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Use of Information Technology to Energy Conservation, Improve Process Performance and Profitability of Iron & Stee

Use of Information Technology to Energy Conservation, Improve Process Performance and Profitability of Iron & Steel/Foundry/Re-rolling Mills A Presentation at the

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Use of Information Technology to Energy Conservation, Improve Process Performance and Profitability of Iron & Stee

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  1. Use of Information Technology to Energy Conservation, Improve Process Performance and Profitability of Iron & Steel/Foundry/Re-rolling Mills A Presentation at the Workshop on Adoption of Energy Efficient Process technologies & Practices and Implementation of Energy Conservation Act 20001 in Iron & Steel/Foundry/Re-rolling Mills August 10th 2009

  2. Present Scenario • No or Different Control systems - S/W Packages at Plant level “ IT MUSEUM ” • Distributed Data Across Organization • Slower Decision Making Process in the Absence of Consolidated Data. • Desynchronized Business Processes • Operational Difficulties due to Multi Locations

  3. Solution • Establish one version of the truth • Deliver real-time, actionable information • Enhance Visibility of Manufacturing Info to Optimize Performance, Increase Responsiveness and Manage Cost. • Emphasis on Business Process Management to Improve Operational and CompetitivePerformance

  4. One Version of Truth • Link and consolidate data from different systems to display common view • Unified, role based views of information across the enterprise • Entire company looks at the same data to archive the common goal

  5. Real Time Information • Enables the faster Decision making process • Automates the error-prone tasks • Tighter control on Business Processes • Un-paralleled Real Time Information helps in taking Right Decision at Right Time

  6. Visibility in the Process • Sharing the Manufacturing data across company for synchronization of Business Processes • Tight Integration of Processes from Order to Delivery • Manufacturing Process OPTIMISATION based on Business Needs

  7. Business Process Management • Sharp focus on key business metrics through use of scorecards and dashboards • Proactive e-mail Alerts to Managers for variance from Expected results • Aligning all Business Processes to achieve Corporate Goal – ( Getting all the Fish to swim in one direction )

  8. Using Information Technology • Is not having 10/100 computers for using word/excel/e-mails • Is having these Computers on the Shop Floor to Improve Material and Energy Utilisation, Productivity and Quality

  9. Using Information Technology • HOW ???

  10. The Answer • Control Systems which…….

  11. The Answer • Control Systems which Control the Processes to deliver Optimal Material and Energy Utilisation, Productivity and Quality, i.e.

  12. The Answer • Minimise Material and Energy Utilisation • Increase Productivity and • Increase Quality

  13. An Example • Consider the Process of Automation of an Arc / Induction Furnace / Reheating Furnaces/ TMT Facilities

  14. An Automation System should ... . Save Energy .. Save Costs … Increase Productivity … Pay for itself

  15. Automation Requires Knowledge / Expertise in • Hardware • Instrumentation • Software • Process

  16. Hardware Issues • Platform (Processor, RAM, Disk Capacity etc.) • Remote Connectivity (Internet / Intranet)

  17. Software Issues • Operating System (Windows/Linux) • Database (Sybase/Oracle/SQL ….) • Languages (C++/VB …. • Automation Tools (Intouch / RS View/ Movicon…)

  18. Instrumentation • Key to Successful Automation • Use Best Instrumentation • Reliability & • Repeatability

  19. Process • Unless we know what we want, we cannot achieve results • Operators are the best tools we have • Build in systems which repeat best results all the time • Model the process to gain a better control

  20. Induction Furnace Process Automation • Monitor & Control Electrical Parameters • Monitor and Control Sponge Iron Feeding • Monitor and Control Composition • Monitor and Control Temperature • Generate Real Time Accurate Data, Log Sheets and Reports

  21. Electrical Parameters • Analog Parameters such as Active Power, Power factor, Currents, Voltages, Frequency…. • Digital Signals such as Furnace On/Off, over current etc. • Alarms & Diagnostics

  22. Metallurgical Parameters • Scrap Mix Optimisation • Control Sponge Iron Feeding • Calculation of Bath Chemistry • Calculation of Bath Temperature

  23. Metallurgical Modelling • To Predict Chemistry of the Bath • To Predict Temperature of the Bath • Verification of Models • Tuning of Models : at site during installation

  24. Logistics Issues, if any • Two Furnaces tapped for one LRF heat • Predicted Bath Chemistry & Temperature • Scheduling

  25. Control • Control is done by the Computer • Parameters are monitored and controlled every second • This results in best quality and highest productivity

  26. Alarms & Events • Every event is recorded • Every Alarm is recorded, informed to the operator, action taken to restore normalcy and record kept as to when normalcy has been restored

  27. Data Collection and Storage • Electrical, Metallurgical and Model Calculated Parameters sampled every second • Data stored for Off line Analysis

  28. Graphs • Customised • Real Time Trends • Historical Trends

  29. Reports • In Excel Format • Customised / Exception Reporting • Shift / Statistical / Event Reports

  30. Plant View : First in the World

  31. Assume that you already have a variety of PLCs, MMIs etc. • Can you bring all of them to one location, i.e. • All the control at one location • All the data to one location

  32. Integrate all MMIs into one …. • Once the data comes to one location we can take it as near to the user as you want • Today the actual users are far away from the data. These could be Production Manager, Maintenance Manager ...

  33. The data can come to tables or their laptops • They do not need to go to the control room to view what is happening in the plant • The data they want to analyse is available to them at their place of work

  34. They can provide solutions to ... • Better Productivity • Better Quality • Better Maintenance ….. Since the control station view is next to them

  35. Let us take an example • It is late night when you are called upon to attend a problem. • You switch on the laptop • View what is happening • Provide the solution as quickly as you arrive at it

  36. Another example • You have a consultant who travels round the world. You want him to advise you on a specific problem. • He is waiting for a flight in Singapore, switches on his laptop, connects to the internet, views what is happening in your plant and advises you on the next step

  37. Savings • Industry : Product and Size Dependent • Steel Industry : 1 month to 1 year • Foundry : 1 month to 2 years • Vegetable Oil Industry : 1 month to 3 months • Typical Industry : 1 month to 1 year

  38. Savings • Arc Furnace ..1 • Minimum energy savings of 20 Kwh/ton • Assume Production : 100,000 tons/year, Power cost Rs 4/Kwh • Savings = 100,000 x 4 x 20 =Rs 80 lakhs/year

  39. Savings • Induction Furnace ..1 • Minimum energy savings of 50 Kwh/ton • Assume Production : 15 *10 = 150 tons/day • 3,750 tons/month , Power cost Rs 4/ Kwh • Savings = 3,750 x 4 x 50 =Rs 15 lakhs per month

  40. Savings • Reheating Furnaces ..1 • Fuel savings of 3 litres/ton • Assume Production : 250 tons/day7,500 tons/month , Fuel cost Rs 20/ litre • Savings = 7,500 x 20 =Rs 1.5 lakhs per month

  41. Savings • Reheating Furnaces ..2 • Less Scale loss of 0.5 % • Assume Production : 250 tons/day7,500 tons/month • Savings = 7,500 x 0.5/100 * 25000 =Rs 9 lakhs per month

  42. To conclude ... • Customised Automation Solutions that • Increase Productivity • Reduce Energy Consumption • Increase Equipment Utilisation • Improve Quality • Provide World Wide Connectivity

  43. Thank You Any Questions ???

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