Leveraging more than a century of knowledge and expertise, to deliver value through proven solutions

Raw Material

Agglomeration

Auto Pelletizing Disc

Objective: Develop an automated pellet size control system using Level II Automation System parameters to control the size distribution of green pellets

Result & Benefits:

1. Elimination of manual inspection of discs to identify discs producing reject and elimination of human judgement in size control
2. Effective control of reject and reduction of feed fluctuations to the induration machine
3. Implemented in all pelletizing disc (10 nos) of TSJ Jamshedpur

Auto Pellet Tester

Objective: To provide a completely autonomous process of testing pellets without any delay in the process

Issues & Concerns:

1. Manual & cumbersome job
2. Time-consuming process

Benefits:

1. Fully autonomous process
2. Results in 1-minute
3. Real-time CCS testing
4. Overall high productivity

Grate Scan

Objective: To develop an automated defect logging, tracking & positioning system for Pallet Cars thus enabling faster detection and maintenance of defective cars which lead to loss of pellets while transport

Automated system is required for

1. Individual car’s defects logging
2. Individual car tracking in chair
3. Auto positioning of the defective car

Key Features:

1. Defect logging
2. Pallet car tracking
3. Precise positioning of cars
4. Overall productivity improvement

Sinter Sizing Estimation

Objective: Image-Analytics-based system to calculate the Sinter size distribution in real-time

Novelty: Using a CNN based Object detection + Instance segmentation model for estimating size distribution

Benefits:

1. Assessment of the sinter granulometry of sinter in real-time
2. Bad-sized Sinter diversion from BF line, minimizing the impact on Blast Furnace productivity

Sinter Plant Level II System

Objective: A complete Level II system for process improvement and an overall increase in productivity at sinter plant through effective operation, management & visualization with analytical models

Iron Making

COSMOS (Coke Oven Scheduling & Heating Monitoring System) - Coke Oven Level II System

Objective:

Heating, scheduling & machine coordination in coke oven battery which leads to improved productivity, battery life, energy efficiency and quality of coke under reduced emission

Process:

1. Dynamic pushing schedule
2. Oven identification and machine coordination
3. Temperature visualization
4. Battery heating control model
5. MIS and data presentation
6. Data science-based models

KPI improves:

1. Energy saving of 6.09%
2. Standard deviation of Min 7.65 degree C° & max 18.14 degree C°

Online Flue Temperature Measurement of Coke Ovens

Objective: To eliminate manual measurement and provide an online temperature of each flue

Solution:

1. Using FO, radiation travels from each flue into a central station
2. A single Pyrometer multiplexes IR radiation to give the temperature of each channel

Benefits:

1. To get the online temperature of Flue
2. Input for the heating model
3. Eliminate manpower to measure

Tie Rod Load Cell Measurement in Coke Ovens

Objective: To provide Load changes that take place during different events of Oven operation

Solution: To install a high-temperature Loadcell on the tie rod

Benefits:

1. Cost reduced and safety improved as manual campaigns decreased
2. Predict oven health conditions
3. Improved Process Visualization

Tuyere Eye

Objective: Visualizing the pulverized coal injection with analytics and eliminating manual observation of the tuyer platform

Solution:

1. Cameras are mounted on the tuyer peephole without compromising on human visibility
2. Live display of the PCI of all tuyers in the control room

Benefits:

1. Improved visibility of PCI for decision making
2. Analytics to aid in decision making and also analysis after-the-fact
3. Human Safety

Wireless Dip Lance

Objective: Wireless enabled measurement of hot metal temperature at the cast house

Features & Benefits:

1. Easy to use & improved safety quotient at cast house
2. Improved ergonomics for operator

Provide BF (Process Visualization & Data Evaluation for Blast Furnace) : Blast Furnace Level – II System

Objective: Visualisation, Simulation & Optimisation of BF processes which improve operational efficiency, furnace health and quality of hot metal

Steel Making

Smart Raking System

Objective:
To facilitate the removal of slag optimally from molten iron

Solution:

1. IR camera differentiates steel and slag.
2. Imaging algorithm detects the endpoint of raking

Feature & Benefits:

1. Improved yield
2. Independent of human skill and experience

Slag Detection System

Objective:
To avoid slag carryover into the ladle during tapping

Solution:

1. IR cameras differentiates between steel and slag based on their emissivity.
2. Imaging algorithm detects slag at the end of the tapping cycle

Feature & Benefits:

1. Cases of Phos Reversal go down.
2. To improve the quality of the steel

Opti BOF: SMS Level II System

Objective:
Consistency in the end blow chemistry and temperature through different models which provides assistance in the planning of heats

• Process Optimisation: Charge Balance,  Alloying Calculation, Dynamic Calculation
• Tracking: Hot Metal Ladles, Steel Ladles
• Production Planning: Daily Schedule Receipt, Heat Planning, Transfer Of Process Data
• Communication Interface: Caster Level-II System, Level-II System, SAP/Data Warehousing, Laboratory Management
• HMIs: Online Display Of Process Parameters
• Process Analysis: Online Trends Of Key Parameter

