Severstal CherMK Improves Production Using Digital Technologies
Russian steel mill Severstal is introducing in-house digital tools in the steelmaking division of the Cherepovets Iron and Steel Works. Severstal
Russian steel mill Severstal is introducing in-house digital tools in the steelmaking division of the Cherepovets Iron and Steel Works. Severstal Russian Steel General Director Mr Evgeny Vinogradov said “In the steelmaking industry, a large system of tools has been created that allow tracking the development of the situation and conducting production processes with minimal human involvement. In recent years, we have made significant progress in the development of digital tools. We introduce digital models, machine vision, calculators. We can analyse a large amount of data, make decisions, excluding the human factor. Digital assistants work to reduce costs and improve product quality. Already now we see a tangible economic effect from their use.”
One of the most effective tools is the automatic release of the heat. A special program analyses the state of the working lining and metal parameters, and then generates a unique converter tilt schedule for each melt, which must be followed during tapping. This avoids slag getting into the steel ladle. The automatic melt drain system tilts the converter at the required angle and in strict accordance with the rotation schedule, which allows for a more complete discharge of metal into the ladle. The operator monitors the operation of the system on the monitor on the control panel. The digital assistant helps to increase the yield of suitable liquid steel, thus reducing its cost. In 2020, the instrument brought in over 100 million rubles.
At each stage of the steelmaking process, calculators have been introduced - a kind of moderators of the technological process. For example, calculators for the supply of ferroalloys, temperature, charge. This makes it possible to reduce production costs and obtain the required chemical composition of steel with maximum accuracy. Thus, the alloy scrap calculator allows you to calculate the optimal amount of alloying materials that must be added to the melt for the production of a particular steel grade. This calculator was improved in 2020, which additionally brought the company about 70 million rubles.
Machine vision is widely used at the steelmaking site. Most often this tool is used to ensure safety, but in 2020 the machine vision model was introduced to improve the efficiency of steelmaking. A model for controlling the height of cast iron was developed. In case of fixing the fill from a great height, the system automatically informs the responsible employee about it. Steelmakers can also monitor the current height online, and, if necessary, correct the actions of the crane driver. The degree of influence of steel on the converter lining depends on the height and inclination of the cast iron ladle. The economic effect of the project over the past year is nine million rubles.
The end-to-end system of dashboards is successfully functioning in the steelmaking industry. These are dashboards that collect data from different sources, transform it, and then visualize key metrics in the form of tables, graphs and charts. The tool allows you to monitor production progress, results and possible deviations in real time.