ABB completes melt shop digitalization project with steel company in India

Building on a longstanding relationship with JSW Steel Ltd. in Mumbai, India, ABB reported June 23 that it recently integrated its Ability Smart Melt Shop software into a wider expansion at JSW's Dolvi Works plant in Maharashtra state. Completed on schedule in March 2021, the upgrade improved the melt shop's productivity and energy efficiency by applying ABB's optimization software to the ladle and crane tracking system, crane scheduling system and thermal loss models.

This solution lets users predict target temperature for the ladle furnaces, and ensures correct superheating at the caster. It's also expected to achieve 4% faster casting speeds, save one working day per month, increase output by 24,000 tons per year, and increase JSW’s earnings before interest, taxes, depreciation and amortization (EBITDA) by about $2 million per year.

“Our performance testing data showed increased superheat compliance, saved more than nine hours per month, and produced nearly 2,000 tons more per month,” adds Amit Kumar Chakraborty, project manager for metals at ABB.

Beyond real-time tracking of steel ladles for process synchronization and better maintenance planning, Ability Smart Melt Shop software will give JSW benefits in wider areas. These include reducing energy consumption, fewer consumables used per batch, and a smaller carbon footprint with less CO₂ produced per ton of steel. The plant's automatic tracking and scheduling also increases personnel safety because staffers aren't in the production area when the crane and ladle is moving. The scheduling solution also reduces tapping delays by ensuring movements are synchronized with process requirements. Other benefits of the ladle-tracking system include reduced tapping delays in the electric-arc furnace, reduced electrode and power consumption at the ladle furnace, and reduced silicon deviation in hot-rolled coils produced from slabs by the continuous caster.

“We relied on the metallurgical expertise of ABB’s metals team because they proved to us this digital solution could be integrated into our complex plant with its diverse procedures,” says Gajraj Singh Rathore, president at JSW. “The figures and the results from testing stacked up, and we could see the capacity to enhance productivity, improve energy efficiency and generate a relativity quick return on investment, too.”

Tarun Mathur, global product manager and digital lead for metals at ABB, adds: “Based on advanced digital algorithms and mathematical modeling, Ability Smart Melt Shop is a true example of technology convergence because it uses cameras and image-processing, weighing systems, radar, lasers and wireless technologies to ensure steel melt shops operate at optimum levels where crane and ladle tracking and their availability are critical to the entire steelmaking process.”