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