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Abstract
MoreefficientBAFoperationnotonlyincreasesthroughputandprofitabilitybutalso improvesschedulingandeffectivenessofdownstreamoperations.Withthecurrentuseof softwareforstacking,heatingandcoolingcycleoptimization,annealfacilitiesareachieving significantefficiencies.
Yet,todaymorethanever,theneedtosqueezeoutmoreateveryturniscritical.
Sowhatcanbeconsideredthenextgenerationinannealoptimization?Andhowcanmore outputbeobtainedwithoutaddingmanpowerorequipment?
Therearetwostepsforthisnew,nextgenerationoptimization.
maximizesefficiencyofcranemovement.Together,thisnewmodelprovidesthehighest utilizationofassetsintheBAF.
ThisnewmodelsqueezesmoreoutofHNorhydrogenBAF,eventhoseoperatingamixture ofequipmentmanufacturers.
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Introduction
Toremaincompetitiveinthecurrenteconomicclimate,steelcompaniesneedtofocustheir attentiononthecostofproduction.Thischallengewillbecomplexastheeconomyrecovers withreshapedmarketsandasnewandidledsteelcapacityisbroughtbackonline.Theability tobeflexibleandoperateefficientlyduringthesedynamicmarketconditionswillbekeyfactors toturningaprofit.
Thisnewsoftwarefurtheroptimizestheprocesstomaximizethroughputcapacity,minimize operatingcosts,andmaintainthehighestlevelofmechanicalpropertyconsistency.
BAFOptimization
Therearethreelayersofoptimizationthatapplytotheannealshop,eachlayerbuildingon theprevious.Thefirstlayeraddressesthecoilandcontroloftheheatingandcoolingprocessing manner.ThesecondlayerofBAFOptimizationaddressesthegroupingofindividualcoilsinto batchesorcharges,consideringeachindividualcoilsneedsaswellasthechargeasawhole. Finallythethirdlayertakesintoaccountthechargesalongwiththeequipmentandmanpower intheshoptoarrangeandmanagethe completeshop.Itisfromthisthird layerthatnewefficienciesarebeing achievedintheBAFthroughthe additionofoptimizationmodeling.
ImprovingShopPerformancewithOptimizationModeling
Whenshopmanagementishandledmanually,therearealargenumberofvariablesforthe personneltoconsiderinordertooptimizetheoperation.Thepersonmanagingtheshopis typicallyjusttryingtokeepeverythingmovingandhaslittletimeorabilitytodevelopand manageaplanmuchbeyondthecurrentturn.Thelargertheshop,themoredifficultthisisto coordinateandthemoreinefficienciesthatsneakin.
ShopOptimizationPlan
FirstanoptimizedShopPlanisgenerated.Thesoftwareusestheheating,coolingand stackingmodeloutputstodeterminethemostefficientuseofresources.Theresourcewiththe leastcapacityisdeterminedfromthecurrentinventoryandequipmentinformationmaintained inCAPS.Protectingthisbottleneckresourcebecomestheprimaryfocusoftheplan.
OperationsPlanning
Nowthataplanisdeveloped,itneedstobeimplemented.TheOperationsPlanningmodule directsresourceactivitiesaccordingtotheShopPlan,suchasrealtimetaskassignmentstothe crane,floor,andfurnaceoperators.Withtheadditionofacrane(locator),navigational functionalityisavailablethatmaximizesefficiencyof cranemovement.
Forexample,inashopwithmultiplecranes,thecrane
Figure2:CraneTaskList
activitymustbecoordinatedtomakesurethattheydonot interferewitheachotherandmoreimportantlythattheywork
BokaroBAF
BokaroSteelPlant,aSteelAuthorityofIndiacompany,locatedinJharkhand,INDIAis currentlyinstallingacompletehydrogenbelltypebatchannealingfacilitythatwillbethemost advancedBAFintheworld,intermsofoverallproductivityefficiency.Whencompleted,the facilitywillprocess860,000tonsperyearofcoldrolledsteel,primarilydestinedforthe automotivemarket,usingonly47bases.Theproductmixofgradesisasfollows:
Mix[%] 10 20 30 20 10 5 5
RADCONisoverseeingthecompleteproductionandturnkeyinstallationofthecompanys H2SHC(100%HydrogenSuperHighConvection)annealingsystemconsistingof:
47baseswith2mchargediameterand6.5mstackingheight;
26mixedgasfiredfurnaces;
20air/watercoolers;
49basepostcoolingfacilityfordehumidifiedair cooling;
o Allassociatedcontrols.
OptimizationmoduleinCAPS.
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Conclusion
TheintroductionoftheShopOptimizationmodeladdressesthefinalBAFlayer managementoftheshoptomaketheshopequipmentandpersonnelasproductiveand efficientaspossible.ThesoftwareallowstheBAFtooperatewithfeweremployees,provides significantlyimprovedcommunicationandassignmentoftasks,reducesincidentsofhuman error,improvesequipmentandmanpowerutilization,increasesthroughputcapacity,lowers productioncosts,andimprovesqualitylevels.Inaddition,BAFproductionbecomesmore predictableandeffectivewhichenhancestheefficiencyandeffectivenessofdownstream operations.TheShopOptimizationmodelcanbeaddedtoexistingshopsornewRADCON installationsthatutilizeCAPSHeating,CoolingandInventoryManagementmodules.
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coldrollingcapacitywilldrivethedevelopmentofassociatedannealingfacilitieswhichwill significantlybenefitfromimprovedcontrolandoptimization.
RADCONhasaprovenrecordofprovidingeffectiveoptimizationsoftwareforBAFs.The ShopOptimizationModelcontinuesthattraditionwithnextgenerationprocessmanagement.
www.RAD-CON.com
Phone: +1.440.871.5720 Fax: +1.216.221.1135
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