ABB has been appointed to provide electrification and automation systems for ArcelorMittal Nippon Steel India’s (AM/NS India) advanced steel cold rolling mill (CRM) in Hazira, Gujarat. The contract at the flagship manufacturing plant comes through John Cockerill India Limited (JCIL), the original equipment manufacturer (OEM) for the project.

• Order placed through original equipment manufacturer John Cockerill India Limited (JCIL) for the new advanced steel processing lines at the client’s flagship Hazira plant in Gujarat
• ABB technology will support increased energy efficiency and optimized zinc consumption, leading to greater sustainability in the steel production process
• The electrification and automation contract is part of a large order placed with John Cockerill India Limited (JCIL)

AM/NS India – a joint venture between two of the world’s leading steel companies ArcelorMittal and Nippon Steel – is setting up the new CRM as part of its downstream expansion plan.

ABB is providing advanced electrification and automation systems, including the ABB Ability™ System 800xA distributed control system (DCS) and associated equipment and components, to support enhanced energy efficiency, optimized zinc consumption and high levels of corrosion resistance throughout the steel production process. This will support AM/NS India in its bid to reach greater levels of sustainability at Hazira.

“Our goal is to help create smarter steels for brighter futures, brighter futures for people and the planet. To do this, we place safety, innovation, and technology at the heart of our manufacturing operations and product development and ABB’s technology will support us in this,” said Mr. Dilip Oommen, Chief Executive Officer, ArcelorMittal Nippon Steel India (AM/NS India). “The new processing lines are designed to produce new-age value-added steel, embedding the most demanding quality standards. This expansion will help us meet the growing demand for high-end steel, while also enhancing our portfolio of value-added, sustainable steel.”

“We are proud of having been chosen by such a first-class steelmaker for the supply of two highly automated processing lines, combining cutting-edge equipment with integrated quality control and enhanced energy efficiency,” said Frédéric Midy, Project Director, John Cockerill Industry. “The fight against climate change is part of John Cockerill’s mission. This new contract will not only enable us to accompany AM/NS India on its journey towards sustainability but will also contribute to the country’s low-carbon economy ambitions.”

“The metals industry is essential for the transition to a net-zero world. Working with JCIL on this milestone project will support AM/NS India in developing one of the most sustainable, efficient, and modern steel operations,” said Vinod C, Local Division Manager, Process Industries, ABB.

The new CRM with advanced processing lines is due to be commissioned in 2024.

A leading integrated flat carbon steel producer in India, AM/NS India has a crude steel capacity of 9 million metric tons per annum with state-of-the-art downstream facilities. It produces a fully diversified range of flat steel products, including value-added steel, and has a pellet capacity of 20 million metric tons.

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation

ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 130 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation.

TotalEnergies confirms its commitment to the energy transition in Kazakhstan with the signature of a Power Purchase Agreement (PPA) for the Mirny project. This will be the first PPA signed in the country for a wind project of such scale. Located in the Zhambyl region, the project aims to build a 1 GW onshore wind farm combined with a 600 MWh battery energy storage system for a reliable power supply. It represents an investment of about $1.4 billion. After Irak, it is another prime example of TotalEnergies’ ability to leverage its position as a major partner in the upstream sector to speed up the development of renewable energy in oil and gas countries.

The electricity to be produced by the Mirny project will be sold in its entirety to the Financial Settlement Center of Renewable Energy, a public entity owned by the Government of Kazakhstan, for the supply of the national grid. The project will provide electricity to 1 million people.

This agreement has been signed in Astana between Total Eren, an affiliate of TotalEnergies, and the FSC, in the presence of Patrick Pouyanné, Chairman and CEO of TotalEnergies and the Minister of Energy and Mineral Resources of the Republic of Kazakhstan, Almasadam Satkaliyev. TotalEnergies will develop the Mirny project in partnership with the National Wealth Fund Samruk-Kazyna and the National Company KazMunayGas, which will each own a 20% stake in the project.

“This project will contribute to the transition of Kazakhstan to the green energy and will be a breakthrough in strengthening French-Kazakh investment cooperation,” said Almassadam Satkaliyev, Minister of Energy and Mineral Resources of the Republic of Kazakhstan.

