Fangda Jiugang and Tupu Software: Digital Twin Smart Steel Plant

foreword

The steel industry is a multi-tool and long-process process industry. In the traditional production process, various chemical reactions, physical changes and important parameters inside the production equipment cannot be seen from the outside. Only through big data, full connection and full collaboration Only by breaking through data silos can the transformation and upgrading of the entire industry be accelerated. Because of this, the steel industry has the most abundant and complex application scenarios for 5G+ Internet. Fangda Jiugang Company has taken the lead in exploring 5G+ industrial Internet.

Fangda Jiugang Co., Ltd. focuses on the needs of the transformation of the management model of iron and steel enterprises, takes advantage of the opportunity of green and low-carbon transformation of energy, and takes the extensive application of information technology as the leading force to vigorously promote "smart manufacturing" and "quench" smart steel. In cooperation with Tupu Software, it took the lead in introducing 5G, visualization and GIS related technologies into the steel industry. Build a smart steel dispatching platform based on 5G + cloud platform, enable high-quality development of enterprises with intelligent management and control, seize new opportunities for digital and intelligent transformation, and promote the green, low-carbon and high-quality development of the steel industry.

Show results

Relying on the self-developed HT for Web product, Tupu software visually displays multiple production lines of Dajiu Steel from the three dimensions of digital twin animation, process flow chart and cockpit. Turning "numbers" into "things", integrating the six iron-making processes and dozens of business system data originally distributed in the area of tens of thousands of square kilometers. Every time a rail is produced, its logistics and information flow will be matched in real time, and process quality data will also be monitored online in real time.

The three-dimensional scene data of the steel plant is obtained by aerial photography modeling. Multiple sensors are used on aircraft or drones to photograph and collect ground objects from five directions, front, rear, left, right and vertical, so as to quickly and efficiently obtain data that truly reflects the situation of the steel plant. information. Through a series of internal processing operations such as correction, adjustment, and multi-view image matching, the 3D model is finally obtained. The result data of aerial photography modeling has geographic coordinate system information, which can be accurately matched with GIS.

System analysis

How the Steel Was Tempered

In the production scheduling room of Fangda Jiugang Company, it is completely different from the traditional production monitoring. In addition to the real-time display of industrial cameras, there is also a real-time display of 3D simulation full-process animation created by Tupu software on the big screen. The 3D simulation animation can display all units, equipment status and production status of the production line in real time. And display important production and quality data on the right 2D panel. Click the "Home" button in the scene to automatically pop up, displaying real-time production, inventory and shipments, raw material procurement, environmental protection data and energy systems. Cooperate with the real scene to give all dispatchers more comprehensive production information.

Aiming at the problem that traditional rail quality inspection can only detect multiple defects in the subsequent cold state, Tupu software builds a steel plant quality control system through the application and mining of all process data, quality data and equipment data on the production line. If problems are found, they can be corrected in real time to avoid more losses.

Safety production has always been an important topic in steel production. The lightweight 3D indoor positioning and electronic fence visualization system constructed by Tupu software (click the link to jump to the relevant page), the front can display a realistic scene of a modern factory. The indoor positioning includes the real-time position of the factory workers, the range of the electronic fence, The safety situation on site, etc., help us to intuitively understand the safety situation of the current factory personnel.

Intelligent management and control of raw material yard

After the raw materials are unloaded from the wharf, they are transported to the raw material yard by belts. The Tupu software is connected to the key equipment of intelligent unloading on the tank and the main belt of the blast furnace, and collects the inventory, type and location data of each material in the raw material field in real time, and realizes all-round three-dimensional monitoring of raw materials.

The HT engine of Tupu software restores the layout of the raw material factory, transfer station, material stacking situation, etc. 1:1 according to the actual scene, and the 2D panel is linked to the 3D scene to display the iron ore, solvent, fuel and other stockpiling parameters of the raw material factory in real time. It supports the roaming of simulated drones or pedestrians, and can browse the raw material factory in all directions without dead ends. When passing through the equipment, the information of mixed ore, coke powder, coal, first-mix and second-mix mixture will be automatically popped up. In the dispatching hall, the business personnel can grasp all angles of the tens of thousands of square meters of raw materials, each equipment, the entry and exit of various raw materials, and the usage in real time.

At the same time, in the cockpit, key information such as raw material pressure, entry into the factory, and cost is presented in a 2D configuration panel, and the time dimension switching function is provided to see the development of data.

