Klaus Lachmann
Steel Solutions Director
Schneider Electric
Optimized Energy Management and
Planning Tools for the Iron and...
Index
The Energy Dilemma
Energy Management Information System
Reference Case
Conclusion
Q & A
The Energy Dilemma
vs
Energy Demand
By 2050
Electricity by 2030
CO2 emissions to
avoid dramatic climate
changes by 2050
Th...
Regulations and Standards are Everywhere
Energy
Management
Program
Iron & Steel Industries are Under Pressure
2nd largest energy consuming industrial sector
 Cos...
Energy
Management
Information
System
Comprehensive Energy Management
Program
Strategy: Holistic strategy and action plans...
Common issues
Insufficient contextual data on individual assets
 Spreadsheet culture with disparate data
 Manual data c...
Energy Management Information
System (EMIS)
Relevant information to key individuals
and departments
Enables energy perfo...
EMIS functional requirements
A closer look (1/2)
Near Real-time Operation
Monitor consumption and any affecting factors
...
EMIS functional requirements
A closer look (2/2)
Enable
Forecasting and planning based on production
parameters
Cost al...
Sustainability KPIs
Tailored for User Groups
Scalable and near real-time information
Plant operators and plant superviso...
EMIS architecture
Simplified
Enterprise HMI:
data display,
analysis,
reports
Enterprise data management:
Enterprise data a...
EMIS architecture
Software and modules
Realtime Monitoring System
Realtime
Monitor
Remote
Operate
Trend
Events &
Logs
Fail...
Energy Analytics
Energy Data
Software
Analytics
Multiple sources
- types
- formats
- protocols
Compliance reporting
Energy...
Information Tools
Visualization
Dashboards (samples)
Role-based capability to:
- monitor and improve operations
- analyze ...
Information Tools
Visualization and Reporting
Dashboards (samples) Reports
(samples)
Role-based capability to monitor, ana...
Efficiency Improvements
Energy and Cost
Major cost savings
Intra-site benchmarking of KPIs, comparing similar
assets lik...
Results
Worldsteel presentation,
published November 2012
Reference Case
China
Large scale vertically integrated mill
13+ mtpa
Numerous long and flat products
Major production ...
EMIS Investment Drivers
Competitive cost pressure
Visibility and decision making capability
Energy and carbon data, ene...
EMIS Scope
Equipment
Metallurgical equipment, mill power plant
25 different energy channels
100+ major energy equipment...
EMIS Scope
Main features
Online and near real-time functions
Energy consumption by channel
Online Energy Balance
Susta...
EMIS Scope
Main features
Forecasting and planning functions
Energy forecast and load
balance for gas
Multi-energy balan...
Conclusion
 Energy related industry challenges are likely to stay
 Manufacturers must establish a holistic approach
 En...
Klaus Lachmann
Steel Solutions Director
Schneider Electric
Thank You
Phone: +49 (0) 2102 / 404 ext. 9368
Mobile: +49 (0) 1...
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Optimized Energy Management and Planning Tools for the Iron and Steel Industry

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Copyright AIST Reprinted with Permission. Presented at the 2013 Iron and Steel Technology Conference and Exposition (AISTech 2013). According to EDF (environmental defense fund) the energy cost for the U.S. iron and steel industry reached U$ 6.8B / year (2008). The industry has improved its energy efficiency significantly over the last decade, however, there are more energy savings opportunities to be explored.

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  • 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.
  • Optimized Energy Management and Planning Tools for the Iron and Steel Industry

    1. 1. Klaus Lachmann Steel Solutions Director Schneider Electric Optimized Energy Management and Planning Tools for the Iron and Steel Industry
    2. 2. Index The Energy Dilemma Energy Management Information System Reference Case Conclusion Q & A
    3. 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. 4. Regulations and Standards are Everywhere
    5. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 15. Information Tools Visualization Dashboards (samples) Role-based capability to: - monitor and improve operations - analyze and drill to detail according to individual needs.
    16. 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. 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
    18. 18. Results Worldsteel presentation, published November 2012
    19. 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. 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. 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. 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. 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. 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. 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: klaus.lachmann@schneider-electric.com

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