"As a global energy leader, TotalEnergies is proud to drive the energy transition in Kazakhstan through such an innovative project as Mirny. This wind and battery project will contribute to the supply and security of the Kazakh power grid. I would like to express my sincere gratitude to the Kazakh authorities for their support and collaboration throughout this process. This represents a significant milestone in TotalEnergies' multi-energy strategy. TotalEnergies will bring its expertise in managing large-scale projects to make it a success, " said Patrick Pouyanné, Chairman and CEO of TotalEnergies.

A wind project contributing to Kazakhstan’s renewable push

The Mirny project, which will consist of around 200 turbines, is the largest wind energy initiative ever undertaken in Kazakhstan. Supported, by both the Kazakh and French authorities, the project will be a strong contributor to the Kazakh Government's target of achieving 15% of electricity from renewable sources by 2030. It will avoid the emission of approximately 3.5 million tons of CO2 annually over the duration of the PPA signed today.

A successful renewable track-record for Total Eren in Kazakhstan

Total Eren has a proven track record of renewable energy developments in Kazakhstan. In particular, Total Eren successfully developed, financed, built, and commissioned in 2019 two solar photovoltaic farms, M-KAT and Nomad, with a combined capacity of 128 MWp. These solar farms, located in the Zhambyl and Kyzylorda regions respectively, have been instrumental in diversifying Kazakhstan's energy mix and reducing carbon emissions.

Used industrial robots from the automotive and metal industries offer an affordable opportunity for companies to add to their operations. On Surplex.com, various models can be auctioned off in June.

Robots are particularly useful in the automotive and metal industries. They ensure faster production with the same quality and less labour. But the advantages that such robots offer come with high acquisition costs. One way to get around these and still get high-quality machines for your own operation is to buy a second-hand machine.

Industrial robots can be used in a variety of ways and optimise production. Used robots can also be an ideal addition for companies. (© Surplex).

The industrial auction house Surplex always offers used industrial robots for auction. In June, too, there are several auctions of high-quality robots up for grabs. The top 3 robot auctions on Surplex.com in June are:

• 14/06 | FANUC & ABB industrial robots of a German car manufacturer
  4 industrial robots in Eger, Hungary
  FANUC models including matching control cabinet, control unit and cable set
• 20/06 | Auction after closure of an automotive supplier
  72 items, including 6 robots, in Siegen, Germany
  ABB handling robots, various models
• 29/06 | Collective auction with various metalworking machines
  04 items, including 20 robots, at locations in Baden-Württemberg, Germany
  e.g. FANUC M-6iB 6 S industrial robot, KUKA KR 6-C industrial robot, KAWASAKI JS006 industrial robot

Handling robots, welding robots, industrial robots from the automotive industry – Surplex offers suitable auctions for every business. The Surplex online auction house is set up throughout Europe and is the ideal partner for the purchase of a used machine. Buyers and sellers are offered a competent all-round service from a single source – from processing to shipping and payment.

Whether orange, blue or yellow: On Surplex.com you can find used industrial robots from many well-known manufacturers (Fanuc, Kuka, ABB, Motoman or Stäubli). (© Surplex).

About Surplex

Surplex is one of Europe’s leading industrial auction houses and trades worldwide with used machinery and equipment. The 16-language auction platform Surplex.com records approximately 50 million-page views annually. More than 55,000 industrial goods are sold each year at more than 800 online auctions. The company is based in Düsseldorf (Germany) and has offices in 16 European countries. Over 220 employees from 20 different nations generate an annual turnover of more than EUR 100 million.

Valmet will supply a Valmet DNA Automation System to Westfield Energy Recovery Limited’s energy-from-waste (EfW) facility under construction in central Scotland in the United Kingdom. The order was placed by Hitachi Zosen Inova AG (HZI), which is the engineering, procurement and construction (EPC) contractor for the facility. This is the eighteenth time HZI has chosen Valmet’s automation technology for its EfW plant projects.

The order was included in Valmet’s orders received of the first quarter 2023. The value of the order will not be disclosed. The deliveries will start in August 2023, and the system will be taken over by the customer in April 2025.

“Valmet is a reliable partner with years of experience in the energy-from-waste business and a long history with HZI. Its solutions and expertise are exactly what HZI requires in the Westfield project. We and the end customer appreciate Valmet’s commitment to sustainability, environmental responsibility and solutions that reduce the carbon footprint,” says Adrian Hiemann, Technical Project Manager DCS, HZI.

