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The Way to Digitalized Steel Production Ijmuiden, May 2017
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Digitalization is driven by steel producers‘ requirements and enabled by new technologies
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NEW TECHNOLOGIES STEEL PRODUCERS‘ REQUIREMENTS
Communication technologies
Computational power
Internet technologies
Cloud technologies
Big data analytics
Self-learning systems
Mobile devices
Augmented reality
End-customer integration
Lot-size 1
New business models
Know-how management
Supplier integration
New steel grades
Availability of information
Ergonomy/operator support
ACHIEVED BY HOLISTIC AUTOMATION
QUALITY
FLEXIBILITY PRODUCTIVITY
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Three major requirements in steel production shall be supported by digitalization
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• Outstanding quality • Reproducible results • Seamlessly documented
• Flexibility to customer requests - Flexible product specification - Shorter delivery times
• Flexible in used raw materials • Flexible in optimization criteria
- Production - Energy consumption - Equipment lifetime
• Throughput • Yield • Plant availability • Operational costs • Maintenance costs
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Digitalization helps to orchestrate the entire production chain
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A digitalized plant is like an orchestra – The Metals Orchestra
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Metals Orchestra Teach your players to play better
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Metals Orchestra The Primetals Technologies portfolio
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Know more – improve your processes More focus on the essentials Your plant and its digital twin
Smart sensors provide additional information about the process or the entire plant.
Smart sensors either directly measure physical values or use existing measures to indirectly calculate additional information.
Smart sensors are the enablers for the implementation of advanced automatic functions, process models, as well as condition monitoring.
Repetitive, labour-intensive and dangerous work is supported by fully-automated mechatronics solutions.
This gives more room to focus on the essential tasks.
Process models, digital “twins” of the plant, enable process optimization in real-time as will as offline simulation.
This means perfect process guidance and full support for further process development.
Example: Camera-based slag detection and free-board measurement for converter tapping
Example: Automated converter tapping incl. the positioning of the ladle transfer car and alloy charging
Example: Blow-end calculation
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Metals Orchestra The Primetals Technologies portfolio
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Knowing how your plant “feels” Get connected – anytime – anywhere All the necessary information – when and where you need it
Comprehensive information about the condition of the equipment an the respective processes enables predictive maintenance, which will help to avoid unplanned outages.
This means improved plant availability and therefore increased plant productivity.
Advanced communication technologies allow for information to be transported beyond conventional limitations.
From the collection of sensor data in harsh environments or from mobile equipment to displaying the information on mobile devices.
From the shop floor to the „manager‘s pocket“
To ensure best possible operation and maintenance of a plant, a vast variety of information sources is required. The core concept of “smart work” is that all personnel will automatically receive exactly the information they need at the time to get their job done. This means that all information is automatically tailored to the actual needs of the staff.
Example: Converter tilting-drive monitoring, LTC drive-train and railway condition monitoring
Example: Wireless data transmission from the ladle transfer car, KPI dashboards for mobile devices
Example: Online-documentation retrieved via QR-coded equipment, augmented reality applications to guide maintenance work
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Smart Sensors help to improve data availability
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Scrap Chute Tracking
Ladle Tracking with RFID Pallet car tracking with RFID
ICE-Tag Protection
• Measurement Identification Communication Tracking
• Scrap Weight • Wireless transmition
• Temperatures • Ladle history
• Identification • Tracking
Improved Tracking and Input Data for the Process Models & Data Analytics
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Advanced Tracking System for ladles, pots, chutes & baskets or vessels
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ICE-TAG technology for harsh environment
Damage detection (self diagnosis)
High read/write distance
High operating temperature
High heat resistent antenna housing
RFID antenna & RFID reader
Optional wireless HART
Teach-In with handheld
location
Waiting time (position based)
C temperature
