Prediction of metallization rate for a steel manufacturing plantManufacturing
The reputation of a company is defined by the quality of its product. Maintaining the quality of the product depends on various factors such as the quality of raw materials, the pre-processing and the environmental conditions followed during the metallurgical process, and the storage procedures followed. Among these factors, environmental conditions play a major role. Ensuring optimal environmental conditions not only optimum use of raw material, utilities, and reduced waste upholding product quality but also reflects the company’s commitment to excellence and sustainability.
The client was a steel manufacturer in the GCC region, and wanted to optimize operational conditions for improved metallization rate resulting in directly reduced iron and improving the overall quality and efficiency of the product. Major challenges were
- Varying input raw materials quality and Iron ore grade
Defining the inputs for varying Raw materials was coming from various places and facing different weather and pre-processing conditions.
- Rate of metallization based on operational conditions
Impact of varying operational and Atmospheric conditions on the rate and quality of metallization
- Contamination Concerns
Determining the rate of metallization in the presence of impurity that is impacting the reaction.
- Developed a predictive model to predict metallization rate using various manufacturing inputs.
- Converted insights of the optimal mix in the form of a dashboard based on inputs and grade of iron ore.
Realtime insight from the model helped client to make timely decisions and helped them to improve the following
- Enhanced Operational Efficiency
- Improved Product Quality
- Utility Cost saving
- Reduced wastage