Jahresarchiv 26th November 2018



Model-based optimisation for efficient use of resources and energy.

Initial situation

  • Process industry is continuously looking for new ways to improve resource efficiency
  • Model based control systems are established for the single process units
  • Integration of unit control systems into plant wide coordinated optimisation applications taking into account also overlying logistic constraints, optimisation criteria and production targets can increase savings in   energy and raw material consumptions

Working points in the project

  • Plant-wide analysis of all material and energy flows in order to identify the bottlenecks and main potentials for savings in energy and resource consumptions
  • Adaption and enhancement of single unit components for real-time monitoring and control along the production route, especially regarding a coordinated optimisation of the phases with high potentials for energy and resource savings (like electrical heating, oxygen refining, chromium oxide reduction)
  • Integration of components into a comprehensive, through-process control system with the help of a suitable framework with common interfaces and communication structures
  • Validation of integrated approach for optimisation of resource efficiency within three use cases for carbon steel, stainless steel and cast steel

The project started at October 1st 2017 and ends at September 30st 2021. Involved partners in the research are:

VDEH-Betriebsforschungsinsitut GmbH
Cybernetica AS
GRIPS Industrial IT Solutions GmbH
Maschinenfabrik Liezen und Gießerei GmbH
SW-Development OY
Teknologian tutkimuskeskus VTT OY
Horizon 2020

Expected results

Model-based offline and real-time optimisation tools for the whole process route to increase overall energy and resource efficiency as well as product quality in production of high-strength carbon steels, stainless steels and cast steels.

The research has received funding from the European Commission, funding reference Horizon 2020 (H2020) / SPIRE-07-2017 / 768652.



Cyber-Physical Production Optimization Systems for Long Production Factories

Cyber-POS project abstract and objectives

Production technology in steel industry has reached a level that significant improvements can only be reached by through process optimization strategies instead of improving each process step separately. Therefore the connection of suitable technological models to describe process and product behavior, methods to find solutions for typical multi-criterial decisions and a strong communication between involved plants becomes mandatory. Cyber-POS will develop a virtual simulation platform for the design of cyber-physical production optimization systems (CPPS) for long production facilities with special emphasis to thermal evolution and related material quality, leading to reduced energy consumption, shortened production time and improved product quality.

The main objectives within this project are:

  • Optimization of throughput and reduction of energy consumption for the production of complex profiles in Mannstaedt’s hot processing line and
  • Optimization of material quality and properties for rail mills at ArcelorMittal España.

This is achieved by applying the developed software and methods for the specific use cases. This implies the following sub-objectives:

  • Virtual simulation platform for the design of cyber-physical production optimization systems (CPPS) for long production facilities; with special emphasis to thermal the evolution and related material quality, leading to reduced energy consumption, shortened production time and improved product quality;
  • Merging of process models (thermal, rolling, transport), material-quality models, logistics/scheduling models and communication models (computers, software, networks);
  • Strategies and methods for cooperative production optimization, enabling fast dynamic and flexible reaction on quality variations, critical states, measurement errors, and changes in set-points, production routes, process disturbances or interruptions;
  • New and comprehensive, model-based (simulation) software for design of CPPS for long product factories, with a cyber-physical library for “drag-and-drop” implementation.

The project started at July 1st 2016 and ends at December 31th 2019. Involved partners in the research are:

VDEH-Betriebsforschungsinsitut GmbH  
Arcelor Mittal España  
Fundación ITMA  
Mannstaedt GmbH
Scuola Superiore Sant’Anna di Studi Universitari e di Perfezionamento  

Cyber-POS project expected industrial impacts

The research has received funding from the European Union’s Research fund for Coal and Steel (RFCS) under grant agreement No. 709669.

The main motivation for introducing the methods of cyber-physical production optimization is essentially to preserve the economic performance and safety level in spite of faults and process changes that may occur over time. The CPS platform to be developed can be regarded as an assistance system that will support plant personnel/operator decisions, and thus can contribute to the improvement of working conditions. All involved processes can actively communicate with each other, know their field of activity and production conditions. The optimizations made are also more tailored to the human workforce.

Higher maintainability, reliability and efficiency of long production factories through cyber-physical production optimization will lead to improved product quality, reduced maintenance costs and decreased material and energy consumption. This will have a positive impact on preservation of natural resources, energy and environment. Needless to say, reducing energy consumption leads to reduced CO2 emissions.

At the two involved plants of ArcelorMittal España and Mannstaedt, the developed concept will be installed as assistance system and tested in the process route reheating, hot rolling and cooling. This leads to increased flexibility of process chain, higher productivity, better disturbance management and energy savings.