autonomous plants to life is ABB Ability™ Smart Melt Shop. It facilitates operational excellence by combining real-time crane and ladle tracking, automatic and optimized crane scheduling and heat loss prediction. Benefits include raising casting speeds by 4-5 percent, 5 degrees Celcius less arcing per heat, reduced delays, less material rejection and increased human safety​.

As steel companies move from traditional blast furnace-basic oxygen furnace (BF-BOF) to more sustainable electric arc furnace (EAF) steelmaking, technologies such as ABB’s ArcSave® electromagnetic stirrer (EMS) can also be deployed in the melt shop to create equilibrium in the melt, enabling more steel to be made, faster and using fewer resources. In partnership with Tenova, this solution has been deployed on the world’s largest EAF, operated by customer Acciaieria Arvedi in Italy. The results include an 18 degrees Celcius lower tapping temperature, a 3.6 percent reduction in electrical energy consumption and a 38,000-ton annual reduction in CO₂e emissions at the plant. EAF productivity has also increased by 5 percent.

ABB Ability™ Energy Management System is a digital solution that provides monitoring and optimization of energy consumption and CO₂e footprint across the metals enterprise. Benefits of this solution include improved planning of operations and 5 to 15 percent energy cost savings in the entire plant.

Electrification is a key pathway to more sustainable metals manufacturing. Leveraging 100 years of metals process know how, ABB experts work together with customers to tailor drives and motors solutions to perform reliably and precisely according to the demands of each process. From primary steelmaking through rolling and processing, using ABB medium and low voltage drives and motors means more efficient energy use, cutting operating costs.

“Alongside some of the foremost steelmakers and aluminium producers in the world, we’re facing a reality that the industries consume large amounts of energy and are responsible for a large proportion of CO₂e and greenhouse gas emissions today,” said Frederik Esterhuizen, Global Business Line Manager, Metals, ABB Process Industries. “We’re enabling mills to take control of their processes and equipment to improve process efficiency, product quality and yield while maximizing resource and energy efficiency. In this way, we will help to limit climate change and create real progress for future generations.”

“Sustainability isn't an option; it’s an imperative for every business leader in our rapidly evolving world. To thrive and create a better future, we must embrace sustainability at the core of our operations,” said Rohit Sharma, Global HSE and Sustainability Manager, ABB Process Industries. “It’s not only about being responsible but also about staying competitive and resilient in an ever-changing global landscape. Our commitment to sustainability today will define our success and impact generations to come.”

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@ABBgroupnews @abbindustryserv @abb_automation #Steel #Pauto

Valve for heavy slurry service.

Emerson’s Clarkson™ KS1 Knife Gate Valve is a true bi-directional, full bore, ASME Class 150 valve designed for the rigours of heavy slurry service. Its advanced, patented sealing system delivers zero-leakage isolation for longer, enabling increased run time and throughput.

The new Clarkson KS1 Knife Gate Valve, designed to help mine, oil sands and pulp & paper operators achieve increased availability of their most challenging slurry processes has been announced by Emerson.

“The Clarkson KS1 is a compelling innovation for operators of heavy slurry processes, such as tailings lines,” explained Mike Gordon, director of Emerson’s knife gate valve business. “This valve is purpose-built for extended zero leakage isolation in these tough environments, so these processes run uninterrupted for longer to improve throughput and minimise valve maintenance costs.”

The new knife gate valve features a patented gate edge seal design that creates a continuous seal around the gate, together with a precision-moulded elastomer seat. This heavy-duty seat increases the contact area and resilient sealing ability of the valve compared to standard O-ring designs, resulting in superior isolation performance over an extended lifecycle.

The valve design has been optimised to thrive in heavy slurry conditions with a full round port that eliminates protrusions into the flow, which minimises turbulence across the valve and reduces wear on valve components and downstream equipment. Reversible, rotatable wear rings also come standard on both sides of the valve to protect the seat and extend maintenance intervals.

Maintenance teams were also top of mind during the design of the KS1. The valve is repairable with standard tools and readily available spare parts. Adjustments can be made to the packing system externally that dynamically self-adjust pressure to the gate edge seal system. The KS1 is also designed to standard MSS SP-135 face-to-face dimensions for simple changeout and upgrade of underperforming installed valves.

The Clarkson KS1 comes built tough for the rigours of severe slurry service in sizes 2” through 30” with a variety of available flange patterns, an ASME Class 150 pressure rating of 290 psi (20 bar) at ambient temperature and a temperature rating up to 300°F (149°C). Alternate materials are also available to combat extraordinary abrasive and corrosive process conditions and a variety of automation options can be configured to suit.

@Emerson_News @EMR_Automation @HHC_Lewis #Pauto #Slurry

Drives in pulp & paper.

