AIST 2011 Presentation April 25

7/30/2019 AIST 2011 Presentation April 25

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Copyright ArcelorMittal 2011

Scott BaylisSenior Specialist

Danny PavanSenior Specialist

Automation Technology SolutionsArcelorMittal Dofasco

The Application Of Simulation Modeling atArcelorMittal Dofasco


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Computer Simulation Modeling

What is it?

The methodology for using computer models to:

Imitate the operation of real-world processes orfacilities.

Draw conclusions about their performance.


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Why to use it?

Model Complex Dynamic Systems You can incorporate the variables, interactions and rules that define a system.

Model Random Variability over Time You can model variation over time by describing system behaviors using

probability distributions.

What-if Analysis

You can run experiments to estimate key performance measures for proposedsolutions and alternative system designs.

Visualization of the system You can provide an animated visual representation of the system.


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Demonstration

The Problem with Averages - Simulation versus Calculation

Averages Model

Grabau, M.R. (2001) Averages kill (or how to sell business process simulation). InProceedings of the 2001 Winter Simulation Conference (pp 1263-1265).

Hot Metal Delivery to Electric Arc Furnace Model

Objective:With a new practice of delivering hot metal to the Electric Arc Furnacedetermine if additional transporters or ladles are required.

(Model Demonstration)


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Hot Metal Delivery to Electric ArcFurnace Model

Objective:With a new practice of delivering hot metal to the Electric Arc Furnace

determine if additional transporters or ladles are required.

Outcome:

A single transporter and a single hot metal ladle was capable of

servicing EAF requirements for hot metal. The purchase of anadditional transporter was not required.

Sample Results


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Summary

Simulation modeling provides the unique capability

of creatingDynamic, Visualrepresentations ofComplexreal-world systems that includes theinherentRandom Variabilityof the systems.



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Simulation At ArcelorMittal Dofasco

Computer simulation modeling has been employed for over30 years.

Current team is three simulation specialists.

Where ever possible we utilized the simulation methodologyin our capital projects evaluation process.



Models are designed to answer specific questions.

Defining the system to be modeled is a collaborative effort between: simulation specialists process experts

IT specialists (system input data) decision makers

Models are the translation of the system definition into the simulationsoftware.

Model scope and detail as well as the level of animation detail aredependant on questions to be addressed.

Typically simulation development is an iterative process.Model> Simulate> Learn> Revise

Model Development




Flexsim Software

Powerful and flexible tool that allows for large scale model customization,visualization and analysis of a wide array of processes.

Rapid prototype model development.

New users can build simple basic models very quickly.

Experienced users can develop more complex, sophisticated models relativelyquickly.

The 3D graphics are integrated with model development.

can be tailored to needs visual verification enhanced credibility, understanding, acceptance

Multiple specialist are able to simultaneously develop portions of the same large,complex models.




Sample

Simulation Projects




Sample Projects

Hot Mill Slab Yard Logistics Capability StudySlab Storage Yards, Transfer cars, Cranes, Hot Mill Depiler, Reheat FurnaceCharge Tables and Entry Doors

Objective:

Determine if existing slab handling equipment is capable of performingall slab sorting and delivery responsibilities at increased throughputlevels and to help identify potential bottlenecks and logisticsimprovement strategies.

Outcome:

Determined that slab handling equipment is capable at targetedproduction rates and anticipated future warm charge levels. Identifiedopportunities to develop strategies to balance crane work loads.




Central Shipping New Axial Wrapper EvaluationCoil storage racks in adjacent buildings, Truck/transporter access lanes, AxialWrapper, Coil Preparation Area, transporter decks, customer trucks, Coil StackerCranes

Objective:Determine if the cranes in adjoining buildings are capable servicing aproposed coil axial wrapper at target throughput rates while maintainingadequate service levels for incoming customer truck and coil transporterdeck traffic.

Sample Projects


Crane Results

WorkElements

Summaries

Time Series Analysis ofCrane Utilization

Utilization Distribution frommultiple model runs


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Central Shipping New Axial Wrapper EvaluationCoil storage racks, Truck access lanes, Axial Wrapper, Coil Preparation Area,transporter decks, customer trucks, Cranes

Objective:

Determine if the cranes in adjoining buildings are capable servicing aproposed coil axial wrapper at target throughput rates while maintainingadequate service levels for incoming customer truck and coil transporterdeck traffic.

