Enabling the

connected steel plant

Rockwell Automation process solutions for steel

BEGIN
 State of the industry

For steel manufacturers, things are changing everyday.

50 300
Trade wars are making the market more complex, a retiring workforce is
+ leaving management with a skills gap to deal with, and globally the steel
industry is operating at high rates of capacity utilization.

And these challenges directly impact every phase of the production lifecycle.
From competition and market pressures, to technology and workforce
The average age of Metric tonnes per annum of issues, things are constantly evolving. No one wants to be left behind.
major steel company excess capacity predicted
workers in the US for 2020 (globally)
Source: McKinsey
The steel industry is facing:

• Trade uncertainties
UP TO

9%
• Geopolitical uncertainties

• Sustainable operations pressures

• Industry operating at high rates of capacity utilization

• Circular economy
The steel industry generates between
7% and 9% of direct emissions the
• Skills gaps/retiring workforce
global use of fossil fuel

Source: Worldsteel

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 Operational challenges
and how they affect profitability
While a small issue on the plant floor may not seem like much, these issues can add up. Compounding on one another, it can intensely impact corporate-wide profitability.
To mitigate this? You must act ahead of times in those areas at risk.

RETURN ON CAPITAL (ROCE)

Sustainability:
Invested capital
People, environment

EARNINGS BEFORE INTEREST AND TAXES (EBIT)

Capital and cost Emissions
management people, safety

LTIFR 0.97 m/hours

2017
Cyber
attacks OPERATIONAL COSTS REVENUE

Other fixed costs Maintenance costs Production costs OEE (Performance, Material Average sales / price
(Training.. etc) (Labor, parts) (Consumables) availability, quality) produced / sold (driven by market forces)

Production yield
Energy costs raw Product innovation
Skills gap Maintenance costs Product quality
Material costs Flexible production
Downtime

Maint. dept. personnel Energy costs 40% Quality issues 40%

Labor costs: $80/h
20% all employees operational costs sales costs

Sources: Arcelor, SSAB, World Steel Association

Lost Time Injury Frequency Rate (LTIFR)

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THE CONNECTED MILL

turn data When you collect, aggregate and analyze data across

into business
operations, you can spot trends and interdependencies
that are missed when data lives in silos. With this type of

decisions information, you can make more informed decisions.

“Data has been around a long time. One of the greatest

challenges for digital transformation is actually turning it
into something useful…”
Former General Manager Rio Tinto
Kennecott and Cornerstone Capital Resources

UP TO

8
EBITDA ​margin growth if metals ​producers harness
% the ​full potential of digital transformation
Source: McKinsey

Digital twin

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 THE CONNECTED MILL TURNS DATA INTO BUSINESS DECISIONS

Enterprise systems

Enterprise Operational Intelligence: Solutions that Connected Workforce

enable better decision-making Modern digital tools help deliver better insights
and improve field experience

Third-party applications MOM/MES

Operational efficiency: Modern technologies improve performance of process, equipment, and people

Intelligent packaged power Process solutions

Smart devices

State of to meet
Solutions connected
The connected Increase
Process Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel plant
mill solutions
operationalfor operations
system design empower your upgrade with
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5 efficiency
areas of the mill PGexpansion
to 14 workforce confidence 5
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Process solutions
PlantPAx®: The modern DCS for
steel applications FPO

Steel manufacturers have a lot to keep track of during

production. Energy management, asset management and
machine safety are just a few. PlantPAx DCS is the core
system to help you achieve your production goals in a smart
way, combining several disciplines in a unified system:

System architecture Batch management

Control and I/O Information/Production intelligence
Networks and virtualization Machine safety
Engineering Process safety
Operations Model predictive control
Field device integration Cybersecurity
of project capital cost
<1%
Asset management
comes from the control
system, but it is the core
of your production

State of to meet
Solutions connected
The connected Increase
Process Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel plant
mill solutions
operationalfor operations
system design empower your upgrade with
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5 efficiency
areas of the mill PGexpansion
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 SOLUTION AT A GLANCE

Integrated visualization
HMI, ERP, WEB IP CAMERA PANELVIEW™ PLUS Divide each monitor screen Use the multi-monitor
MES, CMMS™ CONTENT USB CAMERA PANELVIEW™ 5000 and host content from various function to create low-cost
CONTENT

sources. Create an operator video walls. An open solution

station with a single 4K monitor allows you to connect to
instead of multiple smaller multiple softwares.
monitors positioned next
to each other.
CONFIGURATION

Provides secure configuration and content delivery.