Benefits:

1. Reduction in the standard deviation of turndown temperature
2. Reduction in reblows
3. Reduction in time consumption
4. Reduction in a variation of turn down phosphorous for a given grade
5. Standardization of operational practices

Slab Auto De-grader for SMS

Objective:
An automated ML model with gradient boosting algorithm to determine the best possible alternate for unplanned transitions/degradation due to chemistry

Innovation:

1. Automated searching of the most suitable alternative in terms of Order availability, defect generation due to grade mixing (transition loss) and cost margin
2. A novel approach involving machine learning (Gradient Boosting Algorithm) and search optimization has been used
3. Pro-active correction of the unplanned outages via automated system-driven efficient decisions instead of manually dependent systems at early steelmaking stages

Benefits:

Scrap Yard Management System

Objective:
Auto scrap loading information system eliminates manual-based data logs of scrap charged in BOF and other manual practices coupled with autonomous scrap charging to improve overall productivity

Features & Benefits:

1. Completely automated scrap management system
2. Able to identify the requirement as per the work order received to charge the scrap
3. Complete interface with the level II system and identify the required scrap recipe
4. Camera Lidar system enables to generate a position reference for the crane system to operate

Casting Online Diagnostics system (Break out prediction system)

Objective:
CODS continuously monitors the embedded thermocouple values in real time and generates early alarms to arrest potential sticker breakouts

UPS:
Gives a breakout ability factor

Improved KPIs:
Improved KPIs, 80% true/false sticker alarms

Slab Dimension Measurement System

Objective:
To develop a system that comprehensively measures various casting parameters like Length, Width, Thickness, Bulging and Taper to provide real-time feedback to the operation about the casting quality

Previous Practice:
Length (Auto-Encoder based), Width (Manual), Thickness (Manual), Taper (None), Bulging (None)

New Initiative:
A hybrid of Machine Vision and Laser technology has been developed to measure Slab dimension

Features & Benefits:.

1. Efficient data analysis tools to analyze casting performance embedded in Level II
2. Breakout detection due to Taper Loss

Rhomboidity Measurement System

Objective:
Real-time, precision vision machine for Rhomboidity measurement of Billets/Blooms to improve yield by a reduction in downstream rejects & reduce man-machine interface

Features & Benefits:

1. The system being real-time can measure each billet individually for Rhomboidity, giving an accurate value
2. Able to withstand high-temperature dust and harsh environments
3. Non-contact type system

Mills

Roll Shop Management System

Objective:
The Roll Management monitors the usage of grooves, rolls, roll sets, roll modules and guide boxes in terms of the rolled tonnage and indicates when set limits are reached

Digital Features:

1. Application migrated to web-based
2. Backup and running rolls module
3. Roll shop inventory and production linking for all stands 1 to 16
4. NTM roll inventory and linking are in progress
5. Roll shop status module was deployed

Mill Chatter detection System

Objective:
Chatter marks on coils generated in Cold Rolling Mill often lead to rejection and downgrade downstream. In absence of an online chatter detection system, chatter defects are not detected in real-time which may take upto some days of actual rolling. So, no corrective action can be taken immediately and material rolled with this defect is always exposed to chatter defects

Product Features:

1. Real-time Chatter Detection
2. Long Term vibration trend
3. FFT analysis of stand vibration
4. Coil Wise Chatter severity prediction
5. Daily MIS
6. Data download
7. Configurable as per requirement

V.Eye (An eye for crop optimization)

Objective:
Real-time vision-based system for accurate computation of cut profile of the head and tail ends of Transfer Bar to reduce yield loss due to crop cut. The system also provides accurate speed measurement of the hot strips to assist precision cutting by crop shear

Principle of operation:

1. Imaging of the head & tail end of the transfer bar after the last pass of the roughing mill
2. Determination of the optimum shear lines
3. Downloading of the reference cut position to the shear control system
4. Accurate speed measurement & feedback to shear control system

Benefits:

1. Reduction in yield loss due to crop cut up to 0.1%
2. Reduction in average crop cut length up to 60%
3. Avoids cobbles in mills

Tru-Span

Objective:
Based on stereo photometry and triangulation principles, Tru- SPAN measures the hot/cold coil widths with immaculate precision. Powered by a line laser, the new generation Tru-SPAN is also capable of carrying out width compensation in presence of a moderate bow in the surface

Improved KPIs:

1. Yield loss
2. Downstream rejections

Surface Quality Inspection System

Objective:
Discretion alarms are raised only for significant defects missing zero defects and resulting in accurate classification and revised gradation standards

Principle of operation:

1. Acquisition of images
2. Processing of the images
3. Detection of “flaws”
4. Segmentation into “objects of interest”
5. Classification of these images into defects, e.g. silvers, scratches, edge damage, holes etc.
6. Severity indication
7. Real time result display
8. Detection of defects upto size 1mm2
9. Modular & scalable architecture

Hole Detection System (HDS)

