Optimization of Production in Steel Making

Optimization of Production in Steel Making Advance Hydrau Tech Pvt. Ltd. December 2019

Optimization in the Secondary Steel Making Industry

Optimization of Production

Optimization of Revenue

Optimization of Operating Cost

2

Result-oriented approaches for optimization for tangible and immediate impact

Efficient Scrap Management Through proper handling of incoming scrap, scrap processing and proper transfer process

Process Balancing and Improvement Through optimizing 8 process areas

Cost Optimization Through economies of scale, improvement in yield, improvement in patching life and P.O.T. control

3

Efficient Scrap Management Through proper handling of incoming scrap, scrap processing and proper transfer process

Process Balancing and Improvement Through optimizing 8 process areas

Cost Optimization Through economies of scale, improvement in yield, improvement in patching life and P.O.T. control

4

Proper Handling of Incoming Scrap Proper Handling of Incoming Scrap

Scrap Processing

Transfer to SMS

Saves time Reduces effort Scrap Gradation

Designated Offloading

Reduces cost Inventory tracking

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Advance Hydrau Tech’s C.S.S.D. Framework Proper Handling of Incoming Scrap

Scrap Processing

Cleaning

Transfer to SMS

Sorting

Scrap Processing

Densification

Scrap Management

Sizing

Process Balancing & Improvement

Cost Optimization

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Benefits of C.S.S.D. Framework for Scrap Processing Proper Handling of Incoming Scrap

Scrap Processing

Transfer to SMS

Benefits of CSSD Framework: 1.

2.

3.

4.

5.

Lower Power consumption per tonne More Productivity per hour Faster charging of scrap Lesser melting time Higher yield i.e. Minimum wastage

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Advance Hydrau Tech’s C.S.S.D. Framework Proper Handling of Incoming Scrap

Scrap Processing

Transfer to SMS

Segregation of scrap from mixed waste stream

Unwanted materials removed Cleaning

Sorting

Scrap Processing Volume is reduced Densification

Scrap Management

Sizing

Process Balancing & Improvement

Sizing done according to furnace size

Cost Optimization

8

Advance Hydrau Tech’s Scrap Processing Equipment

Baler

Shredder

Shear

Briquetter

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Transfer of Processed Scrap to Steel Melting Shop Proper Handling of Incoming Scrap

1

Scrap Processing

Optimal Scrap Mix

Timely delivery of processed scrap

2

Preparation of scrap mix (according to requirements and local area dynamics)

Scrap Management

Transfer to SMS

Using suitable and adequate feeding equipment

Process Balancing & Improvement

Cost Optimization

10

Efficient Scrap Management Through proper handling of incoming scrap, scrap processing and proper transfer process

Process Balancing and Improvement Through optimizing of 8 process areas

Cost Optimization Through economies of scale, improvement in yield, improvement in patching life and P.O.T. control

11

Process Balancing and Improvement

“Process Balancing” is a procedure whereby a set of process steps are “equalized” in terms of quantity and time required to accomplish them

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Process Area #1: The 4 T’s • Well-processed scrap

Charging Time

• Proper Transfer mechanism • Proper Charging mechanism

• Well-processed scrap

Melting Time

• Standard scrap mix • Power and temperature control • Agile Shift incharge

Tapping Time

• Timely arrangement of Ladle, Tundish and CCM • Coordination among departments

• Optimum running speed of CCM

Casting Time

Scrap Management

• Good running condition of CCM

Process Balancing & Improvement

Cost Optimization

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Process Area #2: Adequate Working Equipment

When we optimize the entire production process, it is very important that we provide adequate and proper working equipment and tools to our workforce

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Process Area #3: Efficient Store Management

Right consumables and spares

Scrap Management

Right Quantity

Process Balancing & Improvement

Right Time

Cost Optimization

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Process Area #4: Effective Maintenance Management Maintaining adequate skilled staff Finding permanent solution, instead of stopgap measures Active planning, forecasting & scheduling Recording of maintenance activities

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Process Area #5: Easy Internal Communication

All departments should be on an easy, responsive and fast communication network for online and real-time action

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Process Area #6: Welldefined Organizational Chart Assigning clear roles & responsibilities Establishing exact Accountability Avoiding overlap of duties Defining a clear line of Authority

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Process Area #7: Good Working Conditions & Upgradation of Skills

1

Provide safe and motivating working environment

Scrap Management

2

Conduct knowledge transfer sessions and upgrade skills

Process Balancing & Improvement

Cost Optimization

19

Process Area #8: Effective Reporting System 1

Accurate Data Collection

2

Easy to understand Data Presentation

3

Analysis and taking corrective action

Scrap Management

Process Balancing & Improvement

Cost Optimization

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Efficient Scrap Management Through proper handling of incoming scrap, scrap processing and proper transfer process

Process Balancing and Improvement Through optimizing 8 process areas

Cost Optimization Through economies of scale, improvement in yield, improvement in patching life and P.O.T. control

21

Cost Optimization

1

Improvement in Patching Life

Cost Optimization 2

Scrap Management

Optimum Control of Pressure, Oxygen & Temperature

Process Balancing & Improvement

Cost Optimization

22

Improvement in Patching Life

1

Improvement in Patching Life

Cost Optimization 2

Scrap Management

Optimum Control of Pressure, Oxygen & Temperature

Process Balancing & Improvement

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Use of suitable & quality ramming mass

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Use of proper tools for lining and patching

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Following proper ramming procedure

Cost Optimization

23

Optimum Control of Pressure, Oxygen & Temperature

1

Improvement in Patching Life

Cost Optimization 2

Scrap Management

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Saving in fuel cost

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Saving in Yield Loss

Optimum Control of Pressure, Oxygen & Temperature

Process Balancing & Improvement

Cost Optimization

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“Before you say you can’t do something, try it!”

- Sakichi Toyoda (Founder, Toyota)

Contact Us

Any query regarding steel scrap processing solutions please contact Advance Hydrautech Advance Hydrau-tech is the largest and most trusted manufacturer of scrap processing machines. Our Baling Press, shredder, shear and Briquetter is widely demand in market for their quality and productivity.

Address Address:KHASRA NO 86/23, VILLAGE GHEVRA NEAR HIRAN KUDNA MOR, MUNDKA UDYOG NAGAR ROHTAK ROAD, NEW DELHI – 110081 (INDIA) Phone:+91-11-28353700-10 Mob:91-9810028984 / +91-9810728984 Email : info@ahtpl.in, netmart@ahtpl.in +91-98100 28984

info@ahtpl.in

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