ABB and international producer Sun Paper have completed the successful activation of a major drives project at the first modern pulp and paper site in Laos as part of an investment towards reaching an output of 1.2 million tons of pulp and paper annually.

The project, completed by ABB 18 days ahead of schedule despite the restrictions of the pandemic, represents Sun Paper’s first overseas production base and supports China’s Belt and Road Initiative, an important infrastructure development strategy.

“The successful and timely delivery of this large-scale execution from our China Pulp and Paper team proves ABB’s deep process control application expertise and our capability to deliver paper machine modernization projects across the Southeast Asia region,” said Liu YueMing, ABB Pulp and Paper Lead, North Asia and China. “Considering that overseas projects can sometimes be complex, we are pleased that this has been such a smooth and efficient start-up, especially as it took place when Laos was implementing the most stringent measures during the pandemic.”

As well as managing execution and installation, ABB provided its PMC800 multidrive system and ABB Ability™ System 800xA distributed control system to keep production of the two 400,000 ton advanced packaging paper lines (PM1 and PM2) of high-end packaging paper running smoothly. The paper machines have a total installed power capacity of 41,000KW over 120 drive points for both machines and are designed for speeds of 1200m/min. ABB was awarded the project in November 2019, demonstrating its technical capabilities and domain expertise, and successful track record on a similar scope and scale.

Located in the Savannakhet Province of Laos, the digital transformation of the mill means it can now benefit from a fully integrated solution that drives higher system performance due to remote support capability, greater running availability, faster start-up, optimization of the spare parts delivery and a more stable and easy operation overall.

ABB also recently completed another order for Sun Paper, with the installation of a fifth chemical mechanical pulp production line, with an annual output of 200,000 tons, at its Yandian plant in Shandong, eastern China. ABB’s scope of supply included two sets of 14 MW KW AMS Refiner Motors, Brushless Synchronous Motor, ABB Ability™ System 800xA DCS process control system and PMC800 multi-drives.

@ABBgroupnews #PAuto #Paper #Pulp

Slurry Sensor and Transmitter for high noise applications.

Flow measurement solution helps improve product quality, reduce raw material cost and minimise waste and re-work.

Emerson’s Rosemount™ MS Slurry Sensor with the 8782 Slurry Transmitter is a slurry magnetic flow meter specifically designed for high noise and slurry applications for use in the oil and gas, mining, and pulp and paper industries. Featuring robust coils and advanced signal processing, a responsive yet stable flow signal is possible even in high noise applications. With over 25 years of experience delivering products for these challenging applications, the new Slurry Magnetic Flow Meter helps improve product quality, reduce raw material cost, and minimise waste and re-work.


“Through the utilisation of advanced features, the Rosemount Slurry Magnetic Flow Meter can help our customers better achieve their operational goals,” said Laura Chemler, product manager with Emerson’s Automation Solutions business. “The advanced signal processing is able to adapt to changing flow rates without getting bogged down by traditional damping practices, providing more accurate flow rate feedback when it’s needed most, which in turn helps to ensure an efficient overall process that minimises waste and optimises utilisation of precious resources.”

The Slurry Magnetic Flow Meter, or Slurry Mag, provides a flow measurement solution for customers with fluids that contain large solids, mining ore, pulp or sand, or that experience high process noise or signal instability. Featuring the latest advanced signal processing that is the first to adapt to changing process conditions in real time, the Slurry Mag eliminates noise from the flow signal without using excessive damping, giving operators confidence in their measurement calculations.

Accurate measurement of process flow rates is essential to running a plant or mill efficiently - that is why the Slurry Magnetic Flow Meter uses advanced signal processing with real-time diagnostics to deliver flow measurement confidence and the ability to automatically control the loop.

The Slurry Mag Meter includes more standard diagnostics such as the grounding and wiring fault detection that helps ensure the meter is installed correctly the first time. Optional advanced process diagnostics help provide insight into performance through a high process noise detection diagnostic, as well as enable proactive maintenance in applications where coating may be a concern, such as in pulp digester applications where pitch from the wood fibres may result in coating of the meter.

Finally, the 8782 contains Emerson’s patented Smart Meter Verification capabilities providing a simplified means of troubleshooting or verifying the meter, taking a process that used to take hours and simplifying it down to minutes. While the 8782 transmitter is designed to work with the MS sensor, it is also compatible with existing 8707 installations, making the performance, signal processing and advanced diagnostic capabilities available to anyone who is already using Emerson’s solutions for these challenging applications.

 #PAuto #Oil @Emerson_News @EMR_Automation @HHC_Lewis

Magnetic flow meter transmitter.

