Automated Digital Twin System for a Continuous Reheating Furnace
Creating a digital twin to optimize billet heating and manage energy resources
OBJECTIVES
Temperature setting complex
Development of a hardware-software complex for adjusting temperature regimes in the billet heating chambers of a continuous furnace based on data obtained from a specialized analyzer during the full billet heating cycle.
Remote monitoring of mixture composition
Integration of a remote monitoring system for the qualitative and quantitative composition of the gas-air mixture required for furnace operation, based on wireless data transmission. The system allows for a full analysis of heating costs and long-term expenditure planning.
RESULTS
Precision tuning of furnace chambers
Calibration of temperature regimes for all chambers of the continuous furnace was performed. This allowed for the optimization of thermal heating profiles, elimination of overheating and underheating, and established a foundation for subsequent resource savings.
Gas and electricity savings
Through calibration and regime optimization, a 1% reduction in thermal energy consumption and a 30% reduction in electricity costs (for combustion air fans) were achieved. The combined effect provides significant annual savings for the enterprise.
Reduction in rolling defects
Improved temperature control helped reduce scrap-related costs (carbon defects, under-rolling) by 3.5%. This increases the yield of high-quality metal and lowers the production cost of finished goods.
Client
Location
Rolling Shop No. 4
Year
2023