Sintering Smart Control

The sintering process is one of the main production processes in the iron and steel industry, including major processes such as fabric, ignition, and sintering. Its energy consumption accounts for about 23% of the total energy consumption of iron and steel production. Realizing the intelligent control of energy consumption in the sintering process is an important way to reduce the energy consumption of the process. The system connects the data interface according to the demand, and visualizes the device and transmission animation of the sintering machine. Users can intuitively view the equipment and materials of the process production line through the three-dimensional scene, such as sintering machine, ring cooler, etc. The 2D panel focuses on the furnace temperature, furnace pressure, speed and current of the sintering machine. The business personnel can analyze and predict the energy consumption of the sintering process according to the data, which is convenient for the accurate processing of the subsequent process.

Intelligent management and control of iron making

The HT engine of Tupu software can model with high precision according to CAD drawings, bird's-eye views, and three-view equipment. In 1:1 reduction, iron ore, coke and flux are added to the furnace from the top of the blast furnace, and then blown into the furnace by the blower nozzle at the bottom of the furnace. High-temperature hot air produces reducing gas, reducing iron ore, and producing molten iron and slag. Each process adopts a number of intelligent technologies, which greatly improves production efficiency and ensures production safety. Combined with the blast furnace overhaul project, increase the application of on-site robots to achieve less and unmanned production operations and equipment operations.

Intelligent monitoring of temperature of hot blast stove and blast furnace body

Blast furnace visualization technology is a new technology for monitoring charging and smelting conditions in blast furnace and for guiding blast furnace operation. Tupu software performs 3D modeling according to the blast furnace process layout. The entire furnace body, furnace shell, pipes, etc. are considered translucent shells. Through the translucent furnace shell, you can see the furnace base refractory materials and water-cooled wall materials, which are all color-changing materials. Block material corresponds to 1 temperature measurement point. The three areas of blast furnace body, furnace top hoisting and charging, and hot blast furnace are mainly displayed, reflecting the real-time material state and gas state.

By connecting infrared temperature measurement sensors, optical fiber temperature measurement, furnace top cameras, thermal imagers and other equipment, online real-time monitoring of the working conditions of pipelines and equipment can be performed. Differential pressure at each point of pipe flow and furnace body static pressure purging. The 2D panel displays CO, CO2 mass fraction, coke ratio, gas flow rate, furnace top pressure, and gas permeability parameters in real time, and supplemented by a line graph, real-time display of the real-time data change trend of furnace top cross temperature measurement, so that operators can timely understand the airflow in the furnace Changes in distribution and furnace conditions, and timely detection of abnormal conditions in the furnace, so as to actively control the operation of the blast furnace.

Tupu software also built a three-dimensional heat map monitoring system for the blast furnace body and a visualization system for the blast furnace ironmaking plant. The 3D heat map system dynamically presents by reading the real-time incoming thermal sensor data from the back end, and provides a thermal range adjustment function, which can adjust the thermal performance under different peaks as needed. Using this method to generate the furnace body saves the process of 3D designer modeling, and can generate furnace bodies of any size and height in a data-driven way.

The 3D visualization scene of a blast furnace in an iron plant presents the basic operation process of a blast furnace iron plant and the animation of the molten iron tanker transporting steel through a lightweight model. With the surrounding roaming effect, it can monitor the status changes in an all-round way in real time. On the 2D panel, some important early warning data of yesterday's history and today's real-time are presented, which can play a role in real-time monitoring in management and control.

Intelligent inspection and platform maintenance

The traditional methods of hot metal transportation are all manual, the information communication is slow, and the post work is labor-intensive and has certain risks. In addition, the traditional way of transportation by small trains takes about half an hour, and the heat loss of molten iron is too large, which is not conducive to energy saving and emission reduction. Tupu software integrates the remote control and intelligent dispatching system of molten iron tanker with 5G technology, which realizes precise control of the temperature drop of molten iron tank, and realizes the seamless connection of the whole process of molten iron logistics, time flow and information flow from ironmaking to steelmaking. Open the era of intelligent management and control in which the operation efficiency of molten iron tanks is comprehensively improved.

Smart Steelmaking Control

Steelmaking process monitoring The whole process information of molten iron and molten iron tanker from the molten iron pretreatment station to the rolling production line is monitored through the HT 3D effect of the Tupu software, and the information of the converter, LF refining furnace, continuous casting machine and other equipment status is monitored. Twin steelmaking process integration scene. It enables digital visualization of the whole process of steelmaking, intelligent decision-making, and interactive integration of information systems in each link.

