Technology giant ABB and mining expert Boliden have successfully deployed Ethernet-APL instrumentation at the Kokkola zinc plant in Finland.
The project connects next-generation field devices with the existing ABB Ability System 800xA distributed control system (DCS) and is among the first installations of its kind in the country.
Process plants increasingly need access to more detailed field-device and process information to improve maintenance, troubleshooting and operational decision-making, while continuing to protect production availability, safety and existing technology investments. At Kokkola, Ethernet-APL provides a way to introduce this additional connectivity progressively rather than requiring wholesale replacement of the plant’s established automation infrastructure.
By extending Ethernet communications to field-level instrumentation, Ethernet-APL enables richer device diagnostics and easier access to process data from the control environment. This helps maintenance teams identify emerging issues earlier, reduce the need for manual field intervention and provides a stronger foundation for remote operations and future automation initiatives.
The latest milestone builds on a long-standing automation partnership between ABB and Boliden Kokkola, which began in 2014 with the deployment of System 800xA at a new silver recovery plant. Since then, the platform has expanded across the zinc production facility, creating a scalable, automation environment that can support evolving operational requirements and the adoption of new digital technologies.
System 800xA supports a wide range of communication protocols, including PROFIBUS, PROFINET and third-party systems, enabling existing and emerging technologies to coexist within a single automation environment.
“Working with ABB has enabled us to develop our automation platform in a controlled and practical way while ensuring compatibility with existing systems,” said Matti Karjula, Automation Specialist at Boliden Kokkola. “The introduction of Ethernet-APL provides an opportunity to evaluate the suitability of this new technology in a production environment and to explore how more detailed device information can be utilized for maintenance and diagnostics.”
The project was delivered in collaboration with Pepperl+Fuchs, a global industrial automation specialist with expertise in electronic sensors, intrinsic safety and explosion protection technologies for process applications. The architecture allows Ethernet-APL devices to be deployed alongside existing Profibus PA instrumentation, giving Boliden Kokkola the flexibility to introduce new technologies at their own pace.
The implementation also includes a pilot of ABB Ability™ Field Information Manager (FIM), which provides centralized monitoring, configuration and diagnostics for field devices across multiple networks. Integrated with the Ethernet-APL infrastructure and System 800xA, FIM provides a unified view of field devices across both existing and emerging communication technologies.
The project reflects ABB’s ongoing work to support the Ethernet-APL adoption in process industries and demonstrates the value of automation systems designed for long-term lifecycle management.
“Ethernet-APL gives process operators a practical way to bring more field-level information into the automation environment without having to replace technology that continues to perform effectively,” said Petri Vuolukka, Industry Segment Manager for Battery, Metals & Mining, ABB’s Process Industries division in Finland. “At Kokkola, Boliden can evaluate the technology under real production conditions while maintaining compatibility with its existing infrastructure. It is a measured approach to modernisation that can support better maintenance decisions today and create the foundation for further automation over time.”
