Do more with digital in Metals

Do more with digital in Metals

Like reducing your metals production’s carbon footprint by increasing your digital one.

Doing more with digital in the metals industry means harnessing the full potential of data to unlock new possibilities for growth and efficiency. It means forecasting and optimizing your power demand and emissions. Increasing your overall efficiency by tracking and planning your material movement. Improving end-product quality with advanced process control. If you want to keep your operations as strong as the products you produce, let ABB show you how to do more with digital.


 What’s on your mind: Challenges


 What's on ours: Doing more with digital

Environmental/Economic Impact:
Growing pressure from CO2 regulations impacts the manufacturer's cost structure

ABB digital solutions can optimize energy networks in steel plants (forecast and optimize power demand, fuel gases, etc., in an integrated steel facility.) and monitor thermodynamic and electrical efficiency to identify issues that increase energy consumption.

With 60% of integrated steel plant power being consumed by EAFs (electric arc furnaces), forecasting and optimizing the load is important.

Productivity:
Increasing pressure to improve productivity with cost optimization ($/ton)

ABB can close the whole loop: sense data, analyze it and realize the insights into benefits by writing back to OT systems. Our solutions apply to the entire steel production value chain – automating order entry, validation, order tracking and ensuring order meets quality standards. Optimization of overall plant performance enhances production quality and asset lifecycle

Aging Workforce:
Especially impactful in EU regions

ABB's connected workforce, asset performance and other digital solutions enable workforce efficiency, decrease operator loads and support a healthier work environment .

 

Digital value pillars and proof points

Sustainability

Pillar: Sustainability

Product: ABB Ability™ Energy Management System
Promise: Quick payback of initial system
Proof: Module 1, 2 and 3: Energy Optimization – Real-time monitoring and reporting; energy balance management; energy forecasting; energy cost optimization based on generation, consumption and market; 
Asset performance

Pillar: Asset Performance

Product: ABB Asset Performance Management
Promise: 500K€ Savings in maintenance costs per year
Proof: Cold Rolling Mill, Europe – Increased line availability by 5% with condition-based asset health monitoring and predictive maintenance approach. ABB Ability™ Asset Vista installed at CELSA Barcelona.
Process performance

Pillar: Process Performance

Product: ABB Ability™ Expert Optimizer
Promise: 15% reduction in the standard deviation
Proof: Pelletizing Plant, India - Optimizing the pellet plant dryer and indurating machine burners
Connected workforce

Pillar: Connected Workforce

Product: Visual Remote Support
Promise: 100% successful FAT without travel costs
Proof: Steel Rolling Mill, Spain – Used AR with audio, video, document-sharing, live annotations for an upgrade
Cyber security

Pillar: Cyber Security

Product: ABB Ability™ Protect
Promise: Centralized security management
Proof: Steel Mill, Middle East  – To mitigate risks and efficiently manage the security posture

See how we’re doing more with digital

Case studies

ABB completes melt shop digitalization project with India’s leading steel company, boosting productivity and profitability
ABB empowers US steel manufacturer towards net-zero with ABB Ability™ Energy Management System
ABB’s asset management solution for metals set to boost efficiency and productivity at CELSA Barcelona
ABB Ability™ Advanced Process Control for metals
View all case studies

Expert insights

Practical ways to apply data analytics and AI for energy management and emission control in the steel industry
Writing the future of AI to drive digitalisation in the metals industry
4 ways metals manufacturers can advance towards energy transition
Click here to explore more about Digital in Metals
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