Professional Documents
Culture Documents
and Management in an
Ironmaking Process
Abbie DiDonato
Senior Technical Specialist
Essar Steel Algoma Inc.
Businesses
Essar Group
Shipping Ports
Steel Energy Power Communications Projects
& Logistics
Essar Steel Ltd Essar Oil Essar Power / Vodafone Essar Essar Shipping Essar Construction
4.6 MTPA integrated 12.5 MTPA refinery Bhander Power 60 million subscribers Fleet of 26 vessels, - Engineering
steel plant complex 1,015 MW combined DWT of 1.49 mn - Procurement
cycle Essar Telecom - Fabrication
Essar Steel (Hazira) Over 1,200 retail Infrastructure Vadinar Oil Terminal
4 MTPA integrated outlets 3,500 telecom towers - Construction
Vadinar Power Terminal facility of 32
steel plant 125 MW co-generation; operational; 20,000 MTPA – Liquid Cargo
(under implementation) Refinery expansion to expanding to 1250 MW planned by 2010 Fully geared to execute
34 MTPA in two Bulk Terminal turnkey EPC jobs in
Essar Steel Orissa phases Essar Power MP The MobileStore Dry bulk port facilities India and overseas
6 MTPA pellet plant 1,200 MW coal based Over 1,300 outlets
(under implementation) Exploration & (under implementation) operational; 2,500 Essar Oilfields Essar Offshore
Production Assets planned by 2010 A drilling company with Subsea
Algoma Steel, Canada E&P rights in valuable Essar Power Gujarat 13 rigs Expertise in marine
4.0 MTPA integrated oil & gas blocks in 1,200 MW coal based Aegis - BPO construction
steel plant India and abroad (under implementation) 30,000 people in offices Essar Logistics
in the Philippines, Costa Owns and operates Heavy Engineering
Minnesota Steel Essar Power Rica, USA and India transshipment assets Services
6 MTPA pellet plant Jharkhand
(planned) 1,200 MW coal based BPL Mobile
(under implementation) More than 1.8 million Project Management
1.4 billion tonne iron subscribers Consultants
ore reserves
Asia’s largest
PT Essar Indonesia equipment bank
0.4 MTPA cold rolling
complex
Essar Global Steel
Fully integrated producer from iron ore to ready-to-market products
Steel
INDIA
ESSAR STEEL LTD
Energy 4.6 MTPA integrated
steel plant
Communications OVERSEAS
ESSAR STEEL ALGOMA,CANADA
4 MTPA steel complex
Shipping, Ports & ESSAR STEEL MINNESOTA, U S A
Logistics 6 MTPA pellet plant (under implementation)
1.5 billion tonne of iron ore reserves
INDONESIA
Projects 0.4 MTPA Cold Rolling complex
Essar Steel Algoma Inc. (Canada)
• Established in 1901 - 108 years of steelmaking tradition
• Situated in Sault Ste. Marie, Ontario on 2000 acres at the hub of the Great Lakes
• 70MW Cogeneration Facility – commissioned in June, 2009
30 + Interfaces
PI Deployment History
• Ironmaking (1998)
• Cokemaking (2003)
• Steelmaking (2004)
• Utilities (2004)
• Slabcaster (2006)
Ironmaking
– Contributed to the Blast Furnace re-line extension
from the traditional 7 year reline cycle to 12+ years
Utilities:
– Minimize natural gas usage by lowering Plate & Strip
fuel demand when cogen gas supply is limited.
• Goal is to reduce Plate & Strip natural gas
usage by at least 20 % or ~ $680,000 per
year.
• Custom Development?
– Pros/Cons
• Purchased Software?
– Pros/Cons
We make Steel …
We are NOT a software development company…
Proof of Concept Trial
Iron
Assignment of Production,
Downtime
categories, delay and
events
cause codes and quality events
using PI
associated data from TCT
Performance Monitoring
#7 Blast Furnace Operating Conditions
Logging Performance Loss Events
R
a
t
e
$$ Production Loss =
L
o
s
s
Logging Production Events
Logging Quality Events
Communicating Performance
Communicating Performance
Proof of Concept Trial Results
• Production • Energy
• Quality • Safety
• Equipment Utilization & • Environmental
Availability
• Raw Material Utilization
/ Yield
Performance Management Model
Consists of the two basic components which follow the common OEE
model
•Percentage Model
– Using KPI specification sets; managed across production unit
and product groupings
– Process data is rationalized into ‘Performance Percentage’
– Indices provide consistent measures of performance over
time and product production
– Results in a relative index of performance over time showing
trends of improvement or deterioration.
Performance Management Model
SAP Integration
Ensuring a Single
Version of the Truth
Challenges Moving Forward