Centralized Energy Management System Transformed a Steel Manufacturer

Introduction

The principal steel output of the global steel industry is substantial, with an anticipated volume of 1.85 billion tons in 2023. India significantly contributes to this overall output. Nevertheless, a significant obstacle impedes the production of steel: inefficiency. In contrast to more sophisticated steel manufacturing processes, the existing methods employed in India exhibit energy losses that may escalate to 30%. The aforementioned inefficiency results in a tripartite set of disadvantages: increased expenses for production, an expanded ecological impact, and overlooked prospects for sustainable expansion within the steel industry.

The current case study examines the execution of a centralized energy management system that was developed with the steel industry in mind. By utilizing a data-driven approach, we shall be able to optimize energy consumption, reduce expenses, and advance environmental responsibility while analysing the current challenges confronted by steel manufacturers.

Challenge

Difficulties arose for our client, a prominent steel manufacturer in India, in effectively overseeing and controlling energy usage across numerous systems. Compressed air, electricity, water, steam, and propane were all components of these systems. The primary obstacles originated from:

• Poor Integration: Data was gathered autonomously from various systems, resulting in the formation of information silos. This bounded comprehension regarding the interrelation of energy consumption throughout operations.
• Lack of real-time analysis constitutes: Not in real-time, but on a periodic basis, data was analysed. As a result, the detection of inefficiencies and possible opportunities for enhancement was postponed.
• Rigid Visibility: Acquiring an all-encompassing understanding of energy consumption throughout the facility proved to be arduous in the absence of a centralized system. This impeded the ability to identify trends, establish baselines, and monitor progress towards energy-saving objectives.
• Manual Processes: It is probable that data analysis was conducted using rudimentary instruments such as spreadsheets, which resulted in the occurrence of errors and inefficiencies. This hindered the capacity to identify the underlying causes of high energy consumption and conduct complex analyses.

Because of these elements, a centralized energy management system was required to optimize processes, decrease expenditures, and promote environmental friendliness.

Solution?

In response to these obstacles, we have put forth a digital transformation strategy grounded in the tenets of Industry 4.0. This resolution comprised:

• Data Acquisition: In order to facilitate the transmission of data from a variety of systems, including electricity, water, steam, propane, and compressed air, establish communication with the management PLC.
• Hardware Installation: The process of installing hardware components, such as data acquisition devices and sensors, facilitates uninterrupted communication between the centralized server and the PLC.
• Data Transfer: KepServer implementation to facilitate the transmission of data from the PLC to the centralized server in a dependable and efficient manner.
• Industrial IoT Platform: Implementation of an Industrial IoT Platform for accumulating, storing, and analyzing incoming data from the PLC on the centralized server. This platform offers insights into the energy consumption and performance of the system in real time.
• Tailored Analytics: Application of individualized analytical algorithms to scrutinize gathered data and produce practical insights. The insights encompassed the recognition of potential avenues for conserving energy, the enhancement of resource allocation, and the implementation of operational efficiencies.
• Data Visualization: Constructing individualized dashboards on the analytical platform for the purpose of illustrating anomalies, trends, and critical performance indicators. The dashboards furnish stakeholders with user-friendly instruments to oversee energy usage and arrive at well-informed judgments.
• Ongoing Support: delivering maintenance and support services in a continuous manner to guarantee the efficient functioning of the Centralized Energy Management System and promptly resolve any encountered problems.
• Performance Evaluations: Implementing routine performance evaluations and optimization sessions to consistently enhance the system's efficacy and efficiency, in accordance with changing requirements and goals.
• Team Collaboration: Maximizing the system's impact and value proposition through collaboration with the client's internal teams to ensure the Centralized Energy Management System's seamless integration with existing processes and protocols.

Results

Considerable advantages were derived by the client from the implemented solution:

• Scalability: As the organization expands, the solution facilitates smooth expansion and adjustment to accommodate forthcoming demands.
• Ease of Management: The ability to perform system maintenance and add new devices without requiring external assistance was acquired by management, ensuring flexibility and independence.
• A one-time cost was associated with the comprehensive bundle, which effectively eliminated recurring expenses and ensured sustained cost-effectiveness.
• The utilization of customizable interfaces provided stakeholders with practical insights that facilitated the process of making well-informed decisions.
• The provision of dedicated support facilitated a seamless implementation process, continuous maintenance efforts, and timely resolution of issues.
• Concentrate on Optimization: By shifting its attention from data administration duties to energy optimization initiatives, the organization was able to maximize operational efficiency and productivity.
• On-Premises Security: By deploying the system on-premises, the architecture mitigated the risks associated with external data storage and ensured adherence to industry regulations, thereby safeguarding the data.

The implementation of the Centralized Energy Management System facilitated the acquisition of vital energy data, thereby enhancing the ability to make well-informed decisions and implement proactive energy management strategies.?

Conclusion?

The case study illustrates how an energy management strategy informed by data can bring about significant changes in the steel sector. Through the adoption of a centralized system that incorporated real-time data collection and analysis, our client, a prominent steel manufacturer in India, successfully defeated substantial obstacles that were inherent in centralized data, manual procedures, and restricted visibility.

This accomplished implementation functions as a template for other steel manufacturers aiming to enhance energy efficiency, minimize expenses, and advocate for ecological accountability. The steel sector can make substantial strides towards a more sustainable and efficient future through the adoption of digital transformation and the application of data analytics.