Sand For Concrete From Steel Mills Induction Furnace Waste ...
INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace...
Transcript of INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace...
![Page 1: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/1.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com
INTERNET OF THINGS IN STEEL MANUFACTURING
Computer Applications Technology Committee Meeting,
9th Oct 2014Presented by HCL Technologies
![Page 2: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/2.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com2
Agenda
Definition1
Significance of IoT2
Making a Steel Plant Smart 3
Modeling – How IoT can help 4
Big Data Analytics – How IoT can help 5
Cloud & SaaS6
IoT & MES7
IoT Framework 8
Challenges in Implementing IoT9
![Page 3: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/3.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com3
Definition
IoT is enabler for digitizing Manufacturing to be highly efficient and productive. It includes
Using intelligent devices, equipment to produce assets;
a cloud-based infrastructure for data processing
“big data” storage capable of addressing a complex value chain;
a combination of descriptive, predictive and prescriptive analytics and software to support asset and system optimization;
Timelines
![Page 4: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/4.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com4
Significance of IoT
Smart
Manufacturing is
the targeted
“‘New Normal”
US’s SMLC &
Germany’s
Industry 4.0
Every Major
Vendor offers
Remote
monitoring
services
Automation to
substitute ageing
skilled work force
![Page 5: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/5.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com5
Making a Steel Plant Smart
Each Machine is like an Individual
Implement Condition monitoring/Predictive Analytics
Example – System & Causes of Hydraulic system
in Hot Rolling Plant
The process automation data is not enough for diagnosing
such complex machinery as a plate rolling mill.
![Page 6: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/6.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com6
Making a Steel Plant Smart
Interoperability among systems & equipment
![Page 7: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/7.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com7
Making a Steel Plant Smart
Plant Operations Management from Mobile Devices
Accessories on mobile phones – Intelligent Data acquisition devices
Mobile Workflow Management
In near Future –Google Glass
![Page 8: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/8.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com8
Making a Steel Plant Smart
Overall, the Ability to log all activities in a plant –either by humans or machines for analysis
Interoperability – Control System, Mobile Devices
Ease of Remote Management
Wireless
RFID
Track & Trace logistics solutions
![Page 9: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/9.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com9
Modeling – How IoT helps
Many models used in Steel Operations - e.g.
Sinter plant - Ore bed distribution in Sinter Plant
Blast Furnace – Burden Distribution Model
Basic Oxygen Furnace – Steel Bath &
Slag models
Models
provide accurate predictive
information leading to energy savings
IoT Engines
Packages for Genetic Algorithm
Abundant past data for model creation
R can be used for Modeling-solving differential equations – deSolve, ReacTran
CARET package in R –ideal for modeling
Fitment of existing models becomes very easy.
![Page 10: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/10.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com10
Big Data Analytics – How IoT helps
Dynamic Rescheduling using IoT
Hot Charging
MES do not have vision of upstream units
![Page 11: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/11.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com11
Big Data Analytics – How IoT helps
Pattern Recognition
Constant Risk monitoring based on past data
Video Analytics on Cloud
Thermal Imaging of refectories,
High-speed video captures roughing mill operation for analysis
Complex Event Processing (CEP)
Data Stream Analysis – e.g. Alert when sinter size exceed 5% deviation in 10
minute timeframe
Microsoft StreamInsight,
SQLStream –open source
![Page 12: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/12.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com12
Cloud & SaaS
Performance and Availability Guaranteed
Unlimited, almost inexpensive data storage
Multi Tenanted Architecture
Pay only for what is used
Subscription Model – Gold, Silver, Bronze
Services offered
Analytics as a Service
Storage as a Service
Applications as a Service
![Page 13: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/13.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com13
Cloud & SaaS
Name Services
Microsoft Azure Machine
Learning
Based on Azure platform, MS offers standard R and their research
division developed Algorithms
Yottamine Analyticsprovides machine learning (SVM) based predictive models in the cloud.
Pricing is based on usage.
Zementis, Incoffers predictive models as a fully hosted service through Amazon
Elastic Compute Cloud (EC2).
Sight Machine merges machine vision and big data to control quality.
Ayasdiprovides a mathematical framework for analysis of complex, multi-
variate datasets
SkyTree Successfully deployed algorithms for preventive Maintenance
Select List of Providers of Machine Learning as Service
![Page 14: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/14.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com14
ML Studio in MS Azure
![Page 15: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/15.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com15
IoT & MES
MES is specific to 1 plant, IoT is plant wide
Power of IoT is on the Cloud,
Analysis Services, Pay as you Use
Periodic Application change
Remote Monitoring of equipment
Large Historian Data Analysis
![Page 16: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/16.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com16
IoT Framework
![Page 17: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/17.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com17
Challenges in IoT Deployment
Cyber security
Can affect any equipment
Apprehensions of Cloud Security
Making old equipment smart
Reliable Internet connection
scalability, security, availability and inexpensive
Changing Managers/Operation Mindset
Training
See Tangible Benefits
![Page 18: INTERNET OF THINGS IN STEEL MANUFACTURING Furnace –Burden Distribution Model Basic Oxygen Furnace –Steel Bath & Slag models Models provide accurate predictive](https://reader034.fdocuments.in/reader034/viewer/2022051600/5aa9c7717f8b9a81188d335e/html5/thumbnails/18.jpg)
Copyright © 2014 HCL Technologies Limited | www.hcltech.com
Q&A