“We had good cooperation throughout the offer stage and were able to fulfill all technical requirements of HZI and the end customer. For Valmet, this project is important as it will be the first HZI project with our new web-based user interface,” says Rene Neubert, Sales Director, Automation Systems business line, Valmet.

Valmet will supply a Valmet DNA Automation System to Westfield’s energy-from-waste facility under construction in Scotland. Visualization of the facility.

The Westfield plant will consist of an incineration line and a grate boiler, treat up to 220,000 tons of municipal solid waste per year and have a turbine capacity of 25 MW.

Technical information about the delivery

Valmet’s delivery consists of a Valmet DNA Automation System including a web-based Valmet DNA User Interface, an information activity server and a boiler safety system with 2,200 hardwired signals and 8,150 gateway signals.

About the customer Hitachi Zosen Inova

Zurich-based green-tech company Hitachi Zosen Inova is a global leader in solutions for energy transition and circular economy including Energy from Waste (EfW) and Renewable Gas (RG), operating as part of the Hitachi Zosen Corporation Group. HZI acts as project developer, technology supplier and EPC contractor delivering complete turnkey plants and system solutions for thermal and biological waste recovery. Its solutions are based on efficient and environmentally sound technologies, are thoroughly tested, and can be flexibly adapted to customer requirements. More information: www.hz-inova.com.

Valmet is a leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. With our automation systems and flow control solutions we serve an even wider base of process industries. Our 17,500 professionals around the world work close to our customers and are committed to moving our customers’ performance forward – every day.

The company has over 220 years of industrial history and a strong track record in continuous improvement and renewal. In 2022, a major milestone was achieved when the flow control company Neles was merged into Valmet. Valmet’s net sales in 2022 were approximately EUR 5.1 billion. 

Valmet’s shares are listed on the Nasdaq Helsinki and the head office is in Espoo, Finland.     

Follow us on valmet.com

As the demand for sustainable packaging solutions increases worldwide, Swedish innovative packaging company, PulPac, ramps up its US expansion with tooling partner Tek Pak. Earlier this year, the Swedes announced they are setting up their own demonstration site, and they've already partnered with industry leaders in the market.

After its success at the Interpack fair in Düsseldorf last month, Swedish innovative packaging company, PulPac, keeps momentum and ramps up its ongoing US expansion. Tek Pak, based in ST. Charles, Illinois, creates precision thermoforming and prides itself on being one of the fastest tooling suppliers in the North American market. Since 1992, they've provided the medical, electronics, and consumer markets with quick-turn rapid prototyping and short to long-run production thermoforming. Solutions that give their customers competitive advantages in their respective markets. 

"We take our commitment to producing environmental and sustainability packaging seriously at Tek Pak. Having the opportunity to work closely with PulPac to provide tools for dry fiber manufacturing will give our customers a new, exciting, and innovative packaging option," says Tony Beyer, Owner of Tek Pak, Inc. 

PulPac and their patented Dry Molded Fiber technology and machine platform are groundbreaking. The manufacturing process turns renewable pulp into high-performance packaging. The technology uses much less water and energy than traditional wet-forming and has the same output and cost-efficiency as plastic processing. 

"We are really impressed by Tek Pak. Their dedication to speed, quality, and technology is what we're looking for in a partner, as the demand for sustainable packaging solutions increases worldwide," says PulPac Chief Partnership Officer Viktor Börjesson. When PulPac showcased Dry Molded Fiber at the Interpack fair in Düsseldorf in May, the interest in the novel technology was massive. Viktor Börjesson again: "People are stunned when we present data that shows Dry Molded Fiber manufacturing is on par with plastic in cost-efficiency and output speed." 

"Tek Pak was built for quality and speed; known for meeting and exceeding client expectations," comments Tony Beyer. "We are dedicated to providing the finest thermoforming tools with expedited turnaround times, ISO certified, and committed to the highest industrial manufacturing and safety standards."

"In the industrialized world, time is money," says Viktor, and concludes, "And the clock still ticks. So making the technology accessible, being agile, and developing prototypes are key factors if we want to keep up with market needs. Tek Pak's track record speaks for itself, and we know what they are capable of."

Following on PulPac’s community approach to enable a wide and ever-growing network globally within the Dry Molded Fiber breakthrough technology, this partnership is non-exclusive.

About Tek Pak, Inc.