On the basis of MES system platform, secondary development of ladle maximum capacity monitoring function, online monitoring of ladle information, including ladle age, heat number, status, weighing, temperature, etc. Real-time viewing of data, etc. Avoid the occurrence of process accidents due to the failure to obtain abnormal information such as over-thickness and over-standard ladle in time, and adding molten iron according to the normal operation. It provides convenient and reliable data support for the next process, and helps the safe and stable operation of steelmaking and smelting.

Converter visualization

The operation of adding raw materials such as molten iron or steel scrap to an electric furnace or converter is the first step in a steelmaking operation. The Tupu software restores the converter model 1:1, and the user can view the details of the converter according to the roaming perspective. The smelting status, planned steel grade, oxygen opening time, feeding time, molten iron weight and other data are connected to the HT 2D panel of the Tupu software to help business personnel determine the amount of furnace steel auxiliary materials, improve the refractory material at the tapping port, and reduce human factors Damage to the tap hole.

LF refining furnace visualization

The LF refining furnace is the key link in the steelmaking process and is used for molten steel refining, molten steel temperature control and adjustment of production processes and rhythms. Through the 3D high simulation model effect of Tupu software, digital twinning of the external structure of the refining furnace, operation and heating, desulfurization, deoxidation and alloying, and integration of the robot automatic temperature measurement and sampling system, the 2D panel can display the real-time information of the refining furnace according to requirements, including Furnace cover return water flow, total water inlet pressure, furnace cover inlet water temperature, variable pressure gasoline temperature, furnace cover inlet water temperature, electrical degree, secondary arc flow, etc. Effectively solve the restrictive factors such as high temperature in the production process and the inability to automatically collect key parameters of process equipment in dangerous areas.

Smart Steel Rolling Control

By relying on Tupu software visualization technology, rolling process management can digitally display continuous casting, hot-rolled steel, wire rod production processes and other processing processes in 2D configuration and 3D simulation form.

Continuous casting production visualization

Continuous casting operations are the process of converting molten steel into steel billets. Tupu software relies on the HT engine to digitally twin the continuous casting production process and equipment, and realizes a continuous casting production system with 1:1 scene restoration: the molten steel processed by the upstream is transported to the turntable in ladle, and divided into several parts by the molten steel distributor. The strands are respectively injected into the casting molds of specific shapes, and they begin to cool and solidify to form a casting embryo with a solidified shell on the outside and molten steel on the inside. After straightening, it is cut into pieces according to the length of the order, and after the surface treatment of the steel billet, it is sent to the rolling mill for rolling.

The 2D panel is linked to the three-dimensional scene, and the information of the middle package, the equipment and the temperature of the embryo pulling equipment is displayed in a unified manner, which helps the business personnel to break through the limitation of the heating billet temperature measurement technology, and intuitively and accurately reflects the heating state of the billet, providing a basis for real-time tapping.

Hot rolled steel production visualization

Hot rolling is to heat the material during or before rolling, and it is generally heated to above the recrystallization temperature before rolling. The final rolling temperature has an important influence on the microstructure and properties of the steel. Through the visualization of Tupu software, the production line of hot rolling production equipment is made more transparent and clear. It integrates the principle of infrared temperature measurement, and combines the information of the HT 2D panel of Tupu software to display the heating and temperature information of the materials in the heating furnace, including the temperature of the heating section and the temperature of the heating section. , the temperature of the second heating section, and the coal-to-air ratio, gas flow, and air flow of the heating furnace. Help business personnel work accurately.

Wire production process visualization

Through the high simulation model effect of the Tupu software HT 3D, digital twinning of the wire rod production process: the production operation of the wire rod workshop is to heat the small steel billets in the heating furnace, and then pass the rough rolling mill, intermediate rolling mill, finishing mill, reducing forming. It is rolled by machine, then coiled and formed by a coiling machine, and conveyed by a cooling conveyor belt, and then sent to the finishing area for finishing. Through the docking data interface, Tupu software realizes the real-time status display of the whole process of wire rod production in the scene, and forms a visualization of the wire rod production process, supplemented by data such as current, actual speed, and line speed. It is convenient to analyze various indicators in the production process, and managers can coordinate and coordinate all parties through the platform without going to the site.

Logistics visualization

From the delivery of steel to the harvest, the intermediate logistics link is now more and more valued by customers. They not only hope that the steel can reach their hands in time, but also want to know where the steel has gone during the entire transportation process. The HT engine of the Tupu software integrates the intelligent vehicle terminal and vehicle management system. In the scene, vehicle scheduling, vehicle tracking, operation monitoring and transportation performance can be displayed in real time. The 2D panel accesses information such as the total number of vehicles, total weight and weight, etc., to guide the driver to carry out materials. Operations such as transportation and metering.