%
#
utilization
Number of heats
Lining lifetime
ICE-TAG RFID Features
Reading station components Fields of Application • Ladle Furnace • Ladle Transfer Car • Ladle Turret at CCM • Ladle preheater • Ladle Relining Ares • Ladle Transfer Car • Vacuum Plant • Hot Metal Ladle
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Robotics LiquiRob
Temperature measurement Shroud handling Oxygen lancing
• Lock out of personnel from hazardous working areas
• Ensures reliable production • Quality improvement due to reproducible
procedures
• Minimal maintenance required • Customizable robot tasks to guarantee high
flexibility • Highly scalable (i.e. basic systems to highly
sophisticated implementations)
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Solution for Hot Rolling (example) Strip Steering in Finishing Mill
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• Bad strip run and mill stability are the main cause for disturbances in FM
• origin in bad upstream processes condition (e.g wedge/camber in transfer bar)
• Difficult manual control
• Assistance system for operator • ShapeMon camera system • Differential tension Looper and
Looper Shape Meter (LSM) • Model-predictive control
Solution
• Increased fully automatic operation mode
• Reduced head end collision • Reduced tail end pinching • Reduced cobble rate • Increased mill availability and
productivity
Benefits
• Strip Steering is realized by roll swiveling and guidance by side-guides
• Special modes during 3 different rolling phases:
• A) Head end steering with Camera • B) Body steering with diff.tension-
looper and camera • C) Tail end steering with model-based
Roll Alignment Control (RAC)
Challenge
Challenge
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Cyber-Physical System (CPS) The Next Generation in Process Automation
Model-based Control
Modelling
• Simulation allows Pre-Visualization what will happen in the Real Plant
• The Virtual Plant is the Digital Shadow of the Real Plant
Virtual Plant
Real (Physical) Plant
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Simulation
Optimization
September 2016 EA
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Continuous Casting model suite for highest product quality
EA ISC Page 14
• Thermodynamic/segregation process model DynaGap calculates material properties
• Dynacs 3D assures a stable strand surface temperature profile even in transient casting conditions – incl. simulations for metallurgists
• DynaGap Soft Reduction model for internal quality improvements
Metallurgy & material
Process & machine
Smart Segment / Pinch Roll
Real plant
Model-based Control
Modelling
Continuous caster
High dynamics for flexible production of demanding high quality products
DynaPhase
Dynacs 3D
DynaGap Soft Reduction 3D
LIQUID MUSHY SOLID
Know the steel properties according to the actual composition
Calculate the 3D thermal strand profile online
Apply dynamic soft reduction just before the final point of solidification
Simulation
Optimization
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Cooling Model and Power Cooling Ideal Tool for Microstructure Control and New Steel Grades
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High Flexibility and Dynamics by Predictive Simulation, SQP Optimization and Model-based Control
Material
+ Water
Management
Model-based Control
Holistic Modelling
+ Process
Predictive Simulation
Optimization
Austenite
Perlite
Bainite
Martensite
Ferrite
• Holistic Process Model of the entire Process: Material – Process – Plant • including Horizontal Integration with the Rolling Mill
Full Control of Phase Transformation
Thick AHSS and API grades DP
High Carbon
Low Temperature Cooling
„Horizontal Integration“
Real Plant =
High Dynamics for homogenous Properties
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Condition Monitoring - BOX CONCEPT One Source One centralised Condition Monitoring System
Mechatronics
Technological controls (Level 1)
Process models (Level 2)
Vibration monitoring
3rd-Party Information
BOX Concept Informationbroker
Condition Monitoring System
Iron and Steel-
making
Caster
Rolling mill
Process-ing Lines
Utilities supply
M2M Interface
Single source with plant wide data collection
Maintenance/ Process
Team
Process
Plant- Equipment
Automation
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Smart Work Augmented reality supports maintenance and operation
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• Efficient troubleshooting and fast, direct access to the required information • Shortens search times, and reduces errors and mistaken identities
• Reliable identification of plant components with RFID tags or QR codes
• Checking the precise installation location of sensors and actuators in 3D displays
• Checking sequences in animated displays
• Retrieving live and diagnostics data from the automation system
• Retrieving online documentation
Seamless linking of data from the HMI, condition monitoring, diagnostics, automation system
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Acoustic Expert Data Based Services
Cloud Service
Benefits • Automatic detection of equipment malfunction
• Maintenance support
• Island system – no access to plant network from outside possible
