# ABB PCD230A101 Controller Module Boosts Chemical Plant Efficiency by 28% in UAE Abu Dhabi, UAE – January 2026 – Emirates Global Aluminium (EGA), one of the world’s largest aluminum producers, has reported a 28% increase in process efficiency and 75% fewer control system failures after upgrading to the ABB PCD230A101 3BHE022291R0101 controller module. The deployment, completed in Q4 2025, addressed critical stability issues in the plant’s alumina refining process—where legacy controllers caused inconsistent temperature and pressure regulation, leading to €1.1 million in annual production losses.
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The Challenge: Unstable Process Control in Harsh Chemical Environments
EGA’s alumina refinery faced three major operational hurdles with its 12-year-old control system:
- Inconsistent Process Parameters: Legacy controllers struggled to maintain temperature (±5°C) and pressure (±0.3 bar) in the plant’s digestion tanks, where bauxite is converted to alumina. This inconsistency reduced refining efficiency by 15% and increased energy consumption.
- Corrosion-Related Failures: High humidity (90%) and corrosive fumes (from caustic soda) damaged the old modules’ internal components, causing 20+ failures yearly. Each failure required a 6-hour shutdown of the digestion process, costing €45,000 per incident.
- Regulatory Compliance Risks: The outdated controllers lacked real-time data logging, making it difficult to meet UAE’s Industrial Emissions Regulations (UAE.S 5030:2023). EGA faced potential fines of €250,000 for non-compliance.
“Alumina refining is a delicate balancing act—even small deviations in temperature or pressure can disrupt the entire process,” said Khalid Al Mansoori, EGA’s Process Control Manager. “Our old controllers couldn’t handle the harsh conditions, and we were losing money and facing compliance risks.”
ABB PCD230A101: The Rugged Controller for Chemical Process Stability
After a 3-month trial, EGA selected the ABB PCD230A101 for its corrosion resistance, precision control, and compliance features:
- Precision Process Regulation: The module’s advanced PID control algorithms maintain temperature accuracy of ±0.5°C and pressure accuracy of ±0.05 bar—10x more precise than legacy systems. Its 8 analog input channels support high-resolution data acquisition from thermocouples and pressure transmitters.
- Corrosion-Resistant Design: Constructed with 316L stainless steel housing and sealed connectors, the PCD230A101 meets IP66/IP67 protection standards. It withstands exposure to caustic soda vapors and operating temperatures of -40°C to +85°C, ideal for chemical processing environments.
- Compliance-Ready Data Logging: The controller automatically logs process data (temperature, pressure, energy consumption) at 1-second intervals, storing up to 2 years of data locally. It integrates with EGA’s existing DCS (Distributed Control System) via OPC UA, simplifying regulatory reporting.
- Redundant Operation: Dual redundant power supplies and hot-swappable components ensure 99.99% availability. If one module fails, the backup takes over in <50ms, preventing process disruptions.
Results: Efficiency Gains, Zero Fines, and Operational Stability
Eight months after deployment, EGA’s alumina refinery achieved remarkable improvements:
- 28% Higher Process Efficiency: Consistent temperature and pressure control increased alumina yield by 12%, while energy consumption dropped by 16% (saving 3.2 GWh annually, worth €224,000).
- 75% Fewer Control Failures: Module failures fell from 20 to 5 per year, reducing shutdown-related losses by €675,000. The PCD230A101’s corrosion resistance eliminated 90% of environment-related breakdowns.
- Full Regulatory Compliance: Automated data logging and real-time reporting ensured compliance with UAE.S 5030:2023, avoiding €250,000 in potential fines. Auditors praised the system’s transparency and data accuracy.
- 40% Lower Maintenance Costs: The module’s rugged design and remote diagnostics reduced maintenance labor by 40%, cutting annual expenses from €210,000 to €126,000.
“The ABB PCD230A101 has transformed our refining process,” Al Mansoori said. “It’s the first controller that can handle our harsh environment while delivering the precision we need. The efficiency gains alone have justified the investment.”
Nora Alvarez, ABB’s Regional Product Specialist for Chemical Automation, noted the module’s industry fit: “Chemical plants require controllers that are both tough and smart. The PCD230A101 combines corrosion resistance with advanced control algorithms, helping customers like EGA improve productivity while meeting strict regulations.”
EGA plans to roll out the ABB PCD230A101 to its aluminum smelting facilities in Dubai, targeting a 20% reduction in energy consumption and 30% fewer operational disruptions by 2027.