CONDITION MONITORING

ASSET MANAGEMENT
OPTIMIZATION

INSTRUMENTS
VIDEO
HMI
CONSUMERS

Pull together content from multiple systems into a single operating environment.
Connect one or more monitors to a single thin client and control them all with one
keyboard and mouse.
AREAS USERS & GROUPS DEVICES

Link content to the terminal Prevent operator errors Accessible through cell
by geolocation. Only allow by only allowing access to phones and tablets to
access to screens for the relevant content. Enhance enhance employee mobility.
electrical panels from security by requiring
inside the electrical room. operators to log in with
fingerprint ID or a retinal scan.

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 Process solutions benefit each
application area of your steel mill
Process • Iron making

solutions • Casting
• Rolling mill
• Finishing lines
• Crane automation

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Process solutions
for iron making BLAST FURNACE SIMPLIFIED ARCHITECTURE

High availability DCS for PCI Stockhouse Proper Top

critical applications
An integrated process control system reduces engineering risks
and facilitates smoother operations and simplified maintenance.

Our high availability and scalable DCS is a perfect fit for iron
making and steel making processes (coke plants, sintering, pellet
plants, blast furnaces, EAF). Its open technology means you can PCI Stockhouse Proper Top
seamlessly integrate process information into your business (Pulverized coal injection)

systems, field instrumentation and third-party equipment. Hot stove TRT Gas cleaning Indirect water

This means less risk and more productivity for your operations.

An integrated system reduces

engineering risks and facilitates operations,
maintenance and operational changes. Hot stove TRT Circulation water Direct water

State of to meet
Solutions The connected Process
Increase Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel mill
plant solutions
operationalfor operations
system design empower your upgrade with
PG 2 PG 4
5 areas of the mill
efficiency PGexpansion
to 14 workforce confidence 9
PG 89 PG 20 PG 19 PG 22

CUSTOMER CASE STUDY Blast furnace
Automation system upgrade — India

CHALLENGE
• Aging control system
• Furnace capacity from 1250 M3 to 2300 M3

SOLUTION
• Migration to a PlantPAx DCS solution (redundant systems)

• Engineering services (system design, software development, control panel

fabrication, drawings, third-party communication over Modbus RTU and PROFIBUS
DP, software testing/simulation before shutdown, testing and commissioning,
system training)

RESULTS
• New furnace capacity met
• Enhanced system availability/redundancy (including better system segregation:
from five to eight areas)

• Reporting capabilities (stockhouse, charging shift, BF operation parameters,

stoves, water)

• Better production visibility (more productivity/better quality)

• Shortened startup time (with a smoother migration process)

Digital twin • Protected previous investment already made by user (I/Os)

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CUSTOMER CASE STUDY Electric arc furnace
Control system

CHALLENGE
• Upgrade the control infrastructure on three of its electric ladle arc furnaces

• Precise control of the electrode movement needed to maintain the correct

arc length

• Needed solution that was simpler than the current “black box” technology

SOLUTION
• PlantPAx DCS process automation system

• Design application replicates arc furnace control philosophy, which is based on

complex algorithmic principles

RESULTS
• Flexible solution replacing three proprietary “black box” electrode controllers

• Annual savings of £500,000/year across all three furnaces

• Ability for engineers to undertake maintenance in-house

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Process solutions
for casting CASTING MACHINE ILLUSTRATIVE ARCHITECTURE
Enhanced analytics, diagnostics Caster control Cooling Cutting

and advanced motor capabilities

PlantPAx DCS integrates seamlessly with electrical

equipment motor management and drives,
delivering an end-to-end caster solution. Establish Casting
control
Cooling Gas cutting

better operator experience with advanced HMI

displays and system diagnostic capabilities.
Strands

Integrated solutions to
ensure high efficiency

State of to meet
Solutions The connected Process
Increase Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel mill
plant solutions
operationalfor operations
system design empower your upgrade with
PG 2 PG 4
5 areas of the mill
efficiency PGexpansion
to 14 workforce confidence 12
PG 89 PG 20 PG 19 PG 22

