Specialised Topic: Shaogang - CISDI’s new benchmark for intelligent steel manufacturing
Date:2019/3/14 Source: CISDI
Specialised Topic
Shaogang - CISDI’s new benchmark for
intelligent steel manufacturing
CISDI is
implementing the EPC-based construction for Shaogang’s Intelligent Centre, a
benchmark of China’s steel intelligence levels.
Shaogang upstream-BF integrated intelligent
control platform
Critical
technologies:
- Data centre and
big data platform
- AI-based math
model
- Integrated
intelligent control
- Big data-based
production and dynamic optimisation of operation
- Systematic
optimisation and production consulting
- Remote safety
control
- Machine vision
Results and
returns:
- Reducing the
315 staff at the on-site central control room to 190 for the integrated
intelligent control centre
- Increasing
productivity by around 30 per cent
-
Innovations in organisation, flow and
management creating an annual economic benefit of $2.24 million USD
-
Creating an annual economic benefit of $9.72 million USD from a cost saving of $1.5 USD per tonne of hot metal
Shaogang’s Intelligent Centre was built turn-key by CISDI.
The large-scale
centralised control centre features a number of firsts for the Chinese
metallurgical industry, from trans-procedure, cross-area and long-distance
(over 5km) endless coordination to big data decision-making.
A host of intelligent and big data
technologies have been applied and the centre is seeing unprecedented safety
levels, coordination and high efficiency.
It is able to perform intelligent sensing,
intelligent analysis, prediction and decision-making for plant-wide production
and operations and will be capable of achieving the most advanced steel
manufacturing levels in China.
CISDI’s years of engineering and production
expertise have gone into the project. Along with Shaogang, it amassed the
steelworks’ original internal intelligent manufacturing data and integrated it
into the control and decision-making systems for ironmaking and energy media.
The centre was initiated in last September
and put into full use at the end of December 2018.
The Shaogang
Intelligent Centre
Greater safety for workers - whether on-site
or 5km away
The plant’s
traditional operation room, pulpit and control room are located very close to
the production site, making them high-risk areas.
Workers are
exposed to hazards when detecting and solving problems on-site and need greater
protection from the 3Ds – dirty, difficult and dangerous conditions.
A centralised
centre which could control large-scale production from a distance was required.
Using its 60
years of electric and automation expertise, CISDI created a safe, reliable and
stable operation system which features the four safety technologies – power
supply, control, network and data. Video interlock technology sends alarms
automatically to operators when an abnormality is detected.
Working areas reduced from 50 to 18: a
transformation of management and organisation
A streamlined
and highly-efficient organisational structure has been created for the
management of Shaogang’s production. CISDI’s solution – individual plant
managing multiple working areas – is a systematic design coordinating flows,
organisation, management and technology and integrating posts of working areas
to a matrix-style
management.
The original 42
onsite central control rooms have been eradicated and 50 working areas have
been reduced to 18.
An island
layout at the Shaogang Intelligent Centre enables large-scale and long-distance
centralised control
Big data centre is a Chinese first
Shaogang’s
Intelligent Centre is the Chinese steel industry’s first hyper-converged big
data centre, acquiring 350,000 data zoomed from original mere 10,000 data.
The 350,000
data can support six software applications, 100 intelligent models and
150-sheet automatic reports.
The centre
features a CISDI-developed ironmaking integrated intelligent control platform
for data and results interconnectivity.
It acts as the
steelworks’ brain, functioning as an intelligent monitor and alarm, carrying
out analysis and diagnosis and optimised decision-making.
The
CISDI-developed intelligent energy media system, which integrates closely with
production for simulating gas flows and tracking gas sources, has also been
applied.
CISDI team is now dedicated to enabling energy media’s
intelligent control and developing master-procedure-based energy
supply-consumption prediction model, energy intelligent analysis and
optimisation model.
The ultimate
goal is to realise autonomous balance, check, organisation and optimisation.
The intelligent
energy media system is, in the final analysis, expected to meet the steelworks’
higher and systematic energy
conservation needs.
The
intelligence liberates people from repetitive and laborious activities and the
production and management technology enables them to work more creatively.
The
CISDI-developed integrated intelligent control platform in operation
One central control room means endless
coordination and greater efficiency
Shaogang now
has only one centralised control centre, which incorporates 42 previous central
control rooms.
Endless
coordination is now achievable. The blast furnace-centred ironmaking integrated
coordination and mass coordination between ironmaking and energy media have
been formed. The traditional boundaries that exist in a steelworks’ areas and
procedures have been eliminated. Such coordination makes management and
production more efficient.
The platform
indicating the functioning Shaogang BF-centred ironmaking integrated
coordination
Coordination - the results
i) Coordinated
control is realised between triple-flow-coupled energy and master procedure
(the triple flows are mass, energy flows and logistics).
Ironmaking
production involves around 90 per cent of secondary energy conversion while
consuming around 40%. Data show a high-degree coordination and interaction
between ironmaking production and energy media system.
CISDI’s
energy-master procedure integrated control system intensifies functions by
mass-energy gradation, information fusion and coordinated control. It has
created a new method for steel companies to improve systematic energy
efficiency by fusing energy management and master procedure.
2) Efficiencies
have been enhanced – a 30 per cent increase in the efficiency of ironmaking
personnel, and a 60 per cent increase in control system operational efficiency.
Operators
monitoring the site production screens at the centralised control center
CISDI’s team at
work at Shaogang’s Intelligent Centre
Fact file:
Shaogang is
part of China’s Baowu Group and is located in the Guangdong province. It is
China’s most important shipbuilding plate producer and is a high-tech steel
production enterprise.
Developed over
40 years, the Shaogang plant can produce six million tonnes of steel a year and
is China’s main supplier of plates, wire rods and bars.