EMS and Insights changing the dynamics in the steel industry

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

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

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

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

Energy management system calculates the corresponding energy consumption schedules which can be useful for the company for evaluating costs of mismatching between actual and planned consumptions due to unpredictable events. To avoid any changes in production plans or disturbances in operation are continuously updated in the energy management system, and the revised load schedules are sent to the electricity supplier. Operators monitor consumption using the tie-line monitoring display that activates an alarm if a deviation leading to a penalty charge is expected.

Due to the increasing utilization of energy sources, the energy network becomes ever more volatile with alternate energy excesses and undersupplies. The steel production systems must adapt their strategy according to the situation focusing on global cost optimization and considering process stability. In this case, a flexible solution is required in order to achieve the multi-objective optimization. Forecasting energy consumption can be useful for the company for evaluating costs of mismatching between actual and planned consumptions due to unpredictable events.

EMS is to supply current and prognostic information about the energy turnovers in the production units for the people working at the power plant to enable better controlling and adaptation of the conversion and purchase of energy. Flexibility and adaptability are important requirements that drove the design of the whole energy management system

Implementation of Energy Management System in Steel Industry incur Transparency over energy consumption and detailed analytics, Energy efficiency improvements through real-time energy monitoring, advanced analysis, benchmarking and forecasting , Alarm system implementation (to detection of deviations and their causes in energy consumption )

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