Objective:
A precision vision machine that will not let go of any holes undetected. Built on image processing, sophisticated and efficient algorithms are used to detect holes on the fly. Salient features include triggering of Audio/Visual alarm, customized report generation, and advanced analysis of hole defects

Benefits:

1. Real-time detection of holes during rolling
2. 100% coverage of sheet surface
3. Supports quality control & grading of sheets
4. Helps monitoring of the casting & rolling processes
5. Generates coil defects database to facilitate analysis
6. Archival of data

Plant Infrastructure and Logistics

Torpedo Ladle Tracking System

Objective:
Efficient coordination of torpedo ladles for serving Hot Metal “capacity buffers” for the Blast Furnaces and “feed buffers” for the Steel Making Shops
Improved KPIs:
Efficient & optimum management of hot metal movement

Generic Yard Management System

Objective:
Solution for smart Material Handling
Features:

1. Easy to use human machine interface for real time visibility of all yard activities
2. Hand held terminal for the operator to perform field verification and server communication
3. Interfaces with business planning systems, process lines and crane automation systems
4. Centralised database to manage all activities from receipt to dispatch of materials

Benefits:

1. Real- time visibility and tracking of inventory and shipment
2. Reduced material handling time
3. Streamlining work order management to reduce vehicle loading, unloading, and waiting time
4. Prioritisation of transportation as per business needs
5. Online reports on crane performance, yard inventory execution time and VIVO time
6. Handheld terminals for the operator for communication with server

Smart Solutions

Objective:
It helps enable devices on the network, data streaming, data analysis, MIS reports/exceptions, & control/enhance business operations
Process Flow:
Smart Devices >> Cloud Search >> Web Applications

Connected Workforce

Objective: Smart solution for identification & tracking of manpower deployed inside plants
The Solution has 4 critical components – Lora Wan, BLE Beacons, Android / IOS Mobile App & Cloud application

1. LoRaWAN Network – LoRa Network to be installed depending on the Plant/office coverage and reach [only if the solution is used in collaboration with SafePass Cards]
2. BLE Beacon – BLE Beacons to be installed across the plant/office demarking various Zones.
   The BLE beacons will be configured as either:
   » Entry Beacon – Demarking and indicating to the Mobile App that the worker is entering the plant/office
   » Exit Beacon – Demarking and indicating to the Mobile App that the worker is exiting the plant/office
   » Hazardous Beacon – Demarking a Hazardous area within the Plant / Office
   » Safe Beacon – Demarking normal working zones within the plant / Office
3. Mobile App via Bluetooth capable of detecting the various beacons, collecting beacon information, and sending data, alerts via the internet as well generating user alerts via buzzer/vibration
4. Application to generate additional reports and alerts

Smart Barricade

Objective:
Remotely controlled smart access control systems deployable at any Process hazard areas
Features:

1. Works with all Employee/Contractor gate pass
2. Authentication via gate pass cell database over the cloud
3. Real-Time Access & control
4. MIS, Reports, Exceptions & Alarms

Benefits

1. Remotely controlled
2. Scalable
3. Traceability ONLINE

Smart Fleet Management System

Objective:
E-Tracking and Optimization of mobile equipment
Key Functions:

1. GPS-enabled tracking of each fleet’s route
2. Live ETA at various stops
3. Data retrieval of passengers/occupants from Cloud
4. Health Status Alarm of RFID/GPS
5. MIS, Reports, Exceptions & Alarms

Benefits:
Enhanced Tracking and Optimization

UniLORD (Universal Lora wan Solutions)

Objective:
Implementation of smart solutions under LoRaWAN network for effective operation and monitoring on real-time basis.
Application:

1. Spindle run time monitoring system
2. Digitised CO sensors
3. Smart energy meters
4. Anchor bolt monitoring
5. Smart sprinklers

Centralized Condition Monitoring System

Objective:
The CCMS improves equipment reliability by automatically diagnosing and alerting equipment faults
Benefits:

1. Online condition monitoring of critical all across plants
2. Generates alarm/warning and SMS for maintenance
3. Standardisation of maintenance system

DC Motor Spark Monitoring System

Objective:
Real-time monitoring of Sparks in DC motors
Improved KPIs:

1. Continuous monitoring in real-time
2. Machine Vision based, safe and non-intrusive methodology
3. Capable of detecting very short-lived sparks (~40 ms)
4. Enables proactive maintenance

Pipe Conveyor Monitoring System

Objective:
An online system capable of measuring the Overlap & Sway of the Pipe conveyor is needed which can trigger the alarm for corrective action
Features & Benefits:

1. Online Pipe diameter,
2. Sway orientation
3. Overlap data for monitoring & control
4. Early warnings identify pre-mature failures
5. Belt adjustment can be done to maintain Blast Furnace burden

Track Rail Inspection System (Trains)

Objective:
To develop an automatic Inspection system to measure multiple inspection parameters, and process and visualize rail track on the fly
Key features:

1. Motorized vehicle
2. Contact-free measurement
3. Continuous measurement
4. Track joint detection
5. Rail-road crossing detection
6. Local data storage
7. Geo-mapping of inspection data