Optimized Energy Management and Planning Tools for the Iron and Steel Industry
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The document discusses energy management challenges faced by the iron and steel industry and emphasizes the importance of implementing comprehensive Energy Management Information Systems (EMIS) to improve operational efficiency and sustainability. EMIS can provide real-time visibility of energy usage, cost management, and help in achieving sustainability KPIs. Key features of EMIS include data aggregation, forecasting, customizable reporting, and enabling continuous improvement through actionable insights.
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Optimized Energy Management and Planning Tools for the Iron and Steel Industry
- 1. Klaus Lachmann Steel Solutions Director Schneider Electric Optimized Energy Management and Planning Tools for the Iron and Steel Industry
- 2. Index The Energy Dilemma Energy Management Information System Reference Case Conclusion Q & A
- 3. The Energy Dilemma vs Energy Demand By 2050 Electricity by 2030 CO2 emissions to avoid dramatic climate changes by 2050 The Facts The Need Source: IEA 2007 Source: IPCC 2007, figure (vs. 1990 level) Power outages Rising energy prices Climate change Conflicts for resource access & control
- 4. Regulations and Standards are Everywhere
- 5. Energy Management Program Iron & Steel Industries are Under Pressure 2nd largest energy consuming industrial sector Cost of energy versus production costs Serious GHG footprint Business and operational challenges Increasing production, plant availability, flexibility Reducing energy consumption per ton Reducing the cost of energy per ton Taking control of emissions
- 6. Energy Management Information System Comprehensive Energy Management Program Strategy: Holistic strategy and action plans covering the complete industrial operation People: Energy efficiency as company culture, empowerment Processes: Plan-Do-Check-Act Cycle, continuous improvement initiatives, accountability Information technology: visibility of energy, ability to compare, analyze and benchmark
- 7. Common issues Insufficient contextual data on individual assets Spreadsheet culture with disparate data Manual data collection into a multiple systems Lack of detailed KPIs for achieving sustainability Misconception that reducing energy consumption means reduced production Solutions to address WAGES
- 8. Energy Management Information System (EMIS) Relevant information to key individuals and departments Enables energy performance and operation improvement Detection of energy related opportunities and anomalies
- 9. EMIS functional requirements A closer look (1/2) Near Real-time Operation Monitor consumption and any affecting factors Data aggregation from disparate data sources Online energy balance Sustainability KPIs, e.g. kWh/t, GJ/t or m3 water/t Alerts for sudden changes in use patterns Analyze Usage and cost analysis: product, media, process, etc. Benchmark: periods, target performance, best practices Optimal energy consumption target
- 10. EMIS functional requirements A closer look (2/2) Enable Forecasting and planning based on production parameters Cost allocation: cost centers, processes and products Procurement support and utility bill verification Information Near real-time reporting through web portals and customizable dashboards Periodic / triggered reports: KPIs, energy, emissions, cost, configurable aggregation Compliance reporting
- 11. Sustainability KPIs Tailored for User Groups Scalable and near real-time information Plant operators and plant supervisors Energy and energy efficiency manager Top management Key Performance Indicators (KPIs) kWh/t, GJ/t, m3 water/t Emission / t Energy costs / t More...
