Metals

Case Studies

1) Forging pne at Thyssen Krupp Gerlach (pdf)

Steel bodies & billets Weights up to 320 kg Sizes between 800 and 1500 mm

2) Aluminum Company of Malaysia Reaps Productivity Gains of 15% (pdf)

The control system driving the Motor-Generator (M-G) set on the foil separator was installed in 1967 and used an archaic analog system. Since this system could only provide imprecise, low resolution control, ALCOM experienced fluctuating product quality and a high percentage of waste. In addition, the legacy system was difficult to troubleshoot and maintain. Parts were obsolete and becoming scarce. Unscheduled downtime — resulting in lost productivity — was a constant challenge.

3) Liuzhou Iron and Steel Company (pdf)

An important requirement of the retrofit was the integration of the new variable frequency inverter technology with the legacy equipment. This included the existing primary motor for the main draft fan—a 6kV 2,000 kW synchronous motor, over ten years old—and a standby synchronous motor. As each of these motors had a different excitation voltage and current, the solution had to be adjustable in order to accommodate either motor for synchronous excitation.

4) Indian Aluminum (pdf)

In 1999, INDAL decided it was time to completely modernize the controls of two mills at Taloja to become more competitive on both the domestic and export market and realize their vision of becoming an industry leader. The management felt that the mill electrics had become obsolete and did not deliver the desired results. The lack of automated controls resulted in high downtime, inconsistent product quality, fluctuation of operating cost, customer dissatisfaction, and loss in market share.

5) Tata Iron and Steel Company (pdf)

TISCO required a solution that consistently produces high-quality steel, while increasing productivity by improving shop logistics. To improve steel quality, TISCO needed to control temperature and composition, including higher Ferro and carbon content. TISCO also sought to reduce global tap temperature to decrease steel conversion costs and extend refractory life. It also wanted to reduce plant energy costs, stoppages, product waste, and reprocessing. To minimize downtime, the solution had to be delivered according to a strict project schedule.

6) Panzhihua Steel Company (pdf)

The Chinese steel market is extremely competitive. Panzhihua Steel Company faces stiff competition from more than 20 major Chinese iron and steel manufacturers. The company is critically aware that its competitive edge depends on vigilant monitoring, controlling and minimization of its production costs.

7) PT Alumindo Light Metal Industry (pdf)

PT Alumindo's primary market is domestic, but about 30% of its finished products are exported. Demand for refillable containers, food wrappers, cigarette package foil liners and other aluminum products is on the rise in Southeast Asia. As a result, PT Alumindo runs 24 hour production. With increasing demand for PT Alumindo's product, the company ran its five cold mills at or near capacity. To help meet this demand, the company decided to purchase an additional mill—the challenge was to increase output as cost-effectively as possible.

8) Iscor Limited (pdf)

The 30-year-old starting equipment in the hardening and quenching plate treatment plant at the Vanderbijlpark Steel facility had safety issues and offered no protection for the pumps and only basic protection to the motors. Starting direct online (DOL), using an air circuit breaker as a starter, resulted in an uncontrolled starting sequence and very high mechanical wear on the air circuit breaker. This dated technology carried high safety risks with several flash-over occurrences inside the air circuit breaker and bus bar chamber.

9) China Steel Corporation (pdf)

CSC steel mill was first commissioned in 1976 and, despite its relatively young age, the company has embarked on a program of upgrading all equipment older than 15 years. In the late 1990s, theageing equipment in line number 115 presented an opportunity to upgrade the drives and control system and, in the process, rectify any problems. There were two main deficiencies with the tension levelling line. The first was that the recoiling section had insufficient line speed and tension due to meet the current production demand. This limited the gauge of strip that could be produced as well as the amount of steel that the line could process in a given time.

10) Anshan Iron and Steel Company (pdf)

Anshan Iron and Steel Co. required an automation control solution for the continuous casters that would achieve the required levels of production flexibility, improve product quality and reduce production costs.

11) Charging Crane Upgrade at POSCO Kwangyang Steel Works (pdf)

As the majority of POSCO's cranes are in excess of 12 years old, the availability of spare electrical components had become a major problem. In addition, POSCO's maintenance team struggled with poor crane documentation and operational information. Electrical failure at charging crane No.1, caused by vibration and the harsh environment of the mill house, motivated POSCO to embark on a complete refurbishment of the crane's electrical systems. As the charging crane has a daily material throughput valued at US$4 million, ensuring a minimal shutdown period was essential.


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