Bosnian based ArcelorMittal Zenica, a producer of hot rolled steel products for the Balkan and North African markets, realised it needed better data in order to manage steam consumption more efficiently.
Customer challenge
Although steam consumption is an important contributor to the overall profitability of the company, consumption by the different internal customers was only calculated according to empirical standards. Consequently, as prerequisite for efficiency gain, the Energy Plant Department needed to:
* Monitor steam production and consumption in real time.
* Have meaningful data centrally available.
Endress+Hauser’s solution
Endress+Hauser integrated a turnkey steam monitoring solution into the company’s existing energy monitoring system. The solution included:
* Instrumentation: 39 steam measurement systems (Prowirl 72F vortex flowmeter + TR15 temperature sensor + Cerabar PMP51 pressure transmitter with syphon and shut-off valves).
* Energy application managers: EngyCal RS33 including cabinets, cables and required system components.
* Data acquisition and visualisation: P View software, OPC server and workstation PC.
* Mechanical installation: flanges and reducer pipe works, insulation.
Application details
The steam fluxes (in tons/h) are measured using a vortex flowmeter and temperature and pressure sensors. Each of the overall 39 measuring points also includes an energy application manager (EngyCal) providing power (heat flow) and energy (in GJ). The device is not only able to do calorimetric calculations according to relevant standards, it also operates as a gateway and supplies the data via a fibre optic network to the workstation located at the energy centre building.
Here the values are visualised and stored in an OPC database. Finally they are processed again to provide precise and conclusive figures, instead of pure process value. The result is customised reports that include information such as real consumption per cost centre, amount and location of losses and overall efficiency of the steam process are now available in user-friendly format for management review.
Endress+Hauser also performed all the associated services that were required.
1. Energy site survey: a site survey was performed and several concepts were discussed and offered.
2. Consulting: the detailed technical solution was developed together with the customer and local partners taking into account the site-specific IT infrastructure.
3. Installation and commissioning: the monitoring solution was installed, commissioned and the Energy Plant Department supported in analysing the measured data.
4. Consulting energy audit: an audit of the steam process was performed in order to evaluate the measuring results and the amount of losses. This was the basis to recommend effective corrective and preventive actions.
The results:
* Accurate, consolidated data on steam output, transport and consumption.
* Controlled steam consumption via precise metering of each consumer.
* Measured transport efficiency and allocated losses in the steam pipe network.
* Customised reports for management review.
“With the solution and services provided, ArcelorMittal Zenica management is now able to make the right decisions to reduce energy costs. Taking into consideration the total amount of losses, the cost of the supplied solution and further investment, the project provides a return on investment in less than two years,” concludes Emir Krgo, head of production sector energy plant department, ArcelorMittal Zenica.
For more information contact Benjamin Mlangeni, Endress+Hauser, +27 (0)11 262 8000, [email protected], www.za.endress.com
| Tel: | +27 11 262 8000 |
| Email: | [email protected] |
| www: | www.endress.com |
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