Tek Pak, Inc. is a global manufacturing company specializing in thermoforming tooling and providing light gauge thermoform, molded fiber, and packaging solutions for electronic, food, healthcare, and industrial industries from design concept through prototype and production. Headquartered in St. Charles, Illinois, Tek Pak remains a closely held private corporation with five facilities in the western suburbs of Chicago. The company provides the most comprehensive, high-quality, and fastest light gauge thermoforming development in the world. For more information, please visit tekpak.com or call (630) 406 0560. 

About PulPac

PulPac is a Swedish Reasearch & Development company specializing in a cutting-edge technology for fiber-based, sustainable packaging. They develop the Dry Molded Fiber technology, and together with specialized partners within a global network, they provide the packaging industry with a cost and energy efficient packaging alternative to replace unnecessary single-use plastic. Learn more at pulpac.com.

About Dry Molded Fiber

PulPac's patented technology turns generic pulp into almost any three-dimensional shape. With added barrier chemistry, Dry Molded Fiber offers a simple yet brilliant solution to manufacture sustainable packaging solutions, that are biodegradable, highly recyclable ones. And process is as fast as plastic processing, only more energy and cost-efficient. Plus, it uses almost no water, which enables a cost-competitive product with a significantly lower climate impact.

Metso has been awarded orders for a gyratory crusher and apron feeders including related services and spare parts to support a mining customer project in the Americas. The value of the orders is approximately EUR 20 million, of which 80% were booked in Minerals segment’s first-quarter orders received and the balance in Minerals segment’s second quarter.

Metso Superior MKlll primary gyratory crusherMetso’s scope of delivery includes an impressive apron feeder package featuring Metso’s AF18 apron feeder, one of the largest feeders that Metso has ever produced. The apron feeder supplies material downstream to a Metso Superior™ MKIII primary gyratory crusher. The gyratory crusher accepts the largest top size feed in the market, allowing it to provide higher capacities, which makes this crusher the most cost-efficient primary gyratory crusher in the industry.

“We are excited to be able to support our customers to ensure their needs are met. It is especially rewarding when we are able to demonstrate our capabilities for flowsheet synergies such as crushers and apron feeders as this equipment works hand in hand for minerals processing,” says Guillaume Lambert, SVP, Crushing at Metso.

Metso has the capability to design and deliver even the largest apron feeder systems with high project quality. Combined with our advanced line of mining duty crushers, Metso offers complete solutions providing flexible and reliable material processing to meet high demands and ensuring the success of our customers.

Metso AF18 Apron Feeder

Read more about Metso Outotec’s feeding and crushing solutions on our website.

Metso is a frontrunner in providing sustainable technologies, end-to-end solutions and services for the aggregates, minerals processing and metals refining industries globally. By helping our customers increase their productivity, improve their energy and water efficiency and environmental performance with our process and product expertise, we are the partner for positive change.

Headquartered in Helsinki, Finland, Metso employs over 16,000 people in close to 50 countries and sales for 2022 were about EUR 5.3 billion. The company is listed on the Nasdaq Helsinki. metso.com

Outokumpu is launching a new circularity initiative, Outokumpu Inner Circle, to strengthen the circular economy in Europe. The initiative will be launched today at the World Circular Economy in Helsinki, Finland. The Inner Circle initiative will bring transparency to supply chains and smoothen the path from stainless steel to usable scrap, and from scrap to ever more sustainable stainless steel production – ultimately creating a closed loop for steel scrap. This initiative is the first of its kind for the industry.

“Circularity is one crucial element of sustainable stainless steel production. With the Inner Circle initiative, we are bringing our customers and scrap suppliers together to ensure an efficient, transparent, and sustainable supply chain for steel scrap. Ultimately, our vision is to create a visible closed loop for steel – a unique example of circular economy in action,” explains Max Menzel, Head of Sustainability & Technical Customer Service at Outokumpu.

By using existing, efficient supply chains, the ways for the scrap from customers back to the producers can be shortened. Transparency and ESG conformity throughout the supply chain will be ensured by verifying all partners within this initiative.

In the initiative, Outokumpu’s role is to steer the initiative and create networks between customers and verified scrap suppliers. The scrap suppliers’ role is to ensure a sustainable supply chain by providing scrap from the network’s partners and to distribute the scrap sustainably. Customers who join the program will bring their scrap back into the cycle after processing the material or by the end of the product’s life cycle via the scrap suppliers.

