Copyright AIST Reprinted with Permission. Presented at the 2013 Iron and Steel Technology Conference and Exposition (AISTech 2013). According to EDF (environmental defense fund) the energy cost for the U.S. iron and steel industry reached U$ 6.8B / year (2008). The industry has improved its energy efficiency significantly over the last decade, however, there are more energy savings opportunities to be explored.

1. Klaus Lachmann
Steel Solutions Director
Schneider Electric
Optimized Energy Management and
Planning Tools for the Iron and Steel
Industry

2. Index
The Energy Dilemma
Energy Management Information System
Reference Case
Conclusion
Q & A

3. The Energy Dilemma
vs
Energy Demand
By 2050
Electricity by 2030
CO2 emissions to
avoid dramatic climate
changes by 2050
The Facts The Need
Source: IEA 2007
Source: IPCC 2007, figure (vs. 1990 level)
Power outages
Rising
energy prices
Climate change
Conflicts for
resource access
& control

4. Regulations and Standards are Everywhere

5. Energy
Management
Program
Iron & Steel Industries are Under Pressure
2nd largest energy consuming industrial sector
 Cost of energy versus production costs
Serious GHG footprint
Business and operational challenges
Increasing production, plant availability, flexibility
Reducing energy consumption per ton
Reducing the cost of energy per ton
Taking control of emissions

6. Energy
Management
Information
System
Comprehensive Energy Management
Program
Strategy: Holistic strategy and action plans covering the
complete industrial operation
People: Energy efficiency as company culture,
empowerment
Processes: Plan-Do-Check-Act Cycle, continuous
improvement initiatives, accountability
Information technology: visibility of energy,
ability to compare, analyze and benchmark

7. Common issues
Insufficient contextual data on individual assets
 Spreadsheet culture with disparate data
 Manual data collection into a multiple systems
 Lack of detailed KPIs for achieving sustainability
 Misconception that reducing energy consumption
means reduced production
 Solutions to address WAGES

8. Energy Management Information
System (EMIS)
Relevant information to key individuals
and departments
Enables energy performance and
operation improvement
Detection of energy related opportunities
and anomalies

9. EMIS functional requirements
A closer look (1/2)
Near Real-time Operation
Monitor consumption and any affecting factors
Data aggregation from disparate data sources
Online energy balance
Sustainability KPIs, e.g. kWh/t, GJ/t or m3 water/t
Alerts for sudden changes in use patterns
Analyze
Usage and cost analysis: product, media, process, etc.
Benchmark: periods, target performance, best practices
Optimal energy consumption target

10. EMIS functional requirements
A closer look (2/2)
Enable
Forecasting and planning based on production
parameters
Cost allocation: cost centers, processes and products
Procurement support and utility bill verification
Information
Near real-time reporting through web portals and
customizable dashboards
Periodic / triggered reports: KPIs, energy, emissions,
cost, configurable aggregation
Compliance reporting

11. Sustainability KPIs
Tailored for User Groups
Scalable and near real-time information
Plant operators and plant supervisors
Energy and energy efficiency manager
Top management
Key Performance Indicators (KPIs)
kWh/t, GJ/t, m3 water/t
Emission / t
Energy costs / t
 More...

12. EMIS architecture
Simplified
Enterprise HMI:
data display,
analysis,
reports
Enterprise data management:
Enterprise data aggregation and
KPI calculation
ERP
WAGES
Process automation
Plant data management:
Data aggregation and
KPI calculation
Process data
acquisition
Metering architecture
Rolling Mill
Plant HMI:
Data display,
analysis,
reports
MeltshopCoke plant
Sinter plant
Power Plant
…
Site B
Aggregation from different
plants at company level
for an enterprise-wide
picture of total energy usage,
costs, and performance.
Energy &
Sustainability
KPIs

