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…