Steel Plant Simulation - Pmcorp

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SIMETAL (CIS) MESSteel plant simulationSiemens VAI‟s Steel Library OSIRISPhilipp Laaber, I MT SM TY CPSiemens VAI Metals Technologies GmbH & CoTurmstr. 44A-4031 Linz Siemens AG 2011. All rights reserved.

IntroductionIIndustryDivisionsI IAI DTI CSIndustry AutomationDrive TechnologiesCustomer ServicesBusiness UnitsI MTMetals TechnologiesPage 228.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

From Ore to Steel (1/2)Charge MaterialsIronmakingSteelmakingBlast FurnaceSecondary MetallurgyBasic uous CastingThick Slab CastingWidth: 600–3300 mmThickness: 300 mmOres:dressedpelletizedsinteredSlab / Medium Slab CastingWidth: 600–3300 mmThickness: 70–300 mmReducing agents:cokenatural gascoalSolid metallic materialssolid charge materialshot metalliquid crude steelFluxesFINEXBloom / Beam Blank CastingP250 mmCOREXElectricArc furnaceDirect Reduction PlantLadleTreatmentVacuumTreatmentBillet Casting 250 mmSteel scrapRemark: applies for typical process route, special applications might not be coveredPage 328.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

From Ore to Steel (2/2)Continuous CastingReheatingHot RollingPicklingCold RollingSurface TreatmentFinished ProductsHeavy and medium plateThick SlabCastingPlate MillSurface treated sheet:Pickling LineHotstrip MillSlab / Medium SlabCastingHot-Dip GalvanizingColor Coating- galvanized sheet- color coated sheetCold Rolling MillSheet / coilSlabsliquid crude steelsolid “red-hot” steelhot formed steelcold formed steelcoated steelSkin Pass MillHot stripPipe WeldingWelded tubesBloom / Beam BlankCastingBloom,preliminarysectionsSectional steel,(heavy sections, T-beams,rails, sheet piling profiles)Section MillDrawing, scalping, grindingSpecial steelMerchant bar (light sections, square, flat, )BilletCastingBar / Wire-Rod MillWire-rod, barsBilletsPage 428.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Actual situation Impact of transport system can not becalculated analytically Capacities of different aggregate groupsChallengehave to be aligned Coordination within the plant Difficult to evaluate layout variantsSolution Use of metals specific industry librarywith decades of knowlegde Implements a realistic simulation model Conduct experiment using the model Provide complex scheduling algorithms Siemens standard simulation softwareTypicalcustomerbenefit Baosteel COREX C-3000EnvironmentalbenefitPage 5 Reduced consumption ofelectrical energy28.10.2011Andreas Huber/Philipp LaaberIncrease productionIdentify bottlenecksReduce lead timesDecrease of setup operationsReduce refractory costsOptimize crane operationsMT SM TY CP / MT PEP PL3Intellectual property of SVAI

SVAI„s steel library OSIRISCustomer SpecificObjectsCustomized Simulation orsSteel LibraryData eneric Libraries Steel specific library to model the material flows in a steel plant betweenmelting aggregate and casterPage 628.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Data management Definition of products, productroutes and processparameters Predefined steel grades forstandardized layouts available Flexible steel routes can bedefined by using priorityparameters Definition of several ladlecycles (hot metal, steel) ispossiblePage 728.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Order Management Orders are created by using probability functions If a production orders are available these can be used instead of randomly createdordersPage 828.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

APS Scheduler Revise caster starttimes (sequenceremains unchanged) Plan primarymetallurgyaggregates Plan secondarymetallurgyaggregates Plan sub-aggregates(conditioning stands,.)Page 928.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Transport Management Transport management is universallyapplicable Transport heights are defined for eachaggregate/crane Transporters are created on basis of thísobject Network planning is used to restrictcertain areas/transports Intelligent collision control allows reliablecrane transports Several strategies for crane dispatchingare availablePage 1028.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Transport ManagementtTrolley sTrolley/vTrolleytLoadtUnloadtLift sHeight/vHooktLower sHeight/vHooktTrav sTrav/vBridget tLoad max(tTrav,tTrolley,2 x tLift) tUnloadPage 1128.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

MethodologyEvaluateLayoutMaterial FlowExperimentProduct MixOrdersLogistic SystemSchedulePage 1228.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

ExampleSteel plant with 3 BOF, 4 CCMPage 1328.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

ResultsUtilization of aggregatesPage 1428.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

ResultsLead time vs buffer timePage 1528.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

ResultsCrane cyclesPage 1628.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Recent BrasilPage 1728.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

ContactAndreas HuberSenior Simulation ConsultantI MT PEP PL3Siemens VAI Metals Technologies GmbH & CoTurmstr. 44A-4031 LinzPhone: 43 – 732 – 6592 – 74281Mobile: 43 – 664 – 88448362E-mail: huber.a.andreas@siemens.comPhilipp LaaberCalculation EngineerI MT SM TY CPSiemens VAI Metals Technologies GmbH & CoTurmstr. 44A-4031 LinzPhone: 43 – 732 – 6592 – 74611Mobile: 43 – 664 – 6150256E-mail: philipp.laaber@siemens.comPage 1828.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3Intellectual property of SVAI

Thank you for your attention!Page 1928.10.2011Andreas Huber/Philipp LaaberMT SM TY CP / MT PEP PL3ProtectionIntellectualnotice / Copyrightproperty ofnoticeSVAI

COREX FINEX . Page 4 28.10.2011 MT SM TY CP / MT PEP PL3 Intellectual property of SVAI . 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 S

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