Emerson’s New Magnetic Flow Meter Transmitter Simplifies Installation, Maintenance and Operation

The Rosemount 8712EM Wall Mount Magnetic Flow Meter Transmitter from Emerson, has additional protocols, powerful diagnostic capabilities and usability features to help users in the pulp and paper, metals and mining, and other industries gain quick and easy insight into their processes.

The meter’s local operator interface was designed using Human Centered Design concepts, making it easier and faster for technicians to navigate in the field. According to Scott Dudek, product manager for Rosemount magnetic flow meters, “The Rosemount 8712EM melds usability pioneered by Emerson’s Human Centered Design Group with the quality, capabilities, and reliability that customers have come to trust from Emerson.”

The Rosemount 8712EM’s diagnostic suite includes high process noise detection and ground fault detection. The electrode coating diagnostic offers two set points to alert when coating is present and when it is affecting flow measurement, enabling preventative maintenance. Smart Meter Verification continuously monitors the health and performance of the meter for ultimate measurement confidence.

Universal transmitter capability allows the 8712EM to operate with any existing magnetic flow meter sensor and allows backwards compatibility with all Rosemount magnetic sensors. This feature not only makes the transmitter easier to integrate with older units, but it also enables the use of the 8712EM’s advanced diagnostic features.

The Rosemount 8712EM supports HART 7 for 32-character-long tag capability for reduced start-up time, as well as options for intrinsically safe HART outputs and Modbus RS-485.

@EMR_Automation  #PAuto

New leader to focus on #Power, Pulp and Paper Industries!

Maverick Technologies has hired Bud Blankenship to fill the role of Industry Manager for Power, Pulp and Paper. In this capacity, he will oversee the company’s efforts to develop and fulfill client relationships and projects in these critical industries.

Bud Blankensop

Blankenship brings more than 40 years of experience in operations management, business development and project management related to automation in the U.S. and internationally.

“My career has spanned several decades, a great portion of which was as a client and the other providing automation engineering solutions to a variety of industries. Having experienced both sides of this industry, I am very excited to have the opportunity to join this world class organization with one-of-a-kind solution delivery capabilities and a client focus rarely seen anywhere,” said Blankenship.

Prior to joining Maverick, Blankenship served as manager of business development for Mustang Automation and Control. That stint followed more than 20 years as the manager of refinery process operations for Ashland Oil, the director of refining at Litwin Engineering, and the global refinery management for ABB.

“I’m proud to have Bud as a part of our world class team,” commented Paul Galeski, Founder and CEO of Maverick Technologies. “We help Our customers keep their plants running better on an ongoing basis, often enterprise wide, long after individual projects are completed. Providing this kind of service requires an effective leader to maintain and enhance these long-term relationships. I know Bud will excel in this role, and our customers will benefit greatly from having him as a trusted resource.”

Bill Stewart, Maverick Vice President of Operations added, “Bud knows what customers want because he’s been there himself. All his experience has been building to this new position, where he’ll provide a critical combination of technical knowledge with a strong service mindset.”

Increasing process efficiency while reducing maintenance costs in paper

Vortex flowmeter enables reliable and accurate flow measurement in paper mill, reducing downtime, lowering production costs and enhancing safety

BillerudKorsnäs has improved its pulp digester process efficiency and reduced maintenance costs at its paper mill in Gävle, Sweden by installing a Rosemount® 8800 Vortex flowmeter from Emerson Process Management. The accurate and reliable flow measurements provided by the new meter have reduced downtime and lowered production costs.

With over 1500 customers in 100 countries, BillerudKorsnäs is a world-leading manufacturer of strong primary fibre-based packaging material. The mill had previously used a magnetic flow meter to measure the flow of white liquor used in a pulp digester. This technology is frequently used for this type of application; however, it was unsuccessful in this case because the flowmeter was occasionally subjected to a significant vacuum that partially collapsed the liner. This caused the magmeter to read a higher flow rate, resulting in too little alkali input which reduced digester performance. As the process could not be stopped outside the scheduled shutdown period, it was not possible to replace the meter immediately.

"When the flow measurement was inaccurate, unreliable, or completely failed, the alkali-to-wood ratio could not be accurately controlled," said Peter Hallenberg, Project Leader Process Automation, BillerudKorsnäs. "Replacing the meter tied up our maintenance team and incurred a cost of about •3,400 per unit. We needed an accurate and reliable measurement device for this challenging application."

Since the pulp digester is a critical part of the production process, the company tried other technologies to overcome these issues including using an ultrasonic flowmeter. However, this trial proved to be unsuccessful as the solids and fibres in the liquor would build up on the meter walls, causing unpredictable flow readings.

