SteelAsia and SMS group have signed a performance improvement agreement. The aim of the future cooperation is to equip SteelAsia's steel plant in Calaca for the production of green steel with process automation and digitalization solutions. The basis for this will be artificial intelligence. The electric arc furnace (EAF) and the optimization of the environmental systems will be the focus of the EPICA project (EAF Performance Improvement Partnership for Calaca), which uses state-of-the-art combustion technology.
Software and digital components
The package provided by SMS group includes digital components that act solutions based on artificial intelligence and machine learning. As a central data platform, the SMS DataFactory. Here, all plant data is collected, evaluated, and forwarded to the appropriate systems. This is done, for example, to optimize the real-time dashboard for KPI and plant monitoring.
The DataXpert software used is a complete platform for the development and management of condition-based maintenance and Expert systems. It can provide real-time recommendations and notifications. The package also includes Alarm Manager as an intelligent alarm and maintenance management system for simplified fault analysis, which works with intelligent prioritization, multiple analysis options, linking of hints for problem resolution and automatic notifications.
Proactive maintenance measures
To improve performance and increase plant availability, data-driven predictive models are essential. The use of machine learning algorithms provides real-time insights into the condition of the plant and any process failures. Also, with the help of these predictions, it is possible to anticipate machine failures, proactively carry out maintenance measures, reschedule production and thus increase productivity.
The technological know-how of the SMS group enables a cost-effective rebuild of the existing plant to produce green steel. As a result, SteelAsia's steel plant in Calaca can achieve higher energy efficiency, an increase in production volume of up to 20 percent and a reduction in emissions through new digital solutions. Engineers and technicians at SteelAsia's plant will also receive extensive training on the use of all digital technologies.
Sustainable circular economy through recycling
"Advanced Integrated Solutions is the buzzword of the day, and we are proud to be the first steel mill in the Philippines to equip Calaca with our leading technology," explains Prof. Pino Tesè, Chief Sales Officer India and Asia-Pacific Region of SMS group.
Crucial factors for a sustainable circular economy include the use of renewable energies and efficiency improvements to reduce greenhouse gas emissions, in which recycling also plays an important role.
"For the country, this also means a significant expansion of green steel production capacity, as 100 percent renewable energy is used for steel production at the Calaca site," Benjamin Yao, chairman and CEO of SteelAsia, emphasized in addition.
SteelAsia operates five other production facilities in Bulacan, Cebu, Davao and Misamis Oriental, with a seventh plant scheduled to start operations this year in the city of Compostela in Cebu province. Reinforcing steel production will then increase from two million tons per year to three million tons.