Advancing steel production is more than simply modernizing and revamping mechanical equipment to maintain productivity. Cutting-edge steel production is highly digital, automated, and based on a deep understanding of the entire production chain and strengthened through data analysis and quality control. Through-Process Optimization Services from Primetals Technologies is an approach to steel production that takes metallurgical quality and performance to new levels.
Optimize, improve, advance, high-quality. These terms, among others, such as improving energy efficiency or reducing waste, are found prominently throughout the language surrounding the steel industry. In recent years, increased pressures surrounding production chain improvements have producers looking into opportunities to enhance production routes to make these terms a reality—i.e., optimize performance, improve energy efficiency, advance automation, and deliver high-quality steel products. For those producers looking to navigate this complex landscape, Through-Process Optimization Services examines the entire production chain, including the metallurgical and mechanical properties of steel, and finds actionable solutions.
Optimizing Production
Through-Process Optimization Services from Primetals Technologies approach steel production with one primary goal: improving operations across the entire value chain. Producers are pressed to find new means to advance their processes, from transforming production routes to meeting new quality standards, such as automotive-grade steel. Through-Process Optimization is an interdisciplinary approach to consulting and services that provides customized solutions supporting each producer’s individual goals. This approach can be broken down into a series of unique steps that comprise the framework of Through-Process Optimization.
1. Target Definition
A team of specialists from Primetals Technologies works closely with steel producers to discuss the initial targets of the optimization process. Due to the diverse nature of steel producers’ needs, these targets may vary. This process means specific requirements, including targets for certain technologies or production processes, can be laid out. The project’s scope, split, and deliverables are defined along with a time frame. While these initial conversations may seem self-explanatory, they are the basis of a close partnership between the experts at Primetals Technologies and each producer.
2. Information Acquisition
Once the partnership has been established, steel producers share the details of their plants and processes with experts and specialists. This information, which includes plant layout, process flow, and schematics of individual plants, is used to prepare for a complete production analysis. Technical plant details, including automation systems and process automation, provide a complete overview of current operations. Finally, any previous studies or reports from Primetals Technologies will be shared with the team. This information is collected and analyzed to form a concept and approach to meet the defined target. Moreover, the initial information will provide the basis for on-site surveys and data collection.
3. On-Site Survey
Based on the defined target and initial findings, a specialized team from Primetals Technologies, including experts in specific fields, visits the plant to set up on-site investigations. The plant inspection and fact-finding survey examines processes closely to establish benchmarks, evaluate product quality, and receive hands-on information from engineers and plant managers. The on-site survey also provides the opportunity to see the automation system and receive detailed information about the existing maintenance infrastructure.
4. Consolidation
With the information gathered and collected, each piece must be combined and consolidated into a clear report. This process also involves additional analysis, locating gaps and untapped potential in steel plants. Solutions and tailored improvement measures are defined and detailed, including a roadmap and strategy proposal based on benefit estimations. Constraints and limitations are also identified, and a preliminary report will be shared with the steel producer.
5. Final Report
As adjustments are made in an exchange with the on-site and Primetals Technologies team of experts, a final report is delivered to the producer. This report is the “recipe for success” based on the findings from the initial phases of Through-Process Optimization. Thanks to delivered prioritizations, it forms a strategic roadmap and can support decision-making. Moreover, this is where the improvement opportunities go from a theoretical possibility to a reality.
Covering a broad range of activities, Through-Process Optimization Services involve understanding the unique needs and targets of each producer.
Steel grade development and coating technology:
Renewable energy and e-mobility are just some of the emerging markets impacting the steel industry with new grade requirements. Through-Process Optimization can support producers in developing these new grades and recommend coating technologies to ensure high-quality results.
Process standardization and optimization:
While digital tools and automation are integral to the modern steel plant, operations and efficiency will always impact the product. Through-Process Optimization provides clear insights into operational practices to identify areas for improvement and develop a roadmap for digitalization.
KPIs, best practices, and KPI improvement:
Through clear analysis and reporting, including on-site assessment, Through-Process Optimization provides a clear overview of KPIs, can advise on best practices, and sees to seamless performance improvement with low investment.