• Secure / encrypted data transmission
• Comparison of different plants possible
Automation
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Plant
Internet
7.2.2017
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The Digital Unity – The conductor of the Metals Orchestra
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The Digital Unity – The conductor of the Metals Orchestra
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Production Management System A comprehensive approach
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MANUFACTURING EXECUTION Realtime information about the
production process Transparency across the whole
process chain Logistics
PRODUCT DEFINITION, ORDER DRESSER Transformation of sales orders to
process and quality instructions Centralized process knowledge base
ORDER & LINE SCHEDULING Cross-plant scheduling of the
order book Throughput optimization
PLANNING Holistic planning from melt shop to shipping, from demand planning to
material planning
Benefits • Increased utilization of production facilities • Higher productivity with increased flexibility and better quality • Reduced inventory
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Through-Process Optimization (TPO) Quality along the entire production chain
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Benefits • Quality management support • Reduced manual inspection, rework and downgrades • Support for quality certification (ISO/TS16949) • Reduced influence of human factor
THROUGH-PROCESS KNOW-HOW Process and quality optimization
Metallurgical and process rules Product development
QUALITY MONITORING Continuous recording & supervision of
quality parameters Automatic identification of deviations Root cause identification KPI evaluation Statistical process control Product genealy across the entire
process chain Data storage for big data analytics
QUALITY CONTROL Corrective actions feed forward
and feedback Rule based expert system
Quality grading
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Maintenance Asset Technology (Mat)
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Benefits • Smart Maintenance schedule adjusted to order scheduling and vice versa • Trim your expenses according to the best maintenance strategy for your plant • Maintenance data available for analytics and deep learning
MAINTENANCE MANAGEMENT Real time transparency on work, material, assets Automatic work order suggestions based on your asset strategies Advanced planning, mobile work execution Data History for every asset Link business data to ERP
MAINTENANCE KNOW HOW PACKAGES
Actionable items for your team from condition monitoring information
Analytics on your growing
maintenance know how base
Select maintenance strategy to maximize asset performance
Based on advanced analytics
Increase productivity through smart networking with plant data and PMS
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PREDICTIVE MAINTENANCE Pre-set link to CMS Analytics on CMS data and maint history enables predicitive maintenance
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Summary and conclusion
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Industry 4.0 strategy • Industry 4.0 will not be available “off the shelf” • Digitalization started years ago and will not be finished
within a few years • Each steel plant must define their own particular
implementation strategy • Primetals Technologies will actively assist plant operators
in the digital transformation of their production plants with portfolio elements and services
Primetals Technologies supports • Developments in all directions:
Quality, Productivity, Flexibility • Industry 4.0 readiness • Immediate customer value • Implementation step-by-step, e.g. in
modernization projects
April, 2017 K.Herzog / EA I4.0
QUALITY
FLEXIBILITY PRODUCTIVITY
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The information (including, e.g., figures and numbers) provided in this document contains merely general descriptions or characteristics of performance based on estimates and assumptions which have not been verified. It is no representation, does not constitute and/or evidence a contract or an offer to enter into a contract to any extent and is not binding upon the parties. Any obligation to provide and/or demonstrate respective characteristics shall only exist if expressly agreed in the terms of the contract. These estimates and assumptions have to be analyzed on a case-to-case basis and might change as a result of further product development. Primetals Technologies excludes any liability whatsoever under or in connection with any provided information, estimates and assumptions. The provided information, estimates and assumptions shall be without prejudice to any possible future offer and/or contract. Any use of information provided by Primetals Technologies to the recipient shall be subject to applicable confidentiality obligations and for the own convenience of and of the sole risk of the recipient.
Contact
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Kurt Herzog Head of Industrie 4.0 Primetals Technologies Austria GmbH Turmstrasse 44 4031 Linz Austria T +43 (732) 6592-6781 M +43 (664) 6151208 kurt.herzog@primetals.com primetals.com