Process solutions for casting
Embedded artificial intelligence allows optimization at the operation level

Auto-discovery Self-configuration Self-learning Self-maintaining

Immediate value The user defines AI module that Specific AI engines

from managing data the problem and plugs into the address different
at the edge the system defines backplane of needs and
the solution the controller applications

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CUSTOMER CASE STUDY
Caster
Slab caster rebuild
CHALLENGE
• Aging slab caster equipment • High downtime
• Obsolete control system • Aggressive schedule to implement
• Unreliable automatic sequences rebuilds

• Outdated schematics

SOLUTION
• Fifty-six drives, tracking via drive communication over Ethernet

• Add segment load sharing control scheme

• Convert obsolete control system to ControlLogix® Controllers and I/O; change

to distributed I/O concept

• Approximately 1000 I/O, (3) redundant ControlLogix® systems, Ethernet

communication interface to level 2, (12) control enclosures, (2) operator
stations and (4) desks and new HMIs

RESULTS
• Completed first cast six days ahead of schedule

• Successful commissioning sequence with machine builder and end user

• Minimized downtime

• Repeatable automated sequences

Digital twin • Improved troubleshooting capabilities

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Process solutions
for rolling
MILL SIMPLIFIED ARCHITECTURE
Powerful integration between
automation and power
Integrated process controls, visualization and safety combine to
create a reliable and easy-to-use solution for rolling applications.
Premier integration with smart motor control means a unified
approach for design, safety, visualization and predictive analytics. Cooling bed
Furnace Mill and finishing Services
areas
Our solution also incorporates other systems like gauge control,
production scheduling and specialty instrumentation.

Auxilary drives Strand drives Auxilary drives Auxilary drives

Reliable solutions
for steel making

State of to meet
Solutions The connected Process
Increase Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel mill
plant solutions
operationalfor operations
system design empower your upgrade with
PG 2 PG 4
5 areas of the mill
efficiency PGexpansion
to 14 workforce confidence 15
PG 89 PG 20 PG 19 PG 22

 USE CASE Rolling mill automation
Indian greenfield steel rolling mill
delivered by a global system integrator, which designs, manufactures
and markets automation systems, primarily for the metals industry

Four ControlLogix® control systems

provided the primary control for the line, communicating via 3500 I/O

Nineteen DC PowerFlex® drives

including PowerFlex 2000 A Standalone Regulators (SAR) and
control cards

Sixty-nine AC PowerFlex 755 drives

to control the roller tables, shears pinch rolls, laying forming head
and the bar and coil handling, along with four FLEX™ soft starters
for the pumps

Digital twin

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Process solutions
for finishing lines
ILLUSTRATIVE GALVANIZING PLANT
Project experience and references
in key processing/finishing lines
Power and control systems provide high-performance solutions
for complete machine automation control of processing lines:

• Drive control
• Tension control
• Welding tracking
• Process control for cleaning and coating
• Furnace process control
• Auxiliary systems control
• Data analysis (tracking of equipment performance
trends and product quality)

Reliable solutions for

Annealing & pickling line Slitting lines/Cut to length
Hot dip galvanizing line Rewind line
Plate leveler

State of to meet
Solutions The connected Process
Increase Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel mill
plant solutions
operationalfor operations
system design empower your upgrade with
PG 2 PG 4
5 areas of the mill
efficiency PGexpansion
to 14 workforce confidence 17
PG 89 PG 20 PG 19 PG 22

CUSTOMER CASE STUDY Finishing lines
Hot dip galvanizing line control system upgrade
— two lines

CHALLENGE
• AutoMax® drives nearing end of life

• AutoMax control system not expandable

• Ancillary communication systems (gauge, welder, furnace, etc.)

• Upgrade systems within narrow outage windows (12h/month)

SOLUTION
• Upgrade over 100 AutoMax drives and 5000 I/O

RESULTS
• On-time system delivery and startup across all phases causing no impact
to production

• Worked with customer engineering and production personnel to plan

all outages

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 FPO - P

Crane automation
CRANE ILLUSTRATIVE ARCHITECTURE
Automating crane applications leads to faster, Information-ready
more efficient operations and can increase the life • Predictive analytics
• Plant integration

of your equipment through real-time diagnostics

and alerts about equipment productivity.

