Operational Experience with Process Automation Upgrades at Arrium-Onesteel Rolling Mills

by Frank Model

Publisher - Rolling Technology, OneSteel, Melbourne, Australia Rolling Technology, OneSteel, Melbourne, Australia

Category - Engineering & IT

The Rod & Bar manufacturing footprint of OneSteel consists of 3 classical Mini Mills with 3 Melt Shops and 5 Rolling Mills. The focus is on optimising product mix, using synergies and improving Manufacturing Excellence. A concept defining priorities and projects had been developed in 2010 based on comprehensive auditing of all mills by a team of international experts. This presentation provides information and examples of process control upgrades carried out in collaboration with GEVA automation in order to: • Increase throughput and yield • Improve availability • Reduce cobbles and downgrades • Minimize cycle times of equipment • Improve process transparency and operator interactions In 2013 OneSteel had awarded GEVA automation with the upgrade of the mill control systems at their Bar and Rod Mill in Melbourne. The 2nd. Part of the presentation informs about the Upgrade of the Laverton Bar Mill (LBM) control system: • Scope and targets of the project • Project results The Upgrade of the LBM control system resulted in • Reduction of capacity loss time (sizing, cobbles, re-rolling downgrades) by 50% • Reduction of cobbles by 50% • Reduction of downgrades by 70% Examples show the huge potential of upgrade projects and share the success factors. The Rod & Bar manufacturing footprint of OneSteel consists of 3 classical Mini Mills with 3 Melt Shops and 5 Rolling Mills. The focus is on optimising product mix, using synergies and improving Manufacturing Excellence. A concept defining priorities and projects had been developed in 2010 based on comprehensive auditing of all mills by a team of international experts. This presentation provides information and examples of process control upgrades carried out in collaboration with GEVA automation in order to: • Increase throughput and yield • Improve availability • Reduce cobbles and downgrades • Minimize cycle times of equipment • Improve process transparency and operator interactions In 2013 OneSteel had awarded GEVA automation with the upgrade of the mill control systems at their Bar and Rod Mill in Melbourne. The 2nd. Part of the presentation informs about the Upgrade of the Laverton Bar Mill (LBM) control system: • Scope and targets of the project • Project results The Upgrade of the LBM control system resulted in • Reduction of capacity loss time (sizing, cobbles, re-rolling downgrades) by 50% • Reduction of cobbles by 50% • Reduction of downgrades by 70% Examples show the huge potential of upgrade projects and share the success factors.

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