“Together we will show strong initiative and leadership by spearheading the move towards a more circular and a closed-loop economy. Our partners can join this unique and open initiative, which is the first in the industry, and demonstrate their leadership and contribution to the circular economy,” says Max Menzel.

Inviting steel industry partners to join

Outokumpu’s partners can now join this groundbreaking initiative and demonstrate their leadership in circular economy to customers and stakeholders. The first partners will be able to give their input to the creation and development of the network to genuinely add value to the industry’s efforts in sustainability.

“Outokumpu Inner Circle is an open initiative where we would like to welcome all scrap suppliers and stainless steel consumers from Europe to participate. We are now entering the first phase of this initiative and I’m happy to announce CRONIMET as the first scrap supplier partner joining us. At this stage, our focus is on creating the practices and learning about the co-operation. There’s been a lot of interest already, showing that there really is an industry-wide need for this kind of an initiative,” says Max Menzel.

“The Inner Circle initiative builds on the ideas of fairness, openness and the pursuit of long-term partnerships and therefore fits perfectly with our corporate values. At the same time, we are convinced that this is the right approach to achieving sustainability and business success in the circular economy,” says Nico Krueger, Commercial Director at CRONIMET.

Enabling circular economy for a more sustainable future

For Outokumpu, circular economy is at the heart of its sustainability approach. As a material, stainless steel is a key ingredient of circular economy as it is 100% recyclable. Already today, Outokumpu has the highest recycled material content rate in the stainless steel industry at 94%.

“We believe the world does not need more things – but things that last. And when a product is at the end of its life cycle, it should be brought back to life by becoming raw material for something new. The more we use scrap, the lower our emissions are. We would like to enable our customers and partners to actively participate by joining this initiative,” says Juha Erkkilä, VP – Sustainability, Outokumpu.

Outokumpu is the global leader in stainless steel. The foundation of our business is our ability to tailor stainless steel into any form and for almost any purpose. Stainless steel is sustainable, durable and designed to last forever. Our customers use it to create civilization’s basic structures and its most famous landmarks as well as products for households and various industries. Outokumpu employs approximately 8,500 professionals in close to 30 countries, with headquarters in Helsinki, Finland and shares listed in Nasdaq Helsinki. www.outokumpu.com

Despite the soaring prices brought on by an energy crisis that shows no signs of diminishing, ask pump and blower operators about the efficiency of their equipment, and the truth is that most don’t know – according to a leading monitoring technology provider.

The pumps, for example, might often be described as ‘working fine’ and ‘doing their job’, but is that, now more than ever, a strategy? How about saving money now, and in the future?

“The opportunity to truly maintain, protect and optimise assets is here and now, with a Return on Investment (ROI) that is shorter than ever”, says Julian Lowe from Riventa. “The cost of solving asset management challenges is on a much smaller scale than most companies imagine”.

So, just how can you make hidden costs more visible?

At minimum, put some testing in place. By obtaining accurate, quality data, this first proactive step will give you a snapshot of performance, as well as health and efficiency. Even this entry-level testing will help identify poor assets and inefficient pumps.

Riventa’s Julian Lowe added: “All we hear about at the moment, understandably, is the giant hike in energy prices, so best test your pumps (and/or blowers and turbines) to reduce energy consumption and maximise savings. This will almost immediately help identify actions to improve performance. In addition to pump efficiency, measuring key parameters such as flow rate, head and electrical power - current pump performance characteristics can be compared to ‘as new’ and ‘post-refurbishment’ conditions. This provides the same accuracy as a pump manufacturer’s test facility – but with the distinct advantage of real operating conditions”.

Across numerous industries, where for some, running pumps ‘til destruction is the modus operandi, Lowe has a point. He claims that for larger pumps, blowers and turbines, the ROI can be as little as 18 months.

Most pump and blower operators don’t know about the efficiency of their equipment, say Riventa

A level up from pump testing is to look at an Optimisation Service, utilising secure on-site pump monitoring equipment to provide real-time data. This enables you to start seeing what’s happening across your system by capturing data over 14-days or longer. This doesn’t have to involve tons of ‘spaghetti’. Systems can now be cable-free; up and running in around 1 hour per pump, at low risk and with minimal disruption to existing operations.

