MiDA 4.0 ENDLESS CASTING AND ROLLING EMPOWERED BY DIGITAL TECHNOLOGIES
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1 OMAR NARDUZZI DANIELI GROUP 2018 SEAISI CONFERENCE & EXHIBITION JUNE 2018 JAKARTA MiDA 4.0 ENDLESS CASTING AND ROLLING EMPOWERED BY DIGITAL TECHNOLOGIES DANIELI / SINCE 1914 PASSION TO INNOVATE AND PERFORM IN THE METALS INDUSTRY This document contains proprietary information of Danieli & C. Officine Meccaniche S.p.A., not disclosable, not reproducible. All Rights Reserved.
2 MiDA 4.0 INDEX 1. INTRODUCTION TO MiDA 2. DIGI&MET SMART PLANT APPROACH AND APPLICATION 3. CONCLUSIONS
3 MiDA 4.0 > 1. INTRODUCTION TO MiDA 2. DIGI&MET SMART PLANT APPROACH AND APPLICATION INTRODUCTION TO MiDA 3. CONCLUSIONS
4 INTRODUCTION TO MiDA MINIMILL EVOLUTION
5 INTRODUCTION TO MiDA ENDLESS CASTING AND ROLLING FROM LIQUID STEEL TO FINISHED PRODUCT IN 12 MINUTES Uninterrupted single strand endless casting rolling
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7 INTRODUCTION TO MiDA MICROMILL K-FACTORS #1 Compact #5 Fast #2 Regional #6 Cost effective #3 Endless #4 Energy saving #7 Best in quality BEST IN CAPEX AND OPEX From 200,000 to 800,000 tpy in a single endless strand
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9 INTRODUCTION TO MiDA FASTCAST PLUS PATENTED ECO POWER MOLD > High thermomechanical strength > High and uniform heat transfer > Optimized corner cooling > High service life FAST CAST CUBE (FCC ) > Compact design > Bearing free suspension system > Maintenance free philosophy > Ultra precise guiding
10 INTRODUCTION TO MiDA DANIELI MICROMILL DRB DIRECT ROLLING AND BUNDLING > Compact layout > Hot cut for final selling > Precise cutting to length (0 +25mm) > up to +3% yield saving
11 INTRODUCTION TO MIDA SIDENOR GROUP SOVEL (GREECE) The first plant powered by FCC and Power Mould Year 2007
12 INTRODUCTION TO MiDA CMC STEEL ARIZONA Yearly productivity Strand productivity Max casting speed Endless run Endless billet 350,000 tpy 55 tph 7.2 m/min > 23 hours/day > 9 km Yield > 99% Plant uptime > 90% Endless production since 2009 > 2 mio tons
13 INTRODUCTION TO MiDA EGYPTIAN STEEL Yearly productivity Strand productivity Endless billet Max casting speed 830,000 tpy 75 tph 165x165 mm 6.3 m/min Startup JULY conventional strands Cold discharge (billet production) Rolling Mill Endless Casting and Rolling strands Induction Heaters (HI)
14 Single Strand productivity INTRODUCTION TO MiDA MI.DA. / MILESTONES THROUGH THE YEARS AND FUTURE DEVELOPMENTS MI.DA IN OPERATION STARTUP ON 2018 STARTUP ON 2019 [t/h] 2007 SIDENOR SOVEL GREECE 140X140 at 46 t/h 2009 CMC ARIZONA USA 130X130 at 55 t/h 2013 SIDENOR SOVEL GREECE 160X160 at 65 t/h 2016 IIC STEEL EGYPT 165X165 at 80 t/h
15 MiDA 4.0 > 1. INTRODUCTION TO MI.DA. 2. DIGI&MET SMART PLANT APPROACH AND APPLICATION 3. CONCLUSIONS DIGI&MET: SMART PLANT APPROACH AND APPLICATION
16 DIGI&MET: SMART PLANT APPROACH AND APPLICATION «DATA-DRIVEN» APPROACH Data-driven Services Q s -Manufacturing Supply-Chain Process Optimization Q s -Maintenance Predictive Maintenance Q s -Process Technological Process Optimization Q s -Energy Energy & Utility Consumption Optimization Platform Centralized Repository Big Data IIoT Analytics... Data Sources Existing/New products Smart Sensors Plant #1 Plant #N
17 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 DIGITAL PULPIT Unified 3Q control rooms 1 for Meltshop (EAF, LF) 1 for Casting & Rolling > «Soft desks» completely based on computer screens > Plant and area performance indicators and Operator Assistance > Smart, flexible and ergonomic support to augment the quality of human labor
