Learn how to prevent disruptions like slopping, tap hole blockage, metal strip breaks, and more!
Our client is one of the 10 largest steel producers in the world. Its operations and commercial presence extend across the globe. The company offers several downstream products and has production facilities for wires, tubes, bearings, agricultural equipment and industrial by-products. The company employs more than 65,000 people worldwide and generates total revenues of 31.6 billion euros per year.
Unwanted reactions in the molten metal led to process disruptions, environmental pollution and endangered occupational safety. Managing the consequences (metal slopping) is a challenge even for the most experienced operators. Reaction prediction is the most convenient way to ensure a safe environment and avoid production downtime.
Our client used Process Booster to predict and prevent disruptions (slopping). Process Booster can interpret and monitor large amounts of data to warn users before disruptions occur. Its powerful AI is able to process many complex data points in near real-time.
Process Booster allowed our client to understand the causes of disruptions (slopping) and predict them up between 1-2 minutes in advance. Process Booster was able to predict more than 54% of disruptions. The estimated cost savings amount to at least 2.4 million euros per furnace per year. It also enabled our customer to better comply with environmental regulations.