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Colla V.,Sant'Anna School of Advanced Studies | Matino I.,Sant'Anna School of Advanced Studies | Cirilli F.,Centro Sviluppo Materiali S.p.A | Jochler G.,Centro Sviluppo Materiali S.p.A | And 10 more authors.
Materiaux et Techniques | Year: 2016

The European Steel industry is ever more committed to improve the socio-economic and environmental sustainability of its processes by promoting any development, which can increase resource efficiency and lower the environmental footprint of the steel production. The European Steel Technology Platform gives the highest priority to the topic of Sustainable Steel Production within its Strategic Research Agenda since 2013. Several projects have been developed both at corporate level, as well as by associations of companies and research institutions in order to investigate new processes, retrofit actions and apply innovative combinations of existing technologies that can allow to improve the energy and resource efficiency and the management of by-products, waste and wastewater. However, it is still difficult for process managers and plant engineers to find accessible tools to both analyze the process data and to perform scenario analyses aimed at evaluating in a practical and understandable manner the effect of innovations in terms of new technologies or novel procedures and operative practices. Within the research RFCS project entitled "Environmental Impact Evaluation and Effective Management of Resources in the EAF Steelmaking-EIRES" (where EAF stands for Electric Arc Furnace), an integrated tool has been developed, which allows to evaluate the environmental impact of current operating practices, modified operating conditions and major process variations and innovations, thanks to process simulation models for both production processes and auxiliary equipment. Also a dedicated Life Cycle Assessment (LCA) is linked to the simulation models in order to provide a further evaluation from the specific LCA perspective. The paper is focused on the description of the developed integrated scenario analysis tool, which includes both process modelling and metrics tools, and to depict some examples of its application for process data analyses and scenario simulations. © 2017 EDP Sciences.


Otto S.,BFI VDEh Betriebsforschungsinstitut GmbH | Adler W.,BFI VDEh Betriebsforschungsinstitut GmbH | Stranzinger B.,BFI VDEh Betriebsforschungsinstitut GmbH | Ackermann H.,OWI Oel Waerme Institute GmbH | And 6 more authors.
Gaswaerme International | Year: 2017

Deposits forming on heat exchangers in direct fired thermoprocessing plants impair their operation. By experiments and analysis of the deposits their origin and impact in steel treatment furnaces were examined. Experimental volatilization rates for chromium and molybdenum were obtained and in case of chromium rates were also calculated. For the calculations, the knowledge of the structure of the oxide scale on the steel is required. By reproducing the deposits in a burner, rig recommendations concerning prevention and removal of deposits were derived.


Colla V.,Sant'Anna School of Advanced Studies | Cirilli F.,Centro Sviluppo Materiali S.p.A | Kleimt B.,BFI VDEh Betriebsforschungsinstitut GmbH | Unamuno I.,GERDAU ID Basauri | And 5 more authors.
Materiaux et Techniques | Year: 2016

The problem of rating the environmental impact of industrial plants has been widely studied in recent years with a specific focus on CO2 emission and energy consumption. On the contrary, only limited attention has been paid to the evaluation of the resource efficiency and overall environmental impact of industrial plants. This paper presents the first results of the research project entitled "Environmental Impact Evaluation and Effective Management of Resources in the EAF Steelmaking" (EIRES), which aims at a plant-oriented approach with an internal reporting of environmental and energy issues. For this purpose, several Key Performance Indicators (KPIs) have been selected both from literature and operational practices, which can be easily interpreted by plant operators and managers. Furthermore a software tool has been implemented which allows to follow the evolution of these KPIs over time. The tool is not intended to compare the environmental performance of different companies, but to provide a practical support to the personnel of each single steelwork, in order to have an updated overview on the way the processes in the plant are operated from an environmental perspective and in order to identify measures and modifications of operational practices allowing to lower the environmental footprint of the production cycle. © 2016 EDP Sciences.


Ebel A.,BFI VDEh Betriebsforschungsinstitut GmbH | Marchiori F.,Centro Sviluppo Materiali S.p.A
IC3K 2015 - Proceedings of the 7th International Joint Conference on Knowledge Discovery, Knowledge Engineering and Knowledge Management | Year: 2015

In recent years, the steel industry has significantly raised its demands regarding product quality, optimization of production cost, environmental issues and lead-time. The demand for improved production performance has in turn increased the demand on information systems, in particular highlighting the need for improved factory- and company-wide collaboration and information exchange. The heterogeneity in structure, technology and architecture of the information systems deployed in manufacturing plants presents further challenges to the design and implementation of a data exchange system for process optimization. Copyright © 2015 by SCITEPRESS - Science and Technology Publications, Lda. All rights reserved.


Ponten H.-J.,PSI Metals GmbH | Kleimt B.,BFI VDEh Betriebsforschungsinstitut GmbH
Iron and Steel Technology | Year: 2011

The development of an integrated system of heat schedule prediction and temperature development to control the energy consumption of a heat is discussed. The adjustment of the BOF tapping temperature or the energy input in the ladle furnace is optimized according to the current workload. The objective of the system is to provide an integrated and centralized functionality to manage all technological know-how for on-line production and quality control, and to combine this with an optimization of production scheduling and temperature control to increase the quality, stability and reliability of the entire production process. Depending on the production route, the system should enable and help the scheduler to optimize various targets with regard to quality, cost, time and productivity. For instance, throughput optimization usually requires greater energy expenditure to treat as many heats as possible when the facilities are working at full capacity.


