When the fist melt shops started to recycle scrap steel in electric furnaces rather than cook up iron ore and coke in giant ovens, the old-line producers were shaken to their very foundations. The coming together of analytics and engines for tracking, scheduling and thermal control is now helping revolutionize the melt shop itself, turning it onto a smart melt shop. Perfect synchronization of all components in the melt shop – a critical cog in the metals process – is a high priority task in digitalization solutions for the metals industry.
Addressing the challenges in optimizing melt shop operations
In my experience, melt shops are the source of a wide variety of challenges, and any digitalization solution for the metals industry should keep the following factors in mind:
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Maximum energy consumption, both thermal and electrical, happens at the melt shop
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The highest safety risk, with presence of gases and molten material, is at the melt shop
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Excellence at the melt shop stage defines end-product quality
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Most importantly, managing movement of equipment including transfer cars and cranes is an incredibly complex task
Through the ABB Ability™ solution design, for instance, digitalization is helping transform operations in the melt shop – ensuring the highest levels of productivity and planning (therefore, rationalized energy consumption), safety and quality.