ABB & Cemex: Procurement-Powered Energy Efficiency
Cemex, a global leader in building materials, faced a serious issue at its Rudniki plant.
The plant’s massive furnace, vital to its production processes, posed a significant risk during power outages. Restarting the furnace could take up to 36 hours, severely disrupting operations and increasing downtime.
To address this, Cemex is working with ABB, leveraging their decade-long relationship.
ABB offered a tailored retrofit solution to modernise the plant’s electrical systems, avoiding the high costs and operational interruptions associated with a full system replacement and ensuring the upgrades were efficient and cost-effective.
Procurement's role in innovation
The Rudniki plant retrofit reflects a forward-thinking approach to procurement. Cemex’s procurement team adopted strategies that combined technological innovation, sustainability and cost efficiency:
- Strong supplier relationships: The collaboration builds on 10 years of partnership between Cemex and ABB, highlighting the value of long-term relationships.
- Sustainable sourcing: Guided by Cemex’s sustainability goals, procurement decisions aligned with global trends in responsible purchasing.
- Technology-driven solutions: ABB’s cutting-edge retrofit solution included Emax 2 circuit breakers and Ekip Touch trip units, demonstrating how procurement can integrate advanced technologies into operations.
- Cost-effective modernisation: By opting for a retrofit over a full replacement, Cemex avoided unnecessary expenses while achieving significant upgrades.
Kamil Schabiński, Project Manager for ABB Electrification Service, explains: "This is a perfect example of a comprehensive retrofit, tailored to our customer’s specific needs.
"ABB products have transformed the plant’s operating conditions and the reliability and safety of its power supply."
Benefits of strategic procurement
Cemex has seen a host of benefits from this procurement-led initiative:
- Improved safety and reliability: The upgraded system allows operators to isolate and test breakers without disrupting power to the furnace. This ensures critical components remain operational during maintenance.
- Energy efficiency gains: The retrofit has optimised the furnace’s thermal energy efficiency, reducing CO₂ emissions and supporting Cemex’s sustainability objectives.
- Digital transformation: By introducing ABB’s digital analysers and the ABB Ability Energy & Asset Manager, the plant now monitors energy usage in real time, enhancing operational insights.
- Future-ready infrastructure: The retrofit replaced analogue equipment with digital functionality, ensuring the plant is prepared for future technological advancements.
Redefining procurement's potential
By working closely with suppliers, Cemex’s procurement team prioritised long-term value, sustainable practices and cutting-edge technology. The result is a solution that not only resolves immediate operational challenges but also positions the plant for future growth.
Cemex’s partnership with ABB demonstrates how procurement can deliver measurable outcomes while meeting broader corporate sustainability goals.
The Rudniki plant retrofit stands as a testament to what’s possible when procurement teams embrace innovation, collaboration and forward-thinking strategies.
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