ArcelorMittal, the world's leading steel and mining company, was looking at optimizing the energy management of an Industeel factory in France.
Some good practices were already in place, mostly doing manual analysis with Microsoft Excel to model energy baselines. However, corrective actions were time-consuming and were usually postponed until the end of the month - issues remained unsolved all along this ongoing period. Moreover, only two influential factors were considered by linear regressions (tonnage and setpoint temperature), whereas a lot more can impact energy consumption on site.
Digitalization for Augmented Energy Manager
With these challenges in mind, ArcelorMittal selected METRON’s solution, METRON-Factory®, to benefit from a continuous, real-time monitoring and automated reporting of energy consumptions and flows.
The first step was data collection. Over 3,000 data points per second were aggregated by data collectors, then stored into the METRON platform. These data came from 7 OPC servers and other sources of data – internal and external - such as temperature, steam flow rates, etc.
Thanks to this flexible architecture and the use of data science algorithms, all influential factors from the furnace were considered: tonnage, setpoint temperature, type of heat treatment, product dimensions, heating time, regulation mode, etc.
Baseline models for real-time detections
Before METRON it took up to 5-man days to perform an analysis for a given scope, ArcelorMittal can now leverage the computing power of the platform to control energy flows in real-time and for a much broader scope.
METRON’s strength relies on the expertise of its data science engineers, who calculate baselines (reference models used to compare actual and theoretical consumptions) with extreme precision. Thanks to these baselines, factory operators receive real-time alerts for any drift in energy consumption, resulting in real-time corrective actions.
Regarding ArcelorMittal, Industeel’s operators detected consumption drift on a reheating furnace and, while checking it, immediately noticed that a piece of metal had damaged the doors. Without this real-time detection, the excessive consumption would have persisted until the next report and the equipment would have been even more damaged. Another example is the detection of wrong operating procedures, that allowed the client to refine some processes and perfect the operators’ training.
The path towards a more resilient industry
The deployment of the energy intelligence platform and the collaboration between METRON’s energy experts and ArcelorMittal’s operational teams helped the factory to save time and reduce its energy budget for equal consumption, resulting in savings of €340K within 12 months.
The client implemented an in-depth energy management strategy: not only by creating numerous dashboards with customized indicators for each operator to achieve good global results, but also by supporting the development of an energy performance culture within the factory, which will have a major impact in the long term.
This energy management phase is the first step of our project. We are now working more specifically on the optimization of specific perimeters’ energy consumptions in order to build up a more resilient industry.