The Way to Digitalized Steel · PDF fileladle transfer car, KPI dashboards for mobile devices Example: Online-documentation retrieved via QR-coded equipment, augmented reality applications

Restricted © Primetals Technologies 2016 All rights reserved. primetals.com

The Way to Digitalized Steel Production Ijmuiden, May 2017

Restricted © Primetals Technologies 2015 All rights reserved. primetals.com

Restricted © Primetals Technologies 2017 All rights reserved.

Digitalization is driven by steel producers‘ requirements and enabled by new technologies

April, 2017 K.Herzog / EA I4.0 Page 2

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


Three major requirements in steel production shall be supported by digitalization


• 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


Digitalization helps to orchestrate the entire production chain



A digitalized plant is like an orchestra – The Metals Orchestra



Metals Orchestra Teach your players to play better



Metals Orchestra The Primetals Technologies portfolio


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


Metals Orchestra The Primetals Technologies portfolio


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


Smart Sensors help to improve data availability

Page 9

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

April, 2017 K.Herzog / EA I4.0

http://schoolpress.cdn.whipplehill.net/lwhs200/14/files/2015/03/wireless-512.png


Advanced Tracking System for ladles, pots, chutes & baskets or vessels

7.2.2017 K.Herzog / EA I4.0 Page 10

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


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)



Solution for Hot Rolling (example) Strip Steering in Finishing Mill


• 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


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

Page 13

Simulation

Optimization

September 2016 EA


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


Cooling Model and Power Cooling Ideal Tool for Microstructure Control and New Steel Grades

Page 15 April, 2017 K.Herzog / EA I4.0

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


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



Smart Work Augmented reality supports maintenance and operation

Page 17

• 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



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

Page 18 K.Herzog / EA I4.0

Plant

Internet

7.2.2017


The Digital Unity – The conductor of the Metals Orchestra



The Digital Unity – The conductor of the Metals Orchestra



Production Management System A comprehensive approach


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


Through-Process Optimization (TPO) Quality along the entire production chain


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


Maintenance Asset Technology (Mat)


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

1

2

3

4

PREDICTIVE MAINTENANCE Pre-set link to CMS Analytics on CMS data and maint history enables predicitive maintenance


Summary and conclusion

Page 26

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


QUALITY

FLEXIBILITY PRODUCTIVITY

Restricted © Primetals Technologies 2017 All rights reserved. April, 2017 K.Herzog / EA I4.0 Page 27


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


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 [email protected] primetals.com

Documents

The Way to Digitalized Steel · PDF fileladle transfer car, KPI dashboards for mobile devices Example: Online-documentation retrieved via QR-coded equipment, augmented reality applications