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Steel & Metals
Steel Production Process Optimization
Implementation: 7 months
Industry: Steel & Metals
Energy and Quality Challenges
A major steel producer was struggling with high energy costs and inconsistent product quality, leading to customer complaints and competitive disadvantage in a tight-margin industry.
Key Pain Points
- Energy costs representing 30% of production cost
- Quality variations causing customer rejections
- Inefficient furnace operations
- Limited process optimization capabilities
- Difficulty maintaining consistent alloy compositions
Real-Time Process Optimization
Tesan AI implemented an AI-powered process control system that optimizes energy consumption while ensuring consistent product quality.
Key Features Deployed
- Real-time furnace optimization
- AI-powered alloy composition control
- Energy consumption prediction and optimization
- Quality prediction before testing
- Automated process parameter adjustment
- Production scheduling optimization
Efficiency Breakthrough
Measurable outcomes from the implementation
22%
Energy Reduction
Through optimized furnace control
35%
Quality Improvement
Reduction in off-spec production
18%
Yield Increase
Less material waste and scrap
$8M
Annual Savings
From energy and quality improvements
Implementation Journey
A structured approach to transformation
Phase 1
Process Mapping
Detailed analysis of production processes and energy flows
Phase 2
Data Integration
Connection to process control systems and sensors
Phase 3
Model Training
AI models for energy and quality optimization
Phase 4
Control Integration
Closed-loop control system implementation
Phase 5
Optimization
Continuous refinement and expansion
Use Cases Implemented
Specific applications within this implementation
Electric arc furnace optimizationRolling mill controlHeat treatment optimizationAlloy composition controlEnergy demand management
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