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SIMETAL (CIS) MES
© Siemens AG 2011. All rights reserved.
Steel plant simulation Siemens VAI‟s Steel Library OSIRIS
Philipp Laaber, I MT SM TY CP
Siemens VAI Metals Technologies GmbH & Co
Turmstr. 44
A-4031 Linz
Page 2 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Introduction
Industry
Customer ServicesDrive TechnologiesIndustry Automation
Metals Technologies
Divisions
Business Units
I IA I DT
I MT
I CS
I
Page 3 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Ores:
dressed
pelletized
sintered
Reducing agents:
coke
natural gas
coal
Fluxes
Steel scrap
Blast Furnace Basic Oxygen
Converter Ladle
Treatment
Vacuum
Treatment
Direct Reduction Plant
Electric
Arc furnace Vacuum
Treatment
Ladle
Treatment
Charge Materials Ironmaking Steelmaking Secondary Metallurgy Continuous Casting
Thick Slab Casting
Bloom / Beam Blank Casting
Solid metallic materials
solid charge materials
hot metal
liquid crude steel
From Ore to Steel (1/2)
Billet Casting
P250 mm
<250 mm
Remark: applies for typical process route, special applications might not be covered
Width: 600–3300 mm
Thickness: 70–300 mm
Slab / Medium Slab Casting
Width: 600–3300 mm
Thickness: >300 mm
COREX
FINEX
Page 4 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Thick Slab
Casting
Heavy and medium plate
Hot-Dip Galvanizing
Color Coating
Surface treated sheet:
- galvanized sheet
- color coated sheet
Sheet / coil
Hot strip
Welded tubes
Sectional steel, (heavy sections, T-beams, rails, sheet piling profiles)
Special steel
Merchant bar (light sections, square, flat,…)
Wire-rod, bars
Drawing, scalping, grinding
Pipe Welding
Cold Rolling Mill
Plate Mill
Hotstrip Mill
Section Mill
Bar / Wire-Rod Mill
Bloom,
preliminary
sections
Slabs
Continuous Casting Reheating Hot Rolling Pickling Cold Rolling Surface Treatment Finished Products
liquid crude steel
solid “red-hot” steel
hot formed steel
cold formed steel
coated steel
From Ore to Steel (2/2)
Bloom / Beam Blank
Casting
Billet
Casting
Slab / Medium Slab
Casting
Billets
Skin Pass Mill
Pickling Line
Page 5 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Actual situation
Baosteel COREX® C-3000
Challenge
Impact of transport system can not be calculated analytically
Capacities of different aggregate groups have to be aligned
Coordination within the plant
Difficult to evaluate layout variants
Typical customer benefit
Increase production
Identify bottlenecks
Reduce lead times
Decrease of setup operations
Reduce refractory costs
Optimize crane operations
Environ-
mental
benefit
Reduced consumption of electrical energy
Solution
Use of metals specific industry library with decades of knowlegde
Implements a realistic simulation model
Conduct experiment using the model
Provide complex scheduling algorithms
Siemens standard simulation software
Page 6 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
SVAI„s steel library OSIRIS
Steel specific library to model the material flows in a steel plant between melting aggregate and caster
APS
Scheduler
Steel
Aggregates
Order
Management
Transport
ManagementGantt
Performance
Indicators
Customized Simulation Model
Data Management
Steel Library
Generic Libraries
Customer Specific
Objects
Page 7 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Data management
Definition of products, product routes and process parameters
Predefined steel grades for standardized layouts available
Flexible steel routes can be defined by using priority parameters
Definition of several ladle cycles (hot metal, steel) is possible
Page 8 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Order Management
Orders are created by using probability functions
If a production orders are available these can be used instead of randomly created orders
Page 9 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Revise caster start times (sequence remains unchanged)
Plan primary metallurgy aggregates
Plan secondary metallurgy aggregates
Plan sub-aggregates (conditioning stands, ...)
APS Scheduler
Page 10 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Transport Management
Transport management is universally applicable
Transport heights are defined for each aggregate/crane
Transporters are created on basis of thís object
Network planning is used to restrict certain areas/transports
Intelligent collision control allows reliable crane transports
Several strategies for crane dispatching are available
Page 11 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Transport Management
t Lif
t=s H
eig
ht/v
Ho
ok
t L
oa
d
t Lo
we
r=s H
eig
ht/v
Ho
ok
t U
nlo
ad
tTrav=sTrav/vBridge
tTrolley=sTrolley/vTrolley
t=tLoad+max(tTrav,tTrolley,2 x tLift)+tUnload
Page 12 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Methodology
Layout
Orders
Schedule
Logistic System
Material Flow
Evaluate
Experiment
Product Mix
Page 13 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Example
Steel plant with 3 BOF, 4 CCM
Page 14 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Results
Utilization of aggregates
Page 15 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Results
Lead time vs buffer time
Page 16 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Results
Crane cycles
Page 17 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Recent References
Qatar
Brasil
Russia
USA
India
Ucraine
Vietnam
Austria
Page 18 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Contact
Andreas Huber Senior Simulation Consultant I MT PEP PL3 Siemens VAI Metals Technologies GmbH & Co Turmstr. 44 A-4031 Linz Phone: +43 – 732 – 6592 – 74281 Mobile: +43 – 664 – 88448362 E-mail: [email protected] Philipp Laaber Calculation Engineer I MT SM TY CP Siemens VAI Metals Technologies GmbH & Co Turmstr. 44 A-4031 Linz Phone: +43 – 732 – 6592 – 74611 Mobile: +43 – 664 – 6150256 E-mail: [email protected]
Page 19 28.10.2011 MT SM TY CP / MT PEP PL3
Intellectual property of SVAI
Andreas Huber/Philipp Laaber
Thank you for your attention!
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