Peters H.,BFI VDEh Betriebsforschungsinstitut GmbH | Ebel A.,BFI VDEh Betriebsforschungsinstitut GmbH | Holzknecht N.,BFI VDEh Betriebsforschungsinstitut GmbH | Link N.,BFI VDEh Betriebsforschungsinstitut GmbH | And 4 more authors.
Stahl und Eisen | Year: 2012

The continuous improvement of all steel production processes regarding the avoidance of quality deficiencies and the related improvement of production yield is an essential task of each steel producer. Therefore and within the framework of the Zero-Defect strategy popular today, several quality assurance techniques are used. The present report explains in this context the method of Data Mining and describes its application in the industrial environment and here especially in the steel industry. Beside a description of the general procedure different approaches for the realization of the necessary software tools are presented.


Holzknecht N.,BFI VDEh Betriebsforschungsinstitut GmbH | Brandenburger J.,BFI VDEh Betriebsforschungsinstitut GmbH | Keil S.,QuinLogic GmbH | Luecking F.,QuinLogic GmbH
AISTech - Iron and Steel Technology Conference Proceedings | Year: 2012

Describing quality assurance procedures through rules is a common approach. Defining such rules is often difficult. Several factors contribute to this: The vast amount of data delivered by latest technology gauges, ever more detailed specifications and requirements, and the need to transform human knowledge and experience into electronic rules. QuinLogic and BFI have developed innovative software to extend the QA rules approach in two ways: (1) Fuzzy logic helps to map human experience into rule sets. (2) Automatic rule generation, for example driven from a claims database, allows qualifying coils even if written specifications are incompletely describing the customers' requirements. While the employed technologies are known, these concepts have been for the first time applied to rule based QA procedures. The paper describes experiences with rule based QA procedures that have led to the application of fuzzy and automatically generated rules, illustrates the implementation and reviews first experiences.


Reichardt T.,BFI VDEh Betriebsforschungsinstitut GmbH | Reche D.,BFI VDEh Betriebsforschungsinstitut GmbH | Sartor M.,BFI VDEh Betriebsforschungsinstitut GmbH
FME Transactions | Year: 2015

In hot rolling of steel the applied tools face a continuous wear due to thermal and mechanical work load. Depending on the addressed product (strip or profile) and deformation step in the process line (roughing or finishing stands) this load varies in contact time and material flow due to reduction rates and elongation. During the last decades different work roll materials were developed to fulfill these demands. Additionally, lubricants and wear protective coatings contribute to this task in order to decrease production costs and increase product quality. BFI has developed a high temperature testing device, Tribotherm, to enable a targeted pre-selection of potential work roll material, lubricant or wear protective coating. This test plant rotates two cylinders independently against each other with defined and adjustable slip, rolling speed and pressure. One cylinder, representing the product material, can be inductively heated until 1000 °C, while lubricant and cooling can be applied as well. Wear rates (wear profile, gravimetric), topography and torque can be controlled and evaluated. The main aim is to evaluate promising tools to be implemented in the industrial process. A qualitative comparison of different techniques allows to identify the most effective combinations. The Tribotherm plant has been continuously improved in several research projects and first results have been already transferred successfully into industrial practice. © Faculty of Mechanical Engineering, Belgrade.


Muller U.,BFI VDEh Betriebsforschungsinstitut GmbH | Sievering R.,BFI VDEh Betriebsforschungsinstitut GmbH | Wuppermann C.-D.,Cdwuppermann Innovation and Strategy CD WIS
Proceedings of the 10th International Conference on Steel Rolling | Year: 2010

Defined product properties at moderate production costs besides high energy efficiency and a maximum of environmental sustainability will be the key factor for successful competition in globalised markets. These properties, however, are influenced by the material itself, processing technology used in the plants during hot and cold rolling and by the relevant equipment used. Future challenges will be overcome by the development of new processes, plants, control systems etc. for future products, the increase of the reliability of systems, the development of adaptable standard solutions and the standardization of interfaces. New aspects have to be considered into the human-machine interfaces to integrate operator knowledge and experiences into the control system of the process; achieving an optimum from the product, machinery and process hence avoiding defects.


Neuer M.J.,BFI VDEh Betriebsforschungsinstitut GmbH
IEEE Transactions on Nuclear Science | Year: 2014

The shape of the nuclear signal from scintillators contains information about the detection material from which it originated and its current temperature. A digital filter for this type of signals is presented that automatically extracts both of these pieces of information from the shape of the signals and controls the temperature dependency of the resolution by continuous adaption to this shape. Hereby, nuclear signals are a-priori modelled by an all-pole filter. The concept combines a deconvolution approach based on this model with a least-mean-squares iteration. Beneath the iteration, there is a continuous assessment of the signal shape where the mean-squared distance between the assumed shape and measured shape acts as control parameter for the resolution. From the information stored inside the dynamic filter parameters, the material characteristics are retrieved to identify the detector material. An implementation into a multi-channel-analyser is shown and the technique is verified under real-world environmental conditions. © 1963-2012 IEEE.

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