INTEGRATED STEEL WORKS

Benefits

  • Flat and long steels: between € 3 and 7 per ton of steel
  • Steel with high added value (e.g. extra-heavy): between € 10 and 15 per ton of steel
  • Knowledge aggregation of several departments (coke plant, sinter, blast furnace and steel shop) in one common tool

Description

  • Dedicated to basic oxygen steel making
  • Full integration of all the production phases: coke plant, sinter, blast furnace and steel shop
  • Possibility of multiple instances of one department (e.g. multiple blast furnaces)
  • Tool reducing raw material costs between € 3 and 15 per ton of steel 
  • Essential knowledge management tool for continuous improvement
  • Multi-Period definition and optimization
  • Multi-Sites optimization with raw material optimized sharing (global optimum Vs. local optimum)
  • Target of the optimization function: global production cost minimization OR productivity optimization

Inputs 

  • Finished product target quality (coke strength and resistance, sinter RDI, …)
  • Raw materials (ores, pellets, coals, scraps, additions…) with purchase cost and detailed chemical analysis
  • Sourcing (with different prices and availabilities)
  • Yields, productivities, capacities (crushing, injection, sinter…)
  • Fixed and Variable costs (working costs, demurrage…)
  • Sale price of co-products (gas, naphthalene fuel, tar…) 
  • Flaring re-use and recycling
  • Granulometries
  • And more...

Constraints 

  • Target Quality
  • Thermodynamics
  • Chemistry
  • Mechanical constraints (coke, coals…)
  • Charging
  • Crushing
  • Environment
  • Availability
  • Sourcing
  • Costs
  • Productivities (coke ovens, sinter, blast furnace, converter…)
  • Temperatures 
  • Sifting
  • Blowing
  • Drying
  • Volume of baskets, capacity of ladle ovens
  • Technical parameters
  • … 

Output 

  • Cheapest mix of raw materials with respect to the constraints
  • Limit Marginal Price (LMP) (Value in use)
  • Coal mix optimization
  • Composition and quantities of pig iron, steel and slags
  • Coke cost optimization
  • Revenue calculation for co-products (gas, tar, naphthalene fuel…)
  • And more…