In addition, the
ABB Ability™ Energy Management System for industries enabled site-wide optimization of energy consumption and availability for a large European steelmaking site. The solution covered steam yield, by-product gases, energy purchase and production, including site plants and turbines and resulted in 10 percent less flaring of gases, 15 percent improvement in accuracy of electricity purchasing forecasts and an average saving of 15KEUR per month.
By bringing transparency around energy consumption and sustainability performance, both sites were able to deliver on their sustainability commitments and regulatory requirements while maximizing energy cost savings.
The potential benefits of data utilization in steel production are multifaceted. However, no one said that the path to unlocking universal digital transformation would be without its hurdles. Legacy equipment may lack the necessary sensors to collect data for analysis, and integrating these solutions can be time-consuming and the upfront investment costs for sensor networks and digital software can be a barrier for some producers.
The good news is that these challenges are not insurmountable. The cost of implementing AI is steadily decreasing, and the return on investment (ROI) is significant. Steel producers can invest in retrofitting older equipment with sensors, and collaborations between industry experts and digitalization specialists can bridge the knowledge gap. Additionally, companies like ABB are actively developing user-friendly software solutions specifically designed for the steel industry, making adoption easier and more accessible than ever.
Furthermore, the positive impact of AI extends beyond just the technology itself. By embracing AI, steel producers can foster a culture of data-driven decision making, leading to continuous improvement across all aspects of operations.
The marriage of technology and people capabilities can be directly seen with the use of ABB’s data analytics and collaborative technology. Customers of all sizes can gain a competitive advantage by testing in virtual environments or by seeking further domain-specific advice. Often, when
ABB Ability™ Data Analytics Platform for metals is in place, metals producers can learn and conduct simulations based on a range of scenarios, adjusting materials parameters and pushing to limits. It also acts as a plant and enterprise-wide data integration, monitoring, data analytics and optimization platform. Further to this, the
ABB Collaborative Operations Center (COC) for Metals provides round-the-clock service to help predict future failures or potential maintenance issues. The COC team is on hand, with AI tools and big data learnings from real processes at their disposal for customer use.
Looking ahead, the future of the steel industry is undeniably data-driven. As data analysis tools and AI technology continue to evolve, we can expect even more sophisticated solutions to emerge. Imagine self-learning systems that not only optimize processes but also continuously adapt to changing conditions and refine their strategies over time. This level of data-driven intelligence could revolutionize the industry, creating a future where steel production is not just efficient and cost-effective, but also remarkably energy-conscious and environmentally sustainable.
By embracing data and embarking on this digital transformation journey, the steel industry can shed its image as an energy guzzler and a reactive industry. Instead, it can forge a new path, becoming a leader in sustainable manufacturing and a shining example of how data can be harnessed to create a brighter future for generations to come.
ABB is committed to helping the steel industry on this journey by providing cutting-edge AI solutions and collaborating with industry leaders to develop innovative new applications.