Advanced drive systems deliver smoother and

more precise crane movement that, combined with Efficiency and safety
• Operator safety check
• Warehouse positioning guidance
automation, can enhance operational performance,
improve people safety, and reduce operator stress
and fatigue.
More performance and
less maintenance
• Antisway functionalities Precision
• Embedded device analytics • XY positioning
Bridge Trolley Hoist • Collision avoidance
• Coil positioning

Precise crane operation

• Accurate torque and speed control
• Precise positioning
• Unified drive and control integration
• Integration with warehouse management

State of to meet
Solutions The connected Process
Increase Benefits from
Knowledge driven Modernize and Design, build and
steel
the needs
industry steel mill
plant solutions
operationalfor operations
system design empower your upgrade with
PG 2 PG 4
5 areas of the mill
efficiency PGexpansion
to 14 workforce confidence 19
PG 89 PG 20 PG 19 PG 22

 Benefits from
system design to expansion

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 Process design
solutions Easy to design and configure
Streamlined workflows
Consistent project delivery
Solutions across
the lifecycle
build
Easy to integrate

sustain
Operations and maintenance centric
System-level decisions
Safe and cybersecure

improve
Scalable
Future-ready technology
Analytics enabled

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 DESIGN AND BUILD

Easy to design,
configure and integrate
Save engineering costs and
reduce commissioning hassles
• Characterized systems and validated architectures for optimal performance of
the DCS servers, controllers and required memory

• Speed ​​and ease of programming and system configuration including

preconfigured virtual templates and process libraries

• Embedded process instructions reduce system footprint, drive consistent

product delivery, and streamline workflows (reduce tasks and clicks)

• Premier integration with motor control and field instrumentation

A large blast furnace • Easy to integrate main processes with other OEMs (no data remapping)
control system can reach
10,000 I/O points Digital twin

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 SUSTAIN Improve operations
Empower operators and reduce training costs
• Graphics focused on simplicity and situational awareness allow users to
understand the state of equipment immediately.

• Real-time display of all process variables, alarms and trends provide up-to-date
information. Integrated reporting tools convert data into information on a real-
time basis.

• Multilingual support and multiple user modes cater to user roles.

• View need-to-know trends with optimized display of event information with

real-time and historical data.

• Effective alarm management directs the operator’s attention to their job.

Most positions for a continuous casting operator require approximately five years
of experience in the operation of such equipment.

Improved maintenance
A large steel company was Maintain availability in critical areas
unable to identify the root cause
• High-availability servers, controls and networks and out-of-the-box
of its blast furnace’s unexpected diagnostics for system issues.
shutdowns, leading to 28 days of • Seamless visibility of devices for asset management, motor control and
downtime for repairs. other instruments.

Source: Dayton Daily News Digital twin • Breadcrumbs highlight modules that are in an abnormal state and quickly
determine what has been changed or needs attention.

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 SUSTAIN Enable decisions at
the system level
Vast availability of in-chassis capabilities
• Artificial intelligence/machine learning

• Model predictive control

• Compute module (for custom applications)

• Embedded historian

Cyber-secure
Enhances security and compliance
with ISA99/IEC62443
• Certifications for product development

• Certifications for system components

Artificial intelligence module • Validated system reference architectures

installed at the controller level • Projects delivered by Rockwell Automation following process
and certifications for cybersecurity
mitigates slab breakouts. If a
breakout does occur, you can more
In March 2019, one of the largest aluminum producers in the world experienced a crippling cyberattack by
Digital
quickly identify the root cause.twin the LockerGoga malware. It paralyzed the company’s computer networks, forcing it to isolate plants and
switch some operations to manual.

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 IMPROVE

Scalable
Future-proof technologies
• Same system for process, equipment, large and small systems
• Easy to evolve and expand
• Open Ethernet IP uses standard open hardware/software
network infrastructure
• Analytics-enabled solutions

Digital twin

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AutoMax® , ControlLogix®, expanding human possibility®, PANELVIEW™ PLUS, PANELVIEW™
Alphabetically 5000, PlantPAx®,
list all Rockwell PowerFlex®,
Automation ThinManager
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