Flexible and smart software technology to control and optimize metallurgical processes

Transcription

1 Flexible and smart software technology to control and optimize metallurgical processes Robert PIERER Vienna, INTECO speacial melting technoligies GmbH, Bruck a. d. Mur, Austria

2 CONTENT FUNERAL SERVICE POPE JOHANNES PAUL II (2005) Source:

3 WAITING FOR FOLLOWER OF POPE BENEDIKT XVI (2013) Source: CONTENT FUNERAL SERVICE POPE JOHANNES PAUL II (2005) Source:

4 Source: CONTENT WE ARE FACED WITH AN EXTREMELY FAST GROWING INFORMATION TECHNOLOGY (IT)

5 CONTENT Flexible and smart software technology to control and optimize metallurgical processes! FLEXIBLE SMART CONTROL OPTIMIZATION WHAT DOES SMART AND FLEXIBLE MEAN IN SOFTWARE? HOW DO WE REALIZE CONTROL AND OPTIMIZATION?

6 INTECO AT A GLANCE Engineering and supply of equipment and process technology for melting and casting in the steel industry. Steel Plant Technology Special Metallurgy & Remelting Services & Technology Electric ArcFurnace Ladle Furnace VD/VOD Plants Ingot Casting Continuous Casting Electro Slag Remelting Vacuum Arc Remelting Vacuum Induction Melting and Pouring Pre-Investment Studies Engineering Project Management Trainings Consulting

7 INTECO AT A GLANCE Group Bruck / Mur TECTRADE Handelgesellschaft Bruck / Mur INTECO melting & casting technologies Bruck / Mur ART advanced refractory technologies Bruck / Mur TBR casting technologies Leoben INTECO vacuum technologies Tönisvorst, D INTECO metallurgical equipment Dalian, CN PTI process technology int. Tucker, USA RCT recycling crushing technologies Bruck/Mur, A Norberg Steel and engineering Västerfärnebo, S INTECO atec automation Laßnitzhöhe, A DONAU carbon technologies Guanzate, I INTECO India Ltd. New Delhi, IN

8 CONTENT Flexible and smart software technology to control and optimize metallurgical processes! FLEXIBLE SMART CONTROL OPTIMIZATION

9 THE CLASSICAL AUTOMATION LEVELS ENTERPRISE ERP LEVEL 4 PLANT MES LEVEL 3 PROCESS Process Control LEVEL 2 FIELD Equipment Control LEVEL 1

10 OUR CUSTOMER GETS A SOLUTION FROM ONE SOURCE THE SOLUTION OF INTECO ENTERPRISE ERP LEVEL 4 IMAS was developed to bridge the gap between equipment automation and ERP tools Equipment Control LEVEL 1

11 IMAS - THE APP APPROACH

12 CHARACTERISTICS OF SMART AUTOMATION Vertical Integration and Networked Production Systems It is vital that the IT systems at the office floor are networked with production systems (shop floor) and can communicate without barriers or media disruptions.

13 IMAS THE CUSTOMERS CHOICE ERP Information from Material Management Information from Scrap Yard Information from the Process Model IFOB ISEC ISEC IPAS

14 IMAS THE CUSTOMERS CHOICE If Material Management will be done in Level 3 ERP no problem, we are able to connect and communicate with all other systems! IFOB ISEC ISEC IPAS

15 CONTENT Flexible and smart software technology to control and optimize metallurgical processes! FLEXIBLE SMART CONTROL OPTIMIZATION

16 WHAT DOES SMART MEAN? SMART! Enable Continuous Improvement Process (CIP) = SMART

17 HOW DO WE REALIZE PROCESS OPTIMIZATION? Continuous Improvement Process (CIP) = SMART OPTIMIZATION Enables Optimization

18 WHAT DOES SMART MEAN? CONTINUOUS IMPROVEMENT PROCESS (CIP) OPTIMIZATION PLANNING SCRAP YARD LIQUID PHASE SOLID PHASE

19 WHAT DOES SMART MEAN? CONTINUOUS IMPROVEMENT PROCESS (CIP) LIQUID PHASE OPTIMIZATION EAF AOD VOD PLANNING SCRAP YARD LIQUID PHASE SOLID PHASE IC CC Adjust hand over temperature, Minimize reduction material, Minimize treatment time, Optimize Oxygen switch off

20 WHAT DOES SMART MEAN? SMART! Enable Continuous Improvement Process (CIP) = SMART

21 THE MODEL-SET-ACT APPROACH Operation Guidance and Set-Point Control by PROCESS SCHEDULES (Cook Books, Recipes, etc.) and PROCESS MODELS (LEVEL 2) All Data will be stored in the data base (reports) and summarized in the PRODUCTION DATA OVERVIEW Application MODEL SET ACTUAL Level 2 Level 1 Return Purging Lime Addition 5 l/min 150 kg 5 l/min 4.9 l/min 100 kg 102 kg Temperature 1580 C 1582 C Hydrogen 0.8 ppm 0.78 ppm

22 CONTENT Flexible and smart software technology to control and optimize metallurgical processes! FLEXIBLE SMART CONTROL OPTIMIZATION

23 HOW DO WE REALIZE PROCESS CONTROL? CONTROL

24 THE NAVIGATION EXAMPLE THE ACTIVITY OF NAVIGATION REQUIRE THE DETERMINATION OF THE GEOGRAPHIC POSITION USING DIFFERENT METHODS OF LOCALIZATION.

25 Optimization THE NAVIGATION EXAMPLE TRAFFIC INFORMATION HIGH TYPE OF CRAFT TYPE OF ROUTE HIGHWAY NAVIGATION + OPTIONS Car 120/80/40 km/h Fastest Route Use v v v AVOID JAM Automatic v LOW Control / Guidance HIGH ROUTE TRACKING LOW CLASSICAL NAVIGATION

26 NO BLACK BOX APPROCH Process Data Pressure, Stirring Gas Rate, etc. Specific Parameters Ladle Geometry, Type, etc. MetMod MetMod Thermo-Physical and Thermo-Chemical Data Heat Capacity, Enthalpy, Activity, etc.

27 THE EXAMPLE OF DEGASSING VOD 2 VOD 3

28 THE EXAMPLE OF DEGASSING

29 THE EXAMPLE OF DEGASSING VOD 2 VOD 3

30 SUMMARY FLEXIBILITY means the consideration of the customer needs. adjustable (transparent) models. to provide different optimization strategies. SMART means enabling CIP. the transformation of big data into smart data. to provide tools for data analytics. OPTIMIZATION must consider all areas..must be flexible. Local optima to not necessarily lead to a global (overall) optimum. The key of PROCESS CONTROL is the determination of the current state Control must account for the dynamic process (unforeseen events) The tools for process control must be continuously improved

31 Thank you for your Attention Dr. Robert Pierer Product Manager Level 2 Systems