‘Realistic payback calculations’

Dr Tom Clifford from Riventa, continued: “Once in place, real-time data for each asset can be evaluated, with information-driven insights highlighting performance issues and supporting decisions. This can establish best practice recommendations, realistic payback calculations and a business case for moving forward – all backed by precision measurement and innovative analytics”.

Clifford explained how Riventa had recently worked with a food manufacturer; testing the company’s cooling system, which is split into two pumping sub-systems: factory pumps 1-5 for sending chilled water from heat-exchangers to the factory; and evaporator pumps that send chilled water from the factory to refrigeration heat exchangers.

“To test the pumps, we used the thermodynamic measurement technique (with our specialist software) to measure suction and discharge pressures either side of the pump, differential temperature, and motor input power. These measurements enabled us to calculate differential head across the pump, hydraulic efficiency and volumetric flow. Pumps were altered gradually. After each change, a test point was taken, while allowing enough time to obtain the best statistical average. Tests also involved a routine of testing performance at an incumbent set point, followed by throttling the pump to reduce its flow rate. The latter action allowed other pumps running in parallel to increase in speed to compensate, with a final test point taken at this moment”.

He continued: “Throttling meant we could observe the maximum possible flow through each pump under test, without altering the overall flow to the plant. At times this was challenging, because conditions downstream in production would change, altering the cooling load and in-turn the flow set point. Nevertheless, good quality performance information was obtained.

‘Strong case for robust savings’

“We found that all pumps were showing signs of wear. Moreover, manufacturer performance levels were not being achieved. None of the pumps we tested reached the manufacturer’s BEP (81%). In fact, the maximum pump efficiency possible was found to be 75% (achieved by pumps 1 & 2 only). Our findings enabled us to put pumps into a descending order of repair: 1, 2, 3, 4 & 5. While pumps 1-3 achieved a good relationship between power and flow, pumps 4 & 5 were not performing when at lower flows. This indicated a high likelihood of internal recirculation – from high to low pressure parts of the impeller – being caused by high wear. We were able build a strong case for robust savings through the pump refurbishment. Broadly, two options were made available:

• Basic Refurbishment: Internal coating plus replacement of wear-rings, bearings and seals.

• Comprehensive Refurbishment: As per the Basic Refurbishment, plus a new tailored impeller.

“We calculated that pump refurbishment would bring potential

savings of £19,200 per year, with possibilities to refurbish 2, 3 or 5 pumps”.

This is just one example of what Riventa say they are helping companies achieve across industries that also include water, power, mining, petrochemical, to name but a few.

Advanced pump monitoring and optimisation are available too, continuously focusing efforts by evaluating and understanding performance gains across priority pumps and sites. And for some organisations, full optimisation of networks is available.

‘Change in Mindset’

“Nobody wanted an energy crisis”, concluded Clifford, “but as prices soar, we are beginning to see a change in mindset about just how important it is to know how your assets such as pumps, blowers and turbines are really performing.  Initially, some basic testing might reveal some not altogether pleasing facts (!), but you can soon put yourself on a very positive course to make some seriously good, ongoing savings”.

www.riventa.com

The world of hazardous manufacturing and production can be complicated enough without adding extra elements to your workload. Hot work permits are often seen as being an essential part of working in hazardous environments - but what if you could inspect without this having to provide copious amounts of paperwork??

A multinational chemical manufacturing company has recently begun to do just that; freeing up time and labor to redeploy throughout its workforce.

Typically, inspecting in Zone 2 hazardous environments requires getting a hot work permit signed off by a manager. This can consist of extensive manual paperwork and requires that work ceases for at least one hour prior to inspection. It also requires that all potentially explosive materials (such as combustible dust and gases) are carefully measured and monitored to reduce the possibility of ignition.

To inspect key components of machinery in these challenging environments, thermal cameras are often used to identify hotspots, gauge the temperatures of machinery and check that parts such as valves are operating within expected parameters. Unfortunately, these cameras pose an indirect risk to the safety of the facility themselves because they are not intrinsically safe by design - which is why hot work permits must be approved prior to use.

Safer inspection - with the FLIR Cx5
The FLIR Cx5 is a thermal camera specifically designed to provide safer inspections in hazardous locations. The rugged housing which encases the lithium-ion powered thermal camera ensures high-performance thermography without the inherent risk associated with non-intrinsically safe products.

