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Isabella Mazza (Ergolines - IT)

I4MS 2015: Enhancing digital transformation in manufacturing SMEs
I4MS 2015 will explore the progress achieved by the I4MS initiative and the impact participation has had on SMEs.

To date I4MS has achieved over 80% industrial participation. An initial participation of 80 SMEs has now grown to 150 as momentum continues to build. Success is also evident with SME participation in projects leading to the adaption of new technologies and approaches. I4MS phase two will take this success further through additional projects supported by a budget of approximately EUR 35 Mn.

At I4MS 2015 participating SMEs will present their experiences, results achieved and impact made. They will explain how they have benefited and what the adaption of innovative ICT has meant for their business. European support does not just exist at EU level.

Action at regional level supported through programmes such as Smart Specialisation present the good opportunity to reach out to and involve the diverse landscape of European SMEs. At I4MS 2015 participants will be introduced to a new activity designed for such outreach – digital innovation competence centres – and an outlook towards the next stage of I4MS.

I4MS is a EUR 77 Mn initiative of the 'Factories of the Future' partnership designed to support the adaption of innovative ICT by SMEs. Through seven integrated projects in four key areas, I4MS brings manufacturing SMEs directly into research and innovation projects, introducing them to innovative technologies and supporting the adoption of such technologies.

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Isabella Mazza (Ergolines - IT)

  1. 1. Enhancing Digital Transformation in Manufacturing SMEs 22nd of May Brussels 2015 1
  2. 2. Fortissimo Experiment 402 Isabella Mazza Ergolines Lab s.r.l. Cloud-based simulation of continuous casting 2
  3. 3. INDEX 1. WHAT WE ACHIEVED 2. HOW WE DID IT 3. HOW I4MS HELPED 4. HOW WE WILL TAKE IT FORWARD 3
  4. 4. ERGOLINES PRESENTATION I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 4 Ergolines is based in Trieste, Italy Technologies for Steel Continuous Casting: • ELECTROMAGNETIC STIRRERS • SENSORS • INSTRUMENTATION 44 Countries
  5. 5. WHAT WE ACHIEVED 1. THE CHALLENGE I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 5 INDUSTRIAL PROBLEM: SLAG TRANSFER  LOWERS STEEL QUALITY  BREAKOUT AFFECTS:  SAFETY  PRODUCTIVITY Continous Casting LADLE TUNDISH CASTING STRAND
  6. 6. WHAT WE ACHIEVED 1. THE CHALLENGE I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 6 INDUSTRIAL PROBLEM: SLAG TRANSFER  LOWERS STEEL QUALITY  BREAKOUT AFFECTS:  SAFETY  PRODUCTIVITY Continous Casting OUR SOLUTION: DESIGN OF SLAG DETECTION SYSTEM LADLE TUNDISH CASTING STRAND
  7. 7. WHAT WE ACHIEVED 2. WHY HPC? I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 7 SLAG TRANSFERSTEEL POURING INTERRUPTED BEFORE COMPLETE EMPTYING STEEL WASTED = 1 TON/LADLE COSTLY REMELTING NEEDED DEMAND FOR SLAG DETECTION SYSTEM NEW BUSINESS OPPORTUNITY
  8. 8. WHAT WE ACHIEVED 2. WHY HPC? I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 8 SLAG TRANSFERSTEEL POURING INTERRUPTED BEFORE COMPLETE EMPTYING STEEL WASTED = 1 TON/LADLE COSTLY REMELTING NEEDED EXTREME CONDITIONS LIQUID STEEL @ 1500 °C FIELD EXPERIMENTS NOT FEASIBLE DESIGN REQUIRES CFD SIMULATIONS HUGE COMPUTATIONAL LOAD HPC DEMAND FOR SLAG DETECTION SYSTEM NEW BUSINESS OPPORTUNITY
  9. 9. WHAT WE ACHIEVED 3. FORTISSIMO EXPERIMENT 402: “CLOUD-BASED SIMULATION OF CONTINUOUS CASTING” I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 9 • End User  Ergolines Lab s.r.l. (Italy) • HPC Resource  Arctur d.o.o. (Slovenia) • Objective  Exploit HPC to solve an industrial challenge : Prevent slag transfer • Activities  HPC based CFD simulation of slag transfer  Experimental model validation
  10. 10. HOW WE DID IT 4. Rationale I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 10 • Objectives • Correlate vibrational signal with fluid dynamics • Numerical Model • Emptying mechanisms • Experiments • Single Phase Model (STEEL only) • Double Phase Model (SLAG + STEEL) • Performance Criterion • Experimental validation of numerical models  Vortex  Drain Sink  Dedicated Laboratory System
  11. 11. 6. Software used & Simulations I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 11 HOW WE DID IT • Simulation time = 322 s = 5 minutes • Computation time = 183.5 days = more than 6 months Successful experimental validationSoftware: OpenFOAM 2.2.0
  12. 12. HOW I4MS HELPED 11. I4MS-enabled Achievements I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 12 • to achieve accurate results  Transient simulations  very fine geometrical discretization  small time steps ELEVATE COMPUTAIONAL TIME: 6 months to simulate 5 minutes • High quality results: successful experimental validation MODEL RELIABILITY • Complex phenomena, huge computational load CRUCIAL ROLE OF CLOUD HPC
  13. 13. 13. Economic Impact I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 13 Exploitable output: know-how for new product Slag Detection System Target Market Segments: Steel Continuous Casting Benefits for Ergolines: reduced time-to-market, new business opportunity, internationalization Benefits for End-users = Mini Mills: • Increased Steel Yield: save up to 60% of 1 t wasted steel /ladle= 0.6% of production • +0.6% Increased Productivity: save 6000 tonnes of steel /year/ 1 Mt produced • Reduced Remelting costs: 100 €/t X 6000 t/year = 600.000 €/year saved • Reduced Energy costs of remelting: 500 kWh/t X 6000 t/year = 3 GWh/year saved HOW WE WILL TAKE IT FORWARD High Quality High Velocity
  14. 14. THANK YOU FOR YOUR ATTENTION 14

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I4MS 2015: Enhancing digital transformation in manufacturing SMEs I4MS 2015 will explore the progress achieved by the I4MS initiative and the impact participation has had on SMEs. To date I4MS has achieved over 80% industrial participation. An initial participation of 80 SMEs has now grown to 150 as momentum continues to build. Success is also evident with SME participation in projects leading to the adaption of new technologies and approaches. I4MS phase two will take this success further through additional projects supported by a budget of approximately EUR 35 Mn. At I4MS 2015 participating SMEs will present their experiences, results achieved and impact made. They will explain how they have benefited and what the adaption of innovative ICT has meant for their business. European support does not just exist at EU level. Action at regional level supported through programmes such as Smart Specialisation present the good opportunity to reach out to and involve the diverse landscape of European SMEs. At I4MS 2015 participants will be introduced to a new activity designed for such outreach – digital innovation competence centres – and an outlook towards the next stage of I4MS. I4MS is a EUR 77 Mn initiative of the 'Factories of the Future' partnership designed to support the adaption of innovative ICT by SMEs. Through seven integrated projects in four key areas, I4MS brings manufacturing SMEs directly into research and innovation projects, introducing them to innovative technologies and supporting the adoption of such technologies.

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