After the operation is completed, the vehicle terminal will feed back the actual transportation operation performance information and GPS location information to the visualization system. Assist in solving the problems of low visibility of steel logistics management, inability to scientifically and rationally carry out transportation stowage, high empty rate of vehicles, and low transportation efficiency.

Flow chart

Tupu software analyzes the process through a large amount of data on site, integrates the overall scene of Fangda Jiugang Iron and Steel Plant, as well as important processes such as sintering, iron making, steel making, and steel rolling. And through the self-developed HT for Web powerful 2D and 3D rendering engine, through the construction of scenes and animation drives, a digital mirror image that is symmetrical with the working principles of iron and steel making is produced. Provide more detailed and in-depth data for production, operation and decision-making, and optimize all aspects of iron and steel production and operation.

Compared with traditional configuration software such as InTouch/IFix/WinCC, Tupu's web-based platform is more suitable for the general trend of C/S to B/S transformation. The multi-element rich visualization components and fast data binding methods are available. for rapid platform creation and deployment.

Overall view

The interface contains the output information in the production process. The main scene shows some equipment models that need to be used in the ironmaking and steelmaking process, as well as the production route from the raw material factory to the high-end finished product. The scene also has interactive functions with the drawing buttons, including separate viewing of the four processes of sintering, ironmaking, steelmaking and steel rolling. And display the data overview of the monthly and daily unit data of the whole site to strengthen production communication and coordination. The system settings also set two modes of wireframe and solid, click the corresponding button to switch interactively.

Sintering process

Sinter animation process, including animation of a series of operations from ore to sinter. The data and flow chart show the operation and material ratio of the entire sintering system, as well as the data information such as the temperature and pressure of the flue and furnace, so as to optimize the production process. The two-dimensional configuration system created by Tupu software HT supports access to the corresponding camera video screen according to the actual point of the on-site camera, and realizes the restoration of the sintering scene. Realize the detection and query of the equipment operation status related to the sintering process. Once the equipment operation status of the video monitoring system is found to be abnormal, it will automatically send a fault alarm to the operation and maintenance management center.

Ironmaking process

The ironmaking process is essentially the process of reducing iron from its natural form, iron-containing compounds such as ore. Tupu software relies on its multi-element rich visualization components to provide a clear and beautiful 2D visualization service mode for the ironmaking process. The hot blast stove and blast furnace are presented in a two-dimensional configuration diagram, and the 2D configuration panel is connected to the amount of iron and the furnace. Data information such as temperature and pressure, inlet temperature and pressure, thereby helping to reduce energy consumption and reduce costs.

steelmaking process

The display of the steelmaking process is to facilitate the management personnel to understand the layout of the steelmaking equipment. The two-dimensional configuration diagram shows the equipment and partial sections, so that the molten iron injection situation of each equipment (including the converter, ladle, LF refining furnace, and embryo drawing equipment) can be expressed in detail, and managers can also more intuitively from here. View real-time information of all devices, and multiple device information is presented in one image, no longer cluttered.

Steel rolling process

Steel rolling is a pressure processing process that changes the shape of steel ingots and billets between rotating rolls. The Tupu software integrates the temperature data of the billet in the rolling raw material field for the limited steel types in the furnace, and at the same time connects the existing MES system, draws a two-dimensional configuration of the rolling mill equipment working model, adds the visualization function of the temperature control of the raw material billet, and monitors the billet entering the furnace. Precise temperature control improves the working efficiency of the rolling mill and effectively increases the ratio of hot charging.

Data Cockpit

With the maturity of computer technology, the information construction of my country's iron and steel enterprises has developed rapidly. At the same time, more and more data are accumulated by enterprises, and the explosive growth of data in iron and steel enterprises contains huge commercial value. However, in the face of massive data of customer consumption behavior, traditional large-scale server-based data warehouse and data analysis technology cannot meet the application transformation requirements of heterogeneous data source data.

Based on this, Tupu Software has developed a unified, fast-response, multi-dimensional, in-depth and intuitive display of product sales, finance, procurement, and logistics analysis systems that aim to improve the reusability of data resources. The relatively complex and abstract data of the steel plant is displayed in a visual and interactive way, so as to express the information and laws contained in the data visually and intuitively. Managers can intuitively monitor the operation situation as if they were facing the dashboard in the cockpit of a car, and give early warning and mining analysis to abnormal key indicators.

