Machine Learning Applications for Furnace Control … › content-images › main ›...
Transcript of Machine Learning Applications for Furnace Control … › content-images › main ›...
Machine Learning Applications for Furnace Control and Process Optimizationin SteelmakingFuture Steel Forum, Budapest
September 26th, 2019
Giovanni BavestrelliDigital Engineering Director
2019
Techint Group
Tenova Company Profile 2
OUR GROUP
At December 31, 2018
Techint
Humanitas
Tenova
Tenaris Ternium Tecpetrol
4%
5%
5%47%32%
SIX MAIN COMPANIES WITH OPERATIONS WORLDWIDE
6%
Annual RevenuesUS $23.5 billion
Permanent Employees57,100
Total Employees74,500
Continents5 Other
1%
Tenova Company
Tenova Company Profile 3
OUR GLOBAL PRESENCE
Countries
Locations
1940
Employees2500+
30 September 2019Tenova S.p.A. | Confidential & Proprietary 4
Technologies Driving the Digital EraCHALLENGES OR OPPORTUNITIES?
Big Data
Blockchain
Internet of Things
MobilityAugmented
Reality
AutonomousSystems
CloudPlatforms
Data Analytics
Data DrivenDecisions
Cognitive Services
Machine Learning
EdgeComputing
Robotics
Smart Sensors
Digital Twins
Additive Manufacturing
Cyber Security
Collaborative RobotsArtificial
Intelligence
3D Machine Vision
Drones
Wireless Connectivity
Virtual Reality Industry 4.0
30 September 2019Tenova S.p.A. | Confidential & Proprietary 5
Tenova DigitalNEW TEAM TO FACE NEW CHALLENGES
To identify, promote and facilitate a coordinated implementation of new services and business opportunities in Tenova as they are made availableby emerging digital technologies
To solidify Tenova’s position as the leading provider of products and services in the Metals and Mining Industries, making Tenova the idealpartner in a fast changing technological world
Project Product Service Partnership
30 September 2019Tenova S.p.A. | Confidential & Proprietary 6
Partnership with MicrosoftTECHNOLOGICAL PARTNER WITH STRONG INDUSTRIAL BACKGROUND
HoloLens
Cortana Intelligence Suite and Cognitive
Services
Azure IoT Suite
Manufacturing solutions
Microsoft 3D Tools and Windows 10 IoT Core
Vertical integration | Horizontal integration | End-to-end engineering
Industry 4.0 Design Principles
Machine Learning, Stream
Analytics, and Edge analytics
CRMSRMERP…
Process interoperability (IT)Information
Flow (OT)
Collaborative equipment Ecosystem
Interaction
Sourcing: Microsoft
30 September 2019Tenova S.p.A. | Confidential & Proprietary 7
Pilot Digital ProjectsOUR FIRST STEPS IN DIGITAL TRANSFORMATION
\
ROBOTICS
PREDICTIVE MAINTENANCE PLANT OPTIMIZATION
ADDITIVE MANUFACTURING
REMOTE ASSISTANCE
DIGITAL CATALOGS
1 2 3
4 5 6
30 September 2019Tenova S.p.A. | Confidential & Proprietary 8
Our Connected Products in the FieldOUR «GOLD MINE»
Submerged Arc Furnace (SAF)
50Electric Arc
Furnace (EAF)
400Heat treatment
Furnaces
7.000Direct Reduction
Plants
35Burners on Reheating Furnaces
20.000
300 Strip Processing &
Cold rolling mills900 Roll
Grinders
30 September 2019Tenova S.p.A. | Confidential & Proprietary 9
If data is the new oil…
…information is the new energy
…and decisions are the new end goal
30 September 2019Tenova S.p.A. | Confidential & Proprietary 10
IoT ArchitectureCLOUD PLATFORM
IoT Hub
Field Gateway
Customer Plant Microsoft Azure
Stream Analytics
Cold Path
Azure Tables API
Device & Command
Registry
Command Feedback
Pump
Device & Command
API
Tenova WIDE
Future Machines
Current Machines
Event Hub
WebJob
Long TermBlob Storage
Stream Analytics Azure Tables API
Warm Path
Raw data
AdministrationPortal
Hot Path
Azure Active Directory
ConfigurationAPI API
Azure ML ServerData Factory Data Lake
ML Service
Rules engine
30 September 2019Tenova S.p.A. | Confidential & Proprietary 11
Machine Learning SimplifiedA «NEW» PARADIGM FOR SOFTWARE
Traditional Software
Machine Learning
Data
Rules(program)
Data
Results
Results
Rules(model)
30 September 2019Tenova S.p.A. | Confidential & Proprietary 12
Predicting NOx Emissions with Neural NetworksWALKING BEAM FURNACE, 2008
Walking Beam FurnaceTKS Duisburg
30 September 2019Tenova S.p.A. | Confidential & Proprietary 13
Predicting NOx Emissions with Neural NetworksWALKING BEAM FURNACE, 2019
RMSE Train Set 21,6RMSE Test Set 23,4 RMSE Mean 31,5RMSE Median 31,0
MAE Train Set 16,0MAE Test Set 18,3 MAE Mean 25,6MAE Median 25,1
30 September 2019Tenova S.p.A. | Confidential & Proprietary 14
Predicting Steel Temperature in BOF FurnaceBASIC OXYGEN FURNACE
Error on the test set:RMSE of new predictive model: 30,6 degFRMSE of deterministic model: 45.5 degFRMSE Average Improvement: 30%
Data for approximately 4000 heats:Predictions with error >50 degF reduced by 50% to 10%
Static Charge Model for BOF developed by Tenova Canada: Deterministic Mass/Energy Balance model to calculate input materials (HM,SC,..) and blowing Oxygen to reach steel end point Goal to improve final temperature prediction accuracy for better use of fuel/coolant additions
OUTPUT
30 September 2019Tenova S.p.A. | Confidential & Proprietary 15
ORI Martin Lighthouse ProjectORI MARTIN – LIGHTHOUSE PROJECT
Automatic Classification of ScrapCategory from Images
Using Convolutional Neural NetworksTraining on 20000 images, 9 categories
30 September 2019Tenova S.p.A. | Confidential & Proprietary 16
Smart MachineVISION FOR THE FUTURE
Live data (sensors)
Historical Data (Analytics)
PredictiveMaintenance
Self-Optimizing Machines
The Future is Digital
30 September 2019Tenova S.p.A. | Confidential & Proprietary 17
VISION FOR THE FUTURE
«Every Business is a Digital Business»Satya Nadella, CEO Microsoft
«Go Digital or go Home»Dieter Zetsche, ex CEO Daimler AG
Artificial intelligence is a new form of talent, companies won’t be able to compete without it
30 September 2019Tenova S.p.A. | Confidential & Proprietary 18
Digital Transformation DilemmasLESSONS LEARNED
Products versus ServicesIoT & Sensors versus Digital Strategy
Exciting Technology versus Customer ValueReturn on Investment versus Leap of Faith
Cost of Investing versus Cost of Not InvestingPredict and Control versus Learn and Adapt
Internal Digital Team versus Outsourcing Digital ProjectsDigital Team versus Digital Organization
Alone versus PartnershipsBacklog versus Innovation
Share versus Hidehttps://www.linkedin.com/pulse/30-dilemmas-digital-transformation-giovanni-bavestrelli/
30 September 2019Tenova S.p.A. | Confidential & Proprietary 19
Lifelong learning is here to stayHUMAN LEARNING