Quality management and certification support:
Knowledge of various steel grades and product quality analysis is invaluable for quickly identifying the potential of production routes to develop new products. Through-Process Optimization can also streamline the roll-out of new products by supporting product certification.
Data analytics services:
Powered by AI, data analytics in Through-Process Optimization quickly identifies trends and changes in production, including root cause analysis, troubleshooting, and quality predictions, to keep things running smoothly.
Consulting and Training:
Primetals Technologies offers hands-on consulting and training to take full advantage of Through- Process Optimization Services. Having thoroughly trained staff means that the benefits of these services maintain a lasting impact directly at the plant.
From Improvement to Implementation
Through-Process Optimization delivers a clear plan for advancing and improving production processes. More importantly, these activities can be seen as part of a consulting service, where experts merely diagnose and recommend areas for improvement. However, this is only where Through-Process Optimization begins. In these areas of consulting, recommendations for improvement are tied to a close partnership and understanding of the steel plant. In this way, experts can recommend the best technologies and
adjustments moving forward.
In the U.K., steel producer Marcegaglia participated in a Through-Process Optimization study that identified bottlenecks and provided recommendations for improvement. Two clear areas for improvement were their automation systems and the revamping of their entire electric arc furnace. By installing the Melt Expert, a fully automated electrode control system for electric arc furnaces and ladle furnaces, Marcegaglia can ensure optimal operation and energy efficiency. The following steps include implementing process optimization software—i.e., Level 2 automation systems—for the electric arc furnace, AOD converter, and ladle furnace, which currently lack automation infrastructure.
Through-Process Optimization provides producers with the resources and support to meet new market requirements and sustain leading market positions.
Oftentimes, following studies and consulting from Through-Process Optimization Services, experts at Primetals Technologies recommend Though-Process Quality Control (TPQC), which is a comprehensive knowledge-based IT-solution designed for the steel industry.
While implementing TPQC with digitalization experts from Primetals Technologies, Through-Process Optimization customizes functions, commissions the system, and fine-tunes TPQC, including providing hands-on training. Reflecting the complexity and uniqueness of the steelmaking process, TPQC can be tailored to match each plant’s specific configuration, needs, and targets. With vast amounts of information emerging from, for example, automation systems and sensors across multiple aggregates, TPQC is implemented to record and process the information that is key to success.
With the digitalization team, Through-Process Optimization Services examines the existing IT infrastructure to ensure seamless integration of TPQC. Additional data-based AI models support the fine-tuning of these systems for each producer and plant. The result is that TPQC can predict the mechanical properties of products across aggregates and provide prescriptive steps to optimize process parameters. The initial setup from Through-Process Optimization includes checking incoming signals and establishing rules for process and quality grading, root cause analysis and corrective action, and KPIs and statistical process controls. Finally, each producer is provided dashboards and interfaces to understand their data.
From Data Analysis to Action
Through-Process Optimization provides producers with the resources and support to meet new market requirements and sustain leading market positions. Tangsteel is one such producer who, via Through- Process Optimization services, enhanced its production routes for new products and established new KPIs to achieve sustainable success. The choices for Through-Process Optimization included product development, quality management, training, establishing KPIs for improvement, and implementing TPQC.
As the project commenced, new galvanizing processes were developed, enabling the production of new high-quality end products, including hot-dip aluminum-silicon and hot-dip zinc-magnesium coating. The result of these newly developed products meant Tangsteel could supply these end products to major companies in the automotive and appliance industries. With Through-Process Quality Control implemented, the process was effectively monitored toward crucial KPIs to improve output, consumption, yield, quality, and product certification. With the relevant data collected and using data analysis with Through-Process Optimization, several improvements were demonstrated.
By enabling producers like Tangsteel to obtain comprehensive data from their entire production route and combine that information with knowledge of the production process, Through-Process Optimization supports producers by bridging the gap between digital transformation and tangible optimization. With the services offered by Through-Process Optimization, steel producers can achieve their goal of improved production, including yield and quality, and maintain an advantage in expanding markets with strict quality requirements. Through-Process Optimization Services are vital for sustainable high performance and improved quality.
