EMS and Insights changing the dynamics in the steel industry

There are a numberof factors that can impact negatively on productivity and cost-efficiency ofsteel industry, which can be reduced or completely eliminated with Energymanagement system (EMS) to deliver improved Energy efficiency, reduced costsand, more reliable and energy-efficient operation.

Energy consumption in most of theintegrated steel is generally high a due to problems like in old shop floor& operating practices, poor quality of raw material, high ash coal, highalumina iron ore etc.

The steel sectoris an important part of the Energy Intensive Industries it is the secondworld’s main energy intensive manufacturing systems consuming more Energy.

Energy constitutesa significant portion, around 20%, of the cost of steel production and about35% of an integrated facility’s energy input comes from electricity. Thus steelindustry a large consumer of electrical energy, by significantly contributingto the power network overloads. Therefore, actions should be planned thedeployment stage for improving the load flexibility in steel manufacturing;

Energy management system calculates the corresponding energy consumptionschedules which can be usefulfor the company for evaluating costs of mismatching between actual and plannedconsumptions due to unpredictable events. To avoid any changes in production plans or disturbances in operationare continuously updated in the energy management system, and the revised loadschedules are sent to the electricity supplier. Operators monitor consumptionusing the tie-line monitoring display that activates an alarm if a deviation leadingto a penalty charge is expected.

Due to the increasing utilisation of energy sources, the energy networkbecomes ever more volatile with alternate energy excesses and undersupplies.The steel production systems must adapt their strategy according to thesituation focusing on global cost optimisation and considering processstability. In this case, a flexible solution is required in order to achievethe multi-objective optimisation. Forecasting energy consumption can be usefulfor the company for evaluating costs of mismatching between actual and plannedconsumptions due to unpredictable events.

EMSis to supply current and prognostic information about the energy turnovers inthe production units for the people working at the power plant to enable bettercontrolling and adaptation of the conversion and purchase of energy.Flexibility and adaptability are important requirements that drove the designof the whole energy management system

Implementation of EnergyManagement System in Steel Industry incur Transparencyover energy consumption and detailed analytics, Energy efficiency improvementsthrough real-time energy monitoring, advanced analysis, benchmarking andforecasting , Alarm system implementation (to detectionof deviations and their causes in energy consumption )

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