13. EMIS architecture
Software and modules
Realtime Monitoring System
Realtime
Monitor
Remote
Operate
Trend
Events &
Logs
Failure &
Alarming
Data
Archive
Web
Publish
Tag Mgt.
Graphics
Mgt.
Data Collecting Systems
Electric Metering Production Automation
Workflow Management Modul
Report
SSRS
Historian
Database
Performance Management Modul
Plant
Hierarchy
KPIs Mgt.
Data
Analytics
Calculate
Engine
Knowledge
Mgt.
Data
Interface
Database
mgt.
Report
SSRS
Basic Management
Functions
Flow Mgt. Data Mgt.
Workflow
Engine
Event Mgt.Data
Interface
Energy Management Information Publishing
Optimization Modul
Model
Mgt.
Rules
Base
Para. Mgt. Data
Interface
Advanced
Functions
Online
Optimization
Multi Balance
Waste Material
Functions
Knowledge Management
User Authorization Management Customized User Interfaces
Documents and Resource
Management
Dashboard Graphical Representation
Reports and Dashboard
Presentation
Layer
Application
Layer
Data Layer
Existing
Systems
Report
Designer
Forecast
Models
Balance
ModelsSupport
Layer
Forecast
Equipment
Mode
Plan &
Performance
Operation
Mode
Emergency
Plan
Quality
Management
Operation
Logs
Material
Defenition
Performance
Analysis
Plan
Management
Document
Mgt
Master Data
Report
Mgt
Equipment
Data
Energy
Balance
Cost
Allocation
Perioic
Reports
Downtime
Benchmark
Compliance
Equipment
KPI
Equation
ERP
MES
Finance
DMES
Production
Historian Data Flow
Realtime Data
Real-time Monitoring
Modelling Workflows
Performance
Management
Reports &
Dashboard
Knowledge
Man.
Applications
(Balance, Prediction, Alarmi
ng, Optimization, etc.)
Information

14. Energy Analytics
Energy Data
Software
Analytics
Multiple sources
- types
- formats
- protocols
Compliance reporting
Energy savings
GHG reduction
Cost accounting
Irregularities
Users: Multi-site
Multi-purpose

15. Information Tools
Visualization
Dashboards (samples)
Role-based capability to:
- monitor and improve operations
- analyze and drill to detail
according to individual needs.

16. Information Tools
Visualization and Reporting
Dashboards (samples) Reports
(samples)
Role-based capability to monitor, analyze and drill to detail.
Triggered or automatic reports in standardized or customized format.

17. Efficiency Improvements
Energy and Cost
Major cost savings
Intra-site benchmarking of KPIs, comparing similar
assets like blast furnaces, sinter plants
Capabilities to manage off-gas
Identification of process irregularities and equipment
performance issues
Additional cost savings
Automated metering processes
Simpler internal energy cost administration
Easier sustainability reporting

18. Results
Worldsteel presentation,
published November 2012

19. Reference Case
China
Large scale vertically integrated mill
13+ mtpa
Numerous long and flat products
Major production equipment
8 Coke Batteries, 7 Sinter Machines
6 Rotary Kilns, Shaft & Rotary Hearth Furnaces
9 Blast Furnaces, 9 Basic Oxygen Converters
16 Casters, Rolling and Processing Lines

20. EMIS Investment Drivers
Competitive cost pressure
Visibility and decision making capability
Energy and carbon data, energy costs
Disparate sets of data
Energy operation
 Planning of consumption and generation
Optimize use, procurement and sale
Benchmarks, continuous improvement strategy
Reporting mandate, compliance

21. EMIS Scope
Equipment
Metallurgical equipment, mill power plant
25 different energy channels
100+ major energy equipments
Top Gas Recovery Turbines (TRT),
Cogeneration
Gas distribution systems
Water booster stations, water wells,
Steam and gas boilers, etc.

22. EMIS Scope
Main features
Online and near real-time functions
Energy consumption by channel
Online Energy Balance
Sustainability KPIs
Alert system
Analytical functions
Energy usage and cost analysis by product, channel and
process, crew performance
Trending analysis (actual, historical)

23. EMIS Scope
Main features
Forecasting and planning functions
Energy forecast and load
balance for gas
Multi-energy balance
Short and long-term forecast
Reporting functions
Online, customizable dashboards
Periodic and triggered reports
Centralized and redundant data storage

24. Conclusion
 Energy related industry challenges are likely to stay
 Manufacturers must establish a holistic approach
 Energy Management Information Systems (EMIS) play a
key role in strategy and continuous improvement process
 EMIS solutions provide
Real-time visibility of energy and cost
Planning and purchasing support
Sustainability KPIs to facilitate decision making
 Confirmed savings and acceptable ROI period

25. Klaus Lachmann
Steel Solutions Director
Schneider Electric
Thank You
Phone: +49 (0) 2102 / 404 ext. 9368
Mobile: +49 (0) 172 / 211 94 87
Email: klaus.lachmann@schneider-electric.com