Enhancing processes with ironmaking expertise

Ironmaking processes are the largest energy and raw-material consumers within a steel works. They also pose enormous environmental challenges. With the application of individually tailored process models and expert systems, it is possible to dramatically reduce consumption leading to considerable cost savings and emission reductions.

In addition to engineering and technological expertise, Siemens VAI provides a complete range of electrics and automation solutions, from process automation to sophisticated optimization packages and expert systems. Our solutions also include an end-to-end energy supply solution with built-in redundancy to ensure a stable process.

To ensure high-performance plant operation at low costs, the closed-loop optimization system VAiron was developed by the automation division of Siemens VAI in cooperation with the ironmaking division of Voestalpine Stahl. VAiron is based on advanced process models, artificial intelligence, enhanced software applications, graphic user interfaces, and operational know-how. Excellent process performance and significantly lower production costs are the proven results.

SIMETAL Sinter VAiron

Sinter control and optimization system

The SIMETAL Sinter VAiron basis automation system provides a sound foundation for modern sinter plant operation. Anticipatory consideration of the delay times and precise execution of the setpoint ensure smooth production. The optimization system leads to a shift-independent, accurately defined process control. This assures low cost production within a well defined quality range at high productivity levels.

Sinter Solutions

SIMETAL SIMPAX

Quality forecasts during the process for higher quality and lower energy consumption

Providing reliable insight into real-time measurements of process parameters, SIMETAL SIMPAX permits highly accurate prediction of quality parameters of metallization and carbon content during the ongoing process. This allows improved understanding of the ironmaking process and immediate response and adaption in the event of changes, resulting in more consistent quality, lower energy consumption, increased availability, and reduced maintenance costs.

SIMELT SIMPAX

SIMETAL BF VAiron

Blast furnace automation and optimization package

SIMETAL BF VAiron is based on advanced process models, artificial intelligence, operator guidance, a closed-loop expert system, and other advanced software applications. Comprised of modularly structured and expandable process models and expert systems, the process optimization packages can be quickly installed in new or existing ironmaking plants in order to improve the BF operation by reduced fuel consumption and stabilized hot metal quality.

SIMETAL BF VAiron

SIMETAL Coke CPMS

Coking Process Management System

In order to optimize the process control and facilitate the operators’ work, Siemens VAI developed the SIMETAL Coking Process Management System (CPMS) as a state-of-the-art L2 control system for coke ovens. This system is currently in operation at about 20 coke batteries worldwide. Based on real-time measurement information from the process and advanced process model calculations, the system helps the user to heat the battery evenly and operate the coke oven machines (pusher car, charging car, and coke guide car) stably.