The mill solved this flow measurement challenge by installing a Rosemount 8800 Vortex flowmeter, which is not affected by the high liquor temperature, vacuum, coating, or suspended solids in the flow.

Vortex flowmeters are not typically considered for this application, as the fluid contains solids and fibres that would clog the crevices and ports common to traditional vortex flowmeters, impacting the meter performance. However, the unique design of the Rosemount 8800 Vortex eliminates crevices and ports and thus eliminates the risk of clogging. In addition, the 8800 is balanced so it is not affected by vibrations in the pipes that are typical in mill applications. The resulting flow measurement is accurate, stable and reliable.

For BillerudKorsnäs, the more accurate flow measurements translated to more consistent pulp quality and a lower cost per tonne of pulp. The mill has also reduced maintenance costs by eliminating the need to remove and clean the failed flowmeter. This has also enhanced safety at the plant because operators no longer need to maintain faulty equipment. In addition, the reliability of the vortex flowmeter has enabled BillerudKorsnäs to detect that a decrease in the flow reading was being caused by progressive plugging of the heat exchanger. Operators are now able to proactively take corrective action, increasing process efficiency.

"Emerson’s flowmeter has been working reliably for two years with no downtime for cleaning or repair," Hallenberg added. "The accurate and reliable flow measurements provided by the Rosemount 8800 Vortex flowmeter have improved pulp digester process efficiency. In addition, process availability has increased and maintenance costs reduced."

Acquisition strengthens pulp & paper offering

ABB completes acquisition of Lorentzen & Wettre

ABB has completed its acquisition of Lorentzen & Wettre from ASSA ABLOY AB.

Lorentzen & Wettre manufactures equipment for quality control, process optimization and test instrumentation for the pulp and paper industry. The acquisition enhances ABB’s position as a leading pulp and paper solutions provider and complements ABB’s existing portfolio. Lorentzen & Wettre will be integrated into ABB’s Process Automation division.

Pulp & paper offering strengthened

ABB to acquire Swedish manufacturer of quality control and process optimization solutions

ABB has agreed to acquire Lorentzen & Wettre from ASSA ABLOY AB (publ) for a price of about €83m (SEK 750m or US$119m), to strengthen its business in the pulp and paper area.

Based in Sweden, Lorentzen & Wettre manufactures equipment for quality control, process optimization and test instrumentation for the pulp and paper industry. It has production facilities in Kista and Kajaani, Finland, and sales and service offices across Europe and in Canada, China, Japan, Singapore and the US. The company has approximately 190 employees, and will be incorporated into ABB’s Process Automation division.


“This acquisition will nicely complement our existing portfolio of pulp and paper industry offerings,” said Veli-Matti Reinikkala, head of ABB’s Process Automation division. “This is an excellent strategic fit as Lorentzen & Wettre’s products and services will enable us to address the broad spectrum of pulp and paper production challenges.”

Founded in 1895 the company has technology that contributes to improving paper quality, reducing manufacturing costs, and cutting the consumption of raw materials and energy. The company’s offering includes automated fiber and pulp analysis devices, consistency transmitters, moisture sensors, laboratory paper testing instruments, automated paper testing systems, and industry specific services.


"We are very excited to continue to develop our business as part of the global Process Automation business of ABB,” said Patrik Stolpe, CEO of Lorentzen & Wettre.

The transaction is subject to customary regulatory approvals. ABB expects the acquisition to be completed during the second half of the year.

Metal, pulp & paper applications

Yokogawa signs global partnership agreement with ANDRITZ

Yokogawa Electric Corporation has been selected by ANDRITZ as a global partner for the provision of process control systems, field instruments, and process analysers for their customers' metal and pulp & paper plants. The object of this agreement is to standardise the terms and conditions of contracts and promote greater efficiency in the global purchase and supply of products, systems, and services.

Curd Ornig, Head of Category Management of ANDRITZ Group's Global Procurement organisation, commented as follows about this agreement: "The ANDRITZ Pulp & Paper business area is a leading global supplier of turnkey systems and services for the production of all types of pulp, paper, tissue paper, board, fibre board (MDF) and nonwovens, as well as of biomass boilers and gasifiers for energy production. ANDRITZ Metals is one of the leading global suppliers of complete lines for the production and further processing of cold-rolled carbon steel, stainless steel, and non-ferrous metal strip. ANDRITZ values its relationship with Yokogawa and believes that working collaboratively to meet our creative endeavours will continue to deliver value for both companies."
Dr. Tony Lee, Vice President, Yokogawa Electric Corporation, said: "We have become a global partner of ANDRITZ by demonstrating the strength of our products, their reliability, and our global support capability. We look forward to strengthening our corporate relationship with ANDRITZ by delivering cutting-edge solutions from both our companies to end-users."