Use visualization technology to analyze the huge sales data of iron and steel enterprises, and make correct decisions based on the analysis results. Achieving the overview first, zoom and filter on-demand to see the details of the effect. The color scheme is dominated by dark tones, focusing on the consistency of the overall background and the background of individual elements. Users can read the hierarchy and association of data within a simple page.

Sales data visualization

The sales cockpit conducts combined analysis of data from different dimensions to ensure that management can have a more comprehensive grasp of the company's various indicators. The sales section is displayed in the style of a digital map, which can dynamically display the growth of sales amount in each region according to the sales time. Supplemented by a line chart to show the sales trends of coke wastewater, molten iron, Australian mines, etc., the online price rankings are displayed in a rolling manner. Realize multiple users, different permissions and different operations, so that all management levels can view the indicators they care about. Sales staff can quickly grasp the required data characteristics through the mobile phone portal.

Financial Information Visualization

Tupu software converts the information hidden in the data into pictures directly in front of customers through graphics or lines, which is concise and reliable, and can better adapt to the needs of different users, helping people to quickly understand and master it. The financial section covers annual sales revenue, asset scale, technology R&D investment, safety production investment, total tax payment, public welfare donations, etc., and is displayed through rich data tables to express abstract data concretely.

Purchasing Information Visualization

In the procurement section, through appropriate layout, the user's attention is focused on the most important areas in the visualization results, including the entry of raw materials, the entry of imported mines, the entry of coke, the entry of scrap steel, and the trend of futures. In this way, important data information can be highlighted, the user's attention can be captured, and the efficiency of user information interpretation can be improved.

Logistics information visualization

The logistics section adopts a semi-package layout scheme, showing the accumulated cost of the logistics project on the day and the month in the middle, and displaying special indicators on the left and right and below, so as to clearly display all logistics indicators and avoid redundant elements that are too complicated or affect the effect of data presentation. Extend the coverage of the company's logistics informatization through information data sharing.

palm mill

In order to solve the problems of delayed production data, cumbersome process of viewing historical data, and single query method, Tupu software uses digital Kanban to add mobile phone portals, allowing employees to view and understand production data anytime, anywhere. Break the boundaries of time and space, understand production dynamics through mobile phones in real time, and master production changes. Greatly improved the work and management efficiency of the steel plant.

Realize value

Centralized management and control of steel plant equipment

The easiest way for people to understand information is images. Tupu software intuitively displays the three-dimensional structure of the steel production line equipment through visual means, presents each production line of the steel plant in a unified manner, and intuitively reflects the information of each equipment, which is conducive to the monitoring of the steel production line equipment and timely detection of equipment problems. And carry out maintenance, thereby reducing losses, improving the maintenance efficiency of the production line, and realizing centralized equipment control.

leadership cockpit

The leadership cockpit is a management information center system that provides "one-stop" decision support for top management. Tupu software sorts out and integrates the process and data characteristics of Fangda Jiugang's sales business, financial information, procurement information, logistics information, and project information in a cockpit manner, and realizes real-time and batch data processing, data analysis, reporting and visualization, etc. Function. It provides strong support for enterprises to strengthen the integration of business and finance, management analysis of the whole life cycle and panoramic display of project profit and loss, realizes the data at the enterprise management level, and significantly improves the efficiency and level of sales management.

Improve work efficiency

Tupu software provides the steel production process with the creation of a 2D configuration process, providing graphical annotation to operators. They can quickly understand the task content and become proficient. This avoids production delays and improves work efficiency.

Web GIS Aerial Oblique Photography

The OSGB model data of aerial photography modeling has multiple levels of detail (LOD), and the system can display LOD level models with different precisions according to the user's browsing time and the distance of the scene, improving the efficiency of data display and rendering.

The integrated solution of HT and GIS can provide roaming routes based on latitude, longitude and altitude data, allowing users to inspect and roam the steel plant area according to the specified route from a first-person perspective. High-level areas are formulated to present users with key development areas of iron and steel plants and the effectiveness of intelligent development.

Summarize

The digital economy has become the main line of global economic development, driving the digital and intelligent transformation of various industries and the whole society. Tupu Software adheres to innovation-driven, and accelerates the process of "steel intelligence" through advanced technological innovation. The iron and steel smart solutions integrating 5G, cloud computing, big data, edge computing and other technologies can effectively solve the industry pain points existing in the production of enterprises, and have significant effects in improving production efficiency, reducing production costs, and ensuring personnel safety. Jiugang realizes intelligent upgrade to provide comprehensive acceleration.

For more industry application examples, please refer to the case link on the official website of Tupu Software: https://www.hightopo.com/demos/index.html