- 12. EMIS architecture Simplified Enterprise HMI: data display, analysis, reports Enterprise data management: Enterprise data aggregation and KPI calculation ERP WAGES Process automation Plant data management: Data aggregation and KPI calculation Process data acquisition Metering architecture Rolling Mill Plant HMI: Data display, analysis, reports MeltshopCoke plant Sinter plant Power Plant … Site B Aggregation from different plants at company level for an enterprise-wide picture of total energy usage, costs, and performance. Energy & Sustainability KPIs
- 13. EMIS architecture Software and modules Realtime Monitoring System Realtime Monitor Remote Operate Trend Events & Logs Failure & Alarming Data Archive Web Publish Tag Mgt. Graphics Mgt. Data Collecting Systems Electric Metering Production Automation Workflow Management Modul Report SSRS Historian Database Performance Management Modul Plant Hierarchy KPIs Mgt. Data Analytics Calculate Engine Knowledge Mgt. Data Interface Database mgt. Report SSRS Basic Management Functions Flow Mgt. Data Mgt. Workflow Engine Event Mgt.Data Interface Energy Management Information Publishing Optimization Modul Model Mgt. Rules Base Para. Mgt. Data Interface Advanced Functions Online Optimization Multi Balance Waste Material Functions Knowledge Management User Authorization Management Customized User Interfaces Documents and Resource Management Dashboard Graphical Representation Reports and Dashboard Presentation Layer Application Layer Data Layer Existing Systems Report Designer Forecast Models Balance ModelsSupport Layer Forecast Equipment Mode Plan & Performance Operation Mode Emergency Plan Quality Management Operation Logs Material Defenition Performance Analysis Plan Management Document Mgt Master Data Report Mgt Equipment Data Energy Balance Cost Allocation Perioic Reports Downtime Benchmark Compliance Equipment KPI Equation ERP MES Finance DMES Production Historian Data Flow Realtime Data Real-time Monitoring Modelling Workflows Performance Management Reports & Dashboard Knowledge Man. Applications (Balance, Prediction, Alarmi ng, Optimization, etc.) Information
- 14. Energy Analytics Energy Data Software Analytics Multiple sources - types - formats - protocols Compliance reporting Energy savings GHG reduction Cost accounting Irregularities Users: Multi-site Multi-purpose
- 15. Information Tools Visualization Dashboards (samples) Role-based capability to: - monitor and improve operations - analyze and drill to detail according to individual needs.
- 16. Information Tools Visualization and Reporting Dashboards (samples) Reports (samples) Role-based capability to monitor, analyze and drill to detail. Triggered or automatic reports in standardized or customized format.
- 17. Efficiency Improvements Energy and Cost Major cost savings Intra-site benchmarking of KPIs, comparing similar assets like blast furnaces, sinter plants Capabilities to manage off-gas Identification of process irregularities and equipment performance issues Additional cost savings Automated metering processes Simpler internal energy cost administration Easier sustainability reporting
- 19. Reference Case China Large scale vertically integrated mill 13+ mtpa Numerous long and flat products Major production equipment 8 Coke Batteries, 7 Sinter Machines 6 Rotary Kilns, Shaft & Rotary Hearth Furnaces 9 Blast Furnaces, 9 Basic Oxygen Converters 16 Casters, Rolling and Processing Lines
- 20. EMIS Investment Drivers Competitive cost pressure Visibility and decision making capability Energy and carbon data, energy costs Disparate sets of data Energy operation Planning of consumption and generation Optimize use, procurement and sale Benchmarks, continuous improvement strategy Reporting mandate, compliance
- 21. EMIS Scope Equipment Metallurgical equipment, mill power plant 25 different energy channels 100+ major energy equipments Top Gas Recovery Turbines (TRT), Cogeneration Gas distribution systems Water booster stations, water wells, Steam and gas boilers, etc.
- 22. EMIS Scope Main features Online and near real-time functions Energy consumption by channel Online Energy Balance Sustainability KPIs Alert system Analytical functions Energy usage and cost analysis by product, channel and process, crew performance Trending analysis (actual, historical)
- 23. EMIS Scope Main features Forecasting and planning functions Energy forecast and load balance for gas Multi-energy balance Short and long-term forecast Reporting functions Online, customizable dashboards Periodic and triggered reports Centralized and redundant data storage
- 24. Conclusion Energy related industry challenges are likely to stay Manufacturers must establish a holistic approach Energy Management Information Systems (EMIS) play a key role in strategy and continuous improvement process EMIS solutions provide Real-time visibility of energy and cost Planning and purchasing support Sustainability KPIs to facilitate decision making Confirmed savings and acceptable ROI period
- 25. Klaus Lachmann Steel Solutions Director Schneider Electric Thank You Phone: +49 (0) 2102 / 404 ext. 9368 Mobile: +49 (0) 172 / 211 94 87 Email: [email protected]
Editor's Notes
- #5: As a result, Governments all over the globe have introduced regulatory compliance programs requiring industrial companies to reduce both energy consumption and harmful emissions year over year. Many of these targets are continuous reduction targets, meaning that each year large industrials are required to reduce by 5 percentyear over year.China has formally announced its target for the reduction of greenhouse gas emissions. The country says that by 2020, it will reduce carbon dioxide emissions by 40 percentto 45 percentcompared to the level in 2005. The government also pledged a 30 percent reduction in water consumption per unit of industrial value-added output by 2015.India has proposed a 25 percent emission reduction target for 2030 using their Perform and Trade Scheme.