18 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 SCRAP YARD Automatic scrap classification > Independent from operator with 100% materials check > Raw materials traceability > Optimal scrap yard storage A B C
19 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 Q-MELT EAF PROCESS CONTROL Q-REG Electrode control and foaming slag management LINDARC Laser offgas analysis M-ONE Chemical package MELT MODEL - Data-driven adaptive process monitoring and control > Reduction of process variabilities DYNAMIC SETUP Chemical and electrical energy MELT MODEL Q-REG + Dynamic electrodes regulation and arc coverage control LINDARC Real-time off-gas analysis > Consolidation of best practices > Best Process Performances
20 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 Q-ROBOT MELT AND Q-ROBOT CAST > Fully Automated Melting and Casting Floor > Temperature Sampling and Chemical Analysis > Fully Automatic Cartridge Loading and Unloading > Safety and Repeatibility > Oxygen Lancing > Ladle Shroud Manipulation > Slide Gate Connection > Powder Feeding in Tundish
21 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 AUTOMATIC TAPPING Fully remote control of tapping procedure supported by machine vision systems Q-SLAG - Slag carryover detection and automatic backtilting Q-EBT EYE Monitoring of EBT tap hole condition Q-EBT SAND Automatic and controlled feeding of olivine > Reduction of power off time > Safety improvement
22 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 SMART SENSORS AND INSTRUMENTATION > Reliable and consistent > Process parameters monitoring and control > Product dimensional and quality inspection State of the art technologies Mould powder sensor - RF microwaves Speed measurement - machine vision Section gauge eddy current Profile measurement - laser sectioning
23 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 MODELING AND SIMULATION Physical models > State of the art numerical algorithms Data-Driven models > Machine Learning & Predictive analytics Forecast of high-risk events Prediction of product properties > Decision support tool for operators > Automation of control solutions Input Variables (Chemicals, Process) Variables Influence on Final Quality Final Product Quality Prediction
24 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 Q3 INTELLIGENCE Business Analytics > KPI Monitoring > Through-Process Dashboards > Advanced Statistical Analytics > Multi-device Mobile Support
25 DIGI&MET: SMART PLANT APPROACH AND APPLICATION DIGITAL SOLUTIONS FOR MIDA 4.0 MAINTENANCE MANAGEMENT Condition Monitoring Predictive maintenance ENERGY MANAGEMENT Intelligrid Power Monitoring Power Demand Control MANUFACTURING EXECUTION AND OPTIMIZATION
26 MiDA 4.0 > 1. INTRODUCTION TO MI.DA. 2. DIGI&MET SMART PLANT APPROACH AND APPLICATION CONCLUSIONS 3. CONCLUSIONS
27 CONCLUSIONS FACTORS LEADING THE INNOVATION MiDA 4.0 INTEGRATION BENEFITS MiDA PROVEN TECHNOLOGY > Super-compact > Energy-saving > Regional > Endless production DIGI&MET SMART PLANT APPROACH > Plant efficiency > Process repeatibility > Improved safety > Digital supply chain MiDA 4.0 PROCESS + DIGITALIZATION > Faster startup path > Continuous improvement > Road to high quality rebar production
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29 OMAR NARDUZZI DANIELI GROUP 2018 SEAISI CONFERENCE & EXHIBITION JUNE 2018 JAKARTA MiDA 4.0 ENDLESS CASTING AND ROLLING EMPOWERED BY DIGITAL TECHNOLOGIES DANIELI / SINCE 1914 PASSION TO INNOVATE AND PERFORM IN THE METALS INDUSTRY This document contains proprietary information of Danieli & C. Officine Meccaniche S.p.A., not disclosable, not reproducible. All Rights Reserved.
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