Hot Rolling Mill Optimization for Energy and Emissions
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Solution Overview
Problem
Current energy-saving methods in rolling mills, such as reducing roll revolution speeds and pump control, are insufficient in reducing energy usage and carbon dioxide emissions, and often compromise product quality, leading to non-conforming goods.
Innovation Solution
An optimization device that calculates target temperatures for rolling materials at various stages of the rolling process to minimize energy consumption and carbon dioxide emissions while ensuring product quality, using a setting calculator, energy use calculator, and material quality predictor to determine optimal control settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy-saving methods such as reducing roll revolution speeds and pump control are implemented, then energy consumption is reduced, but product quality deteriorates leading to non-conforming goods
Solution Approach 1:
The system changes operational parameters (roll revolution speeds, pump speeds, temperatures) dynamically based on real-time production conditions and product specifications. Instead of fixed reduced speeds for energy saving, the system optimizes each parameter individually to maintain quality while minimizing energy consumption.
Solution Approach 2:
The energy-saving approach transitions from static reduced speeds to dynamic optimization where roll speeds and pump speeds are continuously adjusted based on actual production requirements, material properties, and environmental conditions to maintain product quality while reducing overall energy consumption.
2Use of energy by stationary object
If reheating furnace combustion control is implemented to reduce energy cost, then energy cost is reduced, but significant energy saving effect in whole rolling mill cannot be achieved and product quality may be compromised
Solution Approach 1:
The optimization system integrates control of multiple subsystems (reheating furnace, roughing mill, finishing mill, coiling) into a unified energy management platform. This multi-functional approach ensures that energy savings in the furnace contribute to overall mill energy reduction while maintaining coordination across all processes to achieve significant total energy savings.
Solution Approach 2:
The system performs preliminary optimization calculations and sets target temperatures and speeds before production begins. By pre-calculating optimal parameters based on product specifications and current conditions, the system ensures that energy-saving measures are implemented effectively across the entire rolling process while maintaining product quality.
3Use of energy by moving object
If roll revolution speeds are reduced for energy saving, then energy consumption is reduced, but manufacturing efficiency and productivity decrease
Solution Approach 1:
Roll revolution speeds are dynamically optimized rather than statically reduced. The system adjusts speeds in real-time based on material properties, product specifications, and production targets, maintaining high productivity during critical phases while reducing energy consumption during less critical operations.
Solution Approach 2:
Instead of uniformly reducing all roll speeds, the system selectively adjusts individual roll speeds based on specific production requirements. This targeted parameter optimization maintains manufacturing efficiency for quality-critical operations while achieving energy savings in other phases of the rolling process.
Data Source
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AI summary
A certain embodiment includes a setting calculator (31), an energy use calculator (32), a manufacturing carbon dioxide emission amount calculator (33), and an optimizer (35). The setting calculator (31) operates to depend on an initial size, an initial temperature, and a target temperature of a rolling material (120), to calculate a control setting value for services of a hot rolling mill (100) to mill the rolling material (120). The energy use calculator (32) operates to depend on a control setting value, to calculate a use of energy as a necessary energy for services of the hot rolling mill (100) to mill the rolling material (120). The manufacturing carbon dioxide emission amount calculator (33) operates to depend on a carbon dioxide emission coefficient and a use of energy, to calculate an emission amount of carbon dioxide emitted at the hot rolling mill (100). The optimizer (35) operates to calculate a target temperature to be a temperature equal to or higher than a requisite temperature for the rolling material (120) to be milled with a secured quality, as a temperature to minimize either or both of use of energy and emission amount of manufacturing carbon dioxide.