VMAP analytics

Energy-saving furnace control enhances sustainability and quality in the steel industry

In industries that produce steel and other metal products, achieving optimal heating and quality control is crucial for ensuring efficient production. The Furnace Optimisation Control System (FOCS), co-developed by VMAP analytics project partners Prevas and Swerim together with Swedish industry organisations, offers advanced features such as precise temperature calculations, zone temperature control, and intelligent pacing control. About 90% of all steel produced in Scandinavia is heated in furnaces controlled by FOCS and the implementation on an existing furnace can typically lead to 5-10 % energy savings. However, even with such capabilities, challenges like skid marks (insufficiently heated spots) on reheated slabs in walking beam furnaces persist, causing quality issues during subsequent hot rolling processing.

The 'Furnace use case' developed by Prevas and Swerim in the ITEA project VMAP analytics addressed the skid mark problem by developing a new numerical simulation tool as a new feature in FOCS. The new FOCS solution is a specialised 3D model to handle skid marks during slab heating. This model works online with the factory machine, accurately calculating temperature differences and quickly quantifying the skid mark effects. Subsequently, FOCS can account for the defects and adjust the furnace to avoid making skid marks.

Avoiding skid marks during the energy intense furnace heating helps a lot of people. It means the metal coming out of the furnace is better quality and there's less waste. Factories save energy because they don't have to redo things, it also means better investment of reduced emissions. Additionally, the use of a digital twin allows FOCS, and the furnace to continuously optimise its performance, helping the steel industry becoming more robust and environmentally friendly.

More information:
https://itea4.org/project/vmap-analytics.html