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1Repair Windows errors before they cause bigger problems2Scan for outdated or missing drivers - takes under a minute3Clear out junk files and repair common Windows errorsABB says Tokuyama’s Nanyo Plant in Japan expanded its use of ABB Ability™ Expert Optimizer from a 2024 test on one finish mill to seven mills in total. ABB reports that the mills operated automatically more than 90 percent of the time, with grinding throughput up 3 percent and specific power consumption down 3 percent. The figures are from ABB’s September 1, 2026 announcement; the release does not provide detailed measurement methods or independent verification.
What changed at Tokuyama’s Nanyo Plant?
Tokuyama Corporation’s Nanyo Plant first tested ABB Ability™ Expert Optimizer on one cement finish mill in 2024. ABB says it later delivered and commissioned the system on six additional mills, bringing the finish-mill deployment to seven.
The six additional installations comprised four cement ball mills and two vertical mills used for pre-grinding and slag. Tokuyama’s FY2024 report separately notes that an automatic control system was installed on one cement grinding finishing mill, supporting the initial deployment timeline.
What results did ABB report for the mills?
ABB’s September 2026 announcement attributes these outcomes to the finish-mill rollout:
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- Automatic operation above 90 percent.
- Grinding throughput 3 percent higher.
- Specific power consumption 3 percent lower.
- Stable operations alongside the reported throughput and power changes.
ABB did not publish baseline values, exact measurement periods, detailed calculations, uncertainty estimates, or a third-party audit for these percentages in the cited announcement. Tokuyama’s annual report confirms the installation of an automatic control system on one finishing mill, but does not independently verify the performance figures.
How does Expert Optimizer control the process?
ABB describes Expert Optimizer as advanced process control software that uses model predictive control (MPC) and AI to predict process behavior and adjust operating parameters, including feed rate and mill power. ABB says the adjustments are intended to maintain mill load and throughput. This is the supplier’s description of its system, not an independent technical evaluation.
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How does the mill rollout differ from the earlier kiln project?
The Nanyo Plant also has a separate, earlier Expert Optimizer application for the calciner, kiln, and cooler. ABB’s August 2023 announcement reported about 3 percent lower kiln thermal energy consumption and about 70 percent fewer manual operator actions. ABB’s September 2026 release says the kiln optimization had produced results in 2022 and had been in use for five years.
| Application | Process controlled | Reported outcome |
|---|---|---|
| Finish-mill rollout, starting with a 2024 test | Seven mills: the initial test mill plus four cement ball mills and two vertical mills for pre-grinding and slag | ABB reports automatic operation above 90 percent, throughput up 3 percent, and specific power consumption down 3 percent |
| Kiln optimization, with results reported from 2022 | Calciner, kiln, and cooler | ABB reports about 3 percent lower thermal energy consumption and about 70 percent fewer manual operator actions |
These results concern different process areas and measures. Their percentages should not be treated as directly comparable: the mill figures concern throughput and specific electricity use, while the kiln figures concern thermal energy and manual actions. ABB’s 2023 release also describes the kiln system as using linear and nonlinear MPC, fuzzy logic, and neural networks.
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What do the plant capacity figures mean?
ABB’s 2023 announcement lists Nanyo’s clinker production capacity as 4.54 million tons per year. ABB’s undated industrial software case-study page gives annual production capacity as 4.8 million tons. Because the descriptions refer to differently worded capacity measures, the figures should be kept separate rather than combined or treated as equivalent.
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Sources
- ABB, September 1, 2026: Tokuyama’s mill rollout and reported performance
- ABB, August 24, 2023: kiln application and results
- ABB Industrial Software: Tokuyama case study
- Tokuyama Corporation, Tokuyama Report 2025: FY2024 growth-strategy progress
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