Drastically Reducing Specific Water and Energy In Large Industrial Complexes

Transcription

1 Drastically Reducing Specific Water and Energy In Large Industrial Complexes Presented by Osvaldo A. Bascur Global MMM Industry Principal

2 2

3 Agenda Overview of the Large Industrial Complexes Sustainability Strategies are good Business Real Time Information Integration and Standardization Endesa, Southern Peru, CAP Acero, ArcelorMittal (Dofasco, CSN) Further work and Conclusions 3

4 Overview of the Large Industrial Complexes 4

5 PI System in the Metals Industry 5

6 6

7 Sustainability & Energy/Water Nexus Summary - Discuss observations and real examples from industry, utilities and public sector Saving Water Saving Energy Saving Jobs Energy & Water are inextricably linked. Saving one can save the other. Saving both can save money, capacity, and jobs! 7 The Power of Data Copyright 2013, OSIsoft LLC. All rights Reserved.

8 How are you managing your Ore Types, Energy, Water and Metals Recoveries? Ore Freeport McMoRan Irian Java example. Energy Concentrate Water Sag Milling Products Metal 9

9 10

10 11

11 12

12 Mine to Metals Products Corporate PI Visualization and Collaboration PI Analytics and Notifications PI Server and Data Services Jigsaw

13

14

15 Sustainability Strategies are good business Basic Guidelines 16

16 Overall Integrated Industrial Effectiveness Results Opportunities $ Mr. Porter Shared VALUE Strategy for SUSTAINABILITY Systems E N V I R O M E N T A L S A F E T Y Long term PROFITS With Sustainability C O S T S M A I N T E N A N C E Q U A L I T Y Real Time Integrated Plant Systems P R O D U C T I O N 17

17 18

18 THE PEOPLE EFFECT Local vs. Collaborative Decision Making KPI Examples: Production, Quality, Costs, Equipment Availability, Environmental and Safety alerts with fast resolution and improved decision making. Continuous Improvement and Innovation KPIs -> MONITOR MONITOR In Control? In Control? Yes No Identify Root Causes Identify Root Causes Operations/Maintenance Yes No Local Operations/Maintenance IMPROVE Satisfied? Establish Alternatives Yes No Strategic Competence Centers Maintenance/Engineering/Management 19

19 Real Time Information Integration and Standardization 20

20 PI System Data Infrastructure SCADA / PLC / DCS ISA S95 Level 4: ERP PI Visualization and Diagnostic Tools PI System Level 3: MES Referenced Data Level 2 Process data, Building automation Batch Continuous data, Control Control Level Alarm 1 & Events Level 0: Equipment Data Access Electronic Work Instructions Real-Time Data Infrastructure Common Data Presentation Layer Event Frames Discrete & Batch Control PI Server Analog Events All Variables PI Data Access PI AF Assets & Attributes Calculatio ns PI EF Downtime Batch Real Time Interfaces Startup Event Frames & Attributes Consolidati on 21

21 22

22 Improving the Transformation of Energy Resources into Electricity 23

23 24

24 Weather and Country Energy Limitations Most Arid Region in the World Large Energy Requirements 25

25 Optimizing Latin American Energy Generation Management 26

26 27

27 28

28 ENDESA Examples 29

29 Southern Peru Copper: Cuajone Cuajone Production 87,000 MT fine Copper per day. Conventional open-pit mine Concentrator - 10 Grinding Lines. 30

30 Southern Peru Copper: Cuajone

31 Southern Peru Copper: Cuajone

32 33

33 SIX Sigma PI AF Design Strategy Strategy for Operational Data Mining 34

34 Southern Peru Copper: Cuajone Sharepoint, PI AF, PI Slicers and PI Cubes Using Latest Power Pivot in Memory technologies Slicers 35

35 Tangible benefits: Advanced Mine to Mill Integration Production Benefits: Economic Benefits: 36

36 CAP Acero Huachipato Steel Mill PI System Seminar Chile Y2009 Fully Integrated Steel Company Reduction of Pellets in Blast Furnaces to produce Iron Steel produced in BOF then casted into Slabs 1.2 Tones of Steel per Year. 37

37 Iron and Steel Metallurgical Complex Real Time Information Integration and Standardization RAW Materials, Primary Transformation Secondary 38

38 Manufacturing Services Center 39

39 Strategy: Standardization of Assets and with Dynamic Contextual Information 40

40 Iron and Steel Metallurgical Complex Real Time Information Integration and Standardization 41

41 Operational Multidimensional Analysis 42

42 Integration of Data, Metrics and Events 43

43 Tangible benefits: Instant Power CAP ACERO 44

44 Classification of Productive and LOST Times in a Large Metallurgical Complex 45

45 Tangible benefits: 10 % REDUCTION SPECIFIC POWER or US$ 10 M 46

46 US $ 5.0 millions per year 47

47 Tangible benefits: Web Based Air Quality Management for Authorities 48

48 Mine to Metals Products Corporate PI Visualization and Collaboration PI Analytics and Notifications PI Server and Data Services Jigsaw

49

50

51 Drastic Energy and Water Savings Dynamic Performance Management Infrastructure with Collaborative Services PI Asset Framework standardization and cross-pollination at the local plant and at the Enterprise PI Asset Notification using Performance Metrics and Statistical Tools Visibility Using Internet Web Services with standard BI tools. RESULTS: Improvements in sustainability management with large operational cost reductions 52

52 Osvaldo Bascur Global MMM Industry Principal OSIsoft, LLC 53

53 Brought to you by