Adaptive mill pacing
Research was undertaken in the UK, Spain and Germany on adaptive mill pacing of long product rolling mills. A common approach was used by the partners (Corus, Sidenor and BFI/EWS), while focusing on specific issues in their own processes, manufacturing rail, rod and bar rod respectively. At each plant, recording stoppages in more detail, analysis of process timing and quality signals were introduced and used to configure discrete event simulation models of material flow using Arena software. Physical process models were also developed for stock temperature, critical in hot mill pacing. At Corus, improved visibility of process times was achieved through analysis of the online mill database using Excel/MATLAB. Good pacing is obtained for approximately 60 % of normal operating time, while an estimated 14 % energy saving by furnace control in longer delay periods is possible. The Arena model provides a production-planning tool for the finishing end, predicting throughput versus resources. At Sidenor, where thermal control is crucial to meeting engineering steel quality demands, a through-process stocktemperature model was integrated in Arena and a method obtained for setting the reheating priority order to meet the required thermal cycle. Optimisation guidelines were produced for order of charge and inter-group spacing, from which a 50 % reduction in the free cutting steel rejection ratio is expected. Following a similar approach, BFI/EWS identified a plan to nest mill stoppages and improve equipment availability by maintenance actions. Maintenance schedules and checklists were developed to nest stoppages. The contribution of this project to improved mill utilisation at EWS is estimated at 3 %.
Bibliographic Reference: EUR 22055 EN (2006), 105 pp. Euro: 25
Availability: Katalogue Number: KI-NA-22055-EN-S The paper version can be ordered online and the PDF version downloaded at: http://bookshop.europa.eu
ISBN: ISBN: 92-894-5041-X
Record Number: 200719261 / Last updated on: 2007-07-05
Original language: en
Available languages: en