Outcome:

Determined that cranes are capable of servicing axial wrapper whilemaintaining truck service requirements.

Sample Projects

WorkElementsSummary

UtilizationDistributionfor multiplemodel runs

Axial Wrapper Performance Results

Throughputperformance

Distribution formultiple model

runs


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Sample Projects

21 Bay Coil Storage and ShippingCoil Shuttle Cars, Temper Mill Exit, Cranes, Coil Storage fields , TransporterDeck Locations, Galvanize Line coil consumption

Objective:

Assess cranes capability to service coil movement and storage withinthe bay under various throughput and bay layout scenarios. Also to testcoil storage field capacity allocations

Outcome:Identified limitations in crane capacity under various material volume

and routing scenarios. Also identify areas where planned storage fieldcapacities required modification. Provided follow-up analysis of varioussolution proposals.



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Temper Mill Exit Conveyor StaggeringTemper Mill Entry an Exit Indexing Coil Conveyors and Mandrels, New AutomatedPackaging equipment (Banders and Stencilers)

Objective:Determine if the practice of staggering coils on the exit conveyor of theTemper Mill in order to physically accommodate new automatedpackaging equipment would cause unforeseen throughput/bottleneckissues.

Outcome:

Determined that there were no detrimental flow effects or throughputeffects using coil staggering practice.

Sample Projects



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Sheet Mill A Building Model#2 CPCM, #1 Batch Anneal, Open Coil Anneal, Coil Transporters, Coil Shuttle Cars

Crane Utilization Project

Objective:Assess existing cranes capability of servicing coil movement

requirements within the bay at expected increased throughput levels.Outcome:

Determined that a third crane was required to meet projectedproduction demands.

Coil Movement Logistics Evaluation

Objective:Evaluate existing systems ability to support shorter term increasedthroughput requirements in order to determine if a significant capitalproject designed to support longer term goals could be deferred.

Outcome:Determined that a major $500,000 transporter doors installationexpenditure could be deferred.

Sample ProjectsModels with Multiple Applications


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Hot Metal Delivery System Model(Blast Furnaces, Desulph Station, KOBM Pour Pit, EAF Pour Pit, Coffin Facility, Dekish,Railroad System (Locomotives, torpedo cars, logistics logic))

Steelmaking Improvement ProjectObjectives:

Determine if Metal Delivery System is capable of supporting targeted increasedproduction levels at #2 Melt Shop.

Evaluate multiple torpedo fleet configuration scenarios in support of blast furnacehigh productivity trials.

Outcomes:

Validated that the Hot Metal Delivery System could support the targetedincreased #2 Melt Shop levels.

Supported the blast furnace high productivity trials by analyzing multipleoperating scenarios to ensure that torpedo car fleet configurations wereadequate for the increased production.


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Hot Metal Delivery System Model contdHot Metal to EAF Proof-Of-Concept Study

Evaluated feasibility of supplying EAF facility with hot metal under a 3 blastfurnace operation.

Key justification to move forward with this initiative.

Precipitated several further analysis requests relative to this proposedoperating context:

Torpedo Car Puller Study Desulph Bag House Capability Study Fleet Size Analysis Pig Machine Location and Quantity Analysis



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Hot Band Gantry Yard Simulation ModelHot Mill Coil Exit Conveyors, Gantry Cranes, Coil Storage Yards, Coil Carriersand Tractors, roadways, Coil Decks, coil arrival logic, coil storage logic, exiting

coil load logic.

Objective:

Assess Hot Mill exit coil conveyor throughput capabilities at

anticipated increased levels.

Outcome:

Determined that exit end of the Hot Mill is capable under normaloperating conditions.



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Summary of Benefits

Simulation modeling has provided the capability to answernumerous complex questions.

Specific Outcomes:

Cost avoidance.

Highlighting of deficiencies in proposed system designs. Productivity improvements. Improved equipment utilization. Efficient allocation of resources. Resolution of material handling concerns.

General Benefits:

Avoidance of risk by changing virtual process versus actual processes. Proof-of-concept capabilities. Improved collective understanding of processes. Cost effective evaluation of alternative investment scenarios.

Th k Y


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Scott Baylis-Senior Specialist

Danny Pavan-Senior Specialist

Automation Technology SolutionsArcelorMittal Dofasco

Thank You

AIST 2011 Presentation April 25

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