Whether in hazardous locations dealing with gas, vapor, dust or (in this case) combustible chemicals, it entirely eliminates the need for hot-work permits.

On site at this chemical plant, it allows operators to safely inspect areas that deal with extreme heat, such as the refractory which runs at 1400°C at its core. Operators can clearly see the external temperature of the brick-lined vessel and check to ensure it’s working within guidelines. The FLIR Cx5 is also used in this facility to monitor rotor pumps, the temperature of bearings and the level of liquid inside vessels.

Hours of time, freed up to better serve your facility
A spokesperson for the facility explains: “Use of hazardous area certified equipment is always preferable as the source of ignition is removed and a hot work permit is not required.

“Generating a hot work permit is labor-intensive as a request must be made, the permit to work prepared and all applicable areas confirmed free of flammable gases (and, of course, this only confirms that flammable gases are not present at that point in time). All-in-all, we’re probably looking at 3 hours’ work for each individual inspection - which the Cx5 eliminates - and means we can better put it to use elsewhere.”

With a 3.5-inch touchscreen interface that is simple to use, and the 160 × 120 thermal resolution reveals the accurate temperature measurement of nearby targets between -20 and 400°C. Add the FLIR Cx5 to your toolbox and you’ll always be ready to investigate mechanical and electrical equipment around your production site - with no hot work permit in sight.

Discover how you can free up time and maximise productivity in your facility with the FLIR Cx5.

About Teledyne FLIR
Teledyne FLIR, a Teledyne Technologies company, is a world leader in intelligent sensing solutions for defense and industrial applications with approximately 4,000 employees worldwide. Founded in 1978, the company creates advanced technologies to help professionals make better, faster decisions that save lives and livelihoods. For more information, please visit www.teledyneflir.com or follow @flir.

ArcelorMittal Construction has awarded ABB a contract to deploy solutions specifically designed for metals processing at its cold rolling mill in Contrisson, France, as part of a modernization project. The solutions, which include ABB Ability™ Manufacturing Operations Management for metals (MOM4Metals), Roll-Gap (RGC) and Automatic Gauge Control (AGC), will help the world’s largest steel producer to bring productivity to a new level, improve quality and performance.

• ABB will install its Manufacturing Operations Management system (MOM4Metals) on cold rolling mill at Contrisson plant
• ABB will modernize technology for Roll-Gap Control (RGC) and Automatic Gauge Control (AGC) on the same mill
• ABB’s technology will help the steel producer to bring productivity to a new level, improve quality and performance

ABB MOM4Metals product, based on precise data analytics, improves information sharing, production planning, execution, reporting, asset monitoring and operational performance optimization. It is designed for and used in various metal production processes from rolling mills to processing lines delivering clear benefits over generic industry-agnostic MES platforms.

ABB is also modernizing advanced RGC and AGC technologies to reduce thickness deviations and off-gauge length. The project is expected be completed in the first quarter of 2024.

“ArcelorMittal Construction has placed its trust in ABB know-how and solutions for cold mill applications,” said Frederik Esterhuizen, Global Business Line Manager for Metals at ABB. “Through discussions with the customer we have been able to utilize our deep metals expertise to refine the ABB solution to meet their needs. ABB solutions enable cold rolling mills to improve and maintain performance and meet quality requirements in terms of thickness tolerances, flatness and surface characteristics via precise process control and equipment lifecycle management.”

“ABB will bring a combined MOM4Metals and RGC/AGC automation solution specific to metals processing to our modernization project at Contrisson,” said Frédéric Geoffroy in charge of process and automation department at ArcelorMittal Construction. “This stands out from standard automation and digital solutions and we are pleased that our needs can be met by one supplier with whom we have a long standing relationship at and beyond this site. ABB successfully revamped the drive of the cold rolling mill previously.”

“For ArcelorMittal Construction France, leader in the field of steel building envelopes, ABB supports us through its business solutions and allows us to offer our customers innovative solutions based on decarbonized and sustainable steel.”

Technology is a decisive factor in determining the quality of rolled products. ABB’s rolling mill solutions, including metals specific electrical, process automation and control technologies, leverage over 100 years of metals industry expertise to enable increased speed, reduced non-rolling time and threading problems while allowing for precise process control in terms of strip surface, flatness, thickness, off-gauge length and more to deliver improved strip quality, productivity and resource efficiency.

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation

ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 130 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation.