Unexpected shutdowns are costly and very demanding for the workforce involved. Make your EAF smart in order to increase the availability and quality output.
Today most often technical data sheets coupled with the knowledge of a number of unique experienced individuals are used to determine when maintenance is required for the EAF. Interventions are done on regular intervals, or when something happened. All of this puts tremendous strain on the people responsible for keeping the installation running, while it can be avoided, quite easily.
The only way to validate the actual health is by having a continuous look at a broad data set and adding a specific multi-aspect monitoring setup consisting of different sensor types that follow the behaviour of the general state-of-health of the EAF and its components.
A gantry is used for moving the electrodes in and out the bath and/or for operating the lid of the reactor. The structure, and more specifically the swivel bearings also can suffer from extensive degradation. A dedicated monitoring coupling information about high-sensitivity acceleration data, electrical currents, inclination and/or temperatures in a smart way provides a way of continuous tracking gantry (bearing) health
The electrodes are used to transfer the electrical energy into the furnace and start melting the metal. During this process, the electrodes undergo a lot of force. Based on the properties of the primary materials and the process parameters, the integrity of the electrodes or their support structure can be affected. Coupling information about vibrations, currents, inclination and/or temperatures in a smart way provides a way of continuously tracking electrode health.
Busbars are used to transfer electrical energy to theelectrodes. Due to the high currents involved this results in high vibrations and inductive coupling to other components. Monitoring of vibration levels and temperatures allows to reduce the chance for resulting mechanical or thermal damage.
Structural dynamics vs. Process parameters
The melting process is a function of various operational parameters: electrical currents, composition and mechanical properties of primary materials, gas flow, vibrations, temperatures... Tracking all relevant parameters allows building up models separating 'normal' from 'abnormal' behaviour. Prolonged follow-up in turn allows identifying and quantifying changes in dynamic behaviour for similar process conditions, leading to early detection of damage development or process issues.
Using the data available in the Historian or SCADA system the operation of the EAF is continuously parametrised. Of interest are for example water flows, temperatures, electrical currents... The different stages of the process are automatically identified and when properties start deviating or unexpected values are detected, a warning is sent. The follow-up is based on process knowledge as well as models trained on the behaviour of the specific asset followed.
COOLING SYSTEM HEALTH | POURING PROCESS DEVIATIONS
Our monitoring products are compatible with installations of the following suppliers:
All of Zensor's products are compatible with standard CMMS or EAM software. Connections can be set up to source the most recent interventions and changes on the asset, or to create a ticket when an intervention is required on a section of the rolling line. Compatible with:
We understand the problems you face
Catch them before they cause greater damage
Product quality control
The more perfect the material, the higher its value. A perfect control of the stress distribution within the plate can be reached through permanent monitoring. The associated feedback loop allows generating a maximum amount of top-notch material, coil after coil.
A damaged roll means your entire production comes to a halt. Continuous monitoring of internal pressures allows preventing excessive local forces, thus roll damage.
When continuously tracking currents or vibrations smart algorithms can determine automatically how long the belt operates under a certain condition. Live statistics give you insights into how optimally the asset is used.
The faster perfectly flat plates can be produced after starting a new coil, the less material has to be thrown away. A smart sensor set helps in setting the optimal set point to begin with and to rapidly reach the perfect conditions for each run.
Last week Zensor attended the Hüttentag in Essen. During this annual event the entire German steel industry meets up to discuss the state of affairs and exchange ideas about upcoming developments and changes.
Your privacy is important to us. It is Zensor NV's policy to respect your privacy regarding any information we may collect from you across our website, https://www.zensor.be, and other sites we own and operate.
Information we collect
When you visit our website, our servers may automatically log the standard data provided by your web browser. This data is considered “non-identifying information”, as it does not personally identify you on its own. It may include your computer’s Internet Protocol (IP) address, your browser type and version, the pages you visit, the time and date of your visit, the time spent on each page, and other details.
We may also collect data about the device you are using to access our website. This data may include the device type, operating system, unique device identifiers, device settings, and geo-location data. What we collect can depend on the individual settings of your device and software. We recommend checking the policies of your device manufacturer or software provider to learn what information they make available to us.
We may ask for personal information, such as your:
This data is considered “identifying information”, as it can personally identify you. We only request personal information relevant to providing you with a service, and only use it to help provide or improve this service.
How we collect information
We collect information by fair and lawful means, with your knowledge and consent. We also let you know why we’re collecting it and how it will be used. You are free to refuse our request for this information, with the understanding that we may be unable to provide you with some of your desired services without it.
Use of information
We may use a combination of identifying and non-identifying information to understand who our visitors are, how they use our services, and how we may improve their experience of our website in future. We do not disclose the specifics of this information publicly, but may share aggregated and anonymised versions of this information, for example, in website and customer usage trend reports.
We may use your personal details to contact you with updates about our website and services, along with promotional content that we believe may be of interest to you. If you wish to opt out of receiving promotional content, you can follow the “unsubscribe” instructions provided alongside any promotional correspondence from us.
Data processing and storage
The personal information we collect is stored and processed in Belgium, or where we or our partners, affiliates and third-party providers maintain facilities. We only transfer data within jurisdictions subject to data protection laws that reflect our commitment to protecting the privacy of our users.
We only retain personal information for as long as necessary to provide a service, or to improve our services in future. While we retain this data, we will protect it within commercially acceptable means to prevent loss and theft, as well as unauthorised access, disclosure, copying, use or modification. That said, we advise that no method of electronic transmission or storage is 100% secure, and cannot guarantee absolute data security.
If you request your personal information be deleted, or where your personal information becomes no longer relevant to our operations, we will erase it from our system within a reasonable timeframe.
Third-party access to information
We use third-party services for:
Analytics trackingUser authenticationAdvertising and promotionContent marketingEmail marketing
These services may access our data solely for the purpose of performing specific tasks on our behalf. We do not share any personally identifying information with them without your explicit consent. We do not give them permission to disclose or use any of our data for any other purpose.
We may, from time to time, allow limited access to our data by external consultants and agencies for the purpose of analysis and service improvement. This access is only permitted for as long as necessary to perform a specific function. We only work with external agencies whose privacy policies align with ours.
We will refuse government and law enforcement requests for data if we believe a request is too broad or unrelated to its stated purpose. However, we may cooperate if we believe the requested information is necessary and appropriate to comply with legal process, to protect our own rights and property, to protect the safety of the public and any person, to prevent a crime, or to prevent what we reasonably believe to be illegal, legally actionable, or unethical activity.
We do not otherwise share or supply personal information to third parties. We do not sell or rent your personal information to marketers or third parties.
Limits of our policy
Our website may link to external sites that are not operated by us. Please be aware that we have no control over the content and policies of those sites, and cannot accept responsibility or liability for their respective privacy practices.
Changes to this policy
Your rights and responsibilities
As our user, you have the right to be informed about how your data is collected and used. You are entitled to know what data we collect about you, and how it is processed. You are entitled to correct and update any personal information about you, and to request this information be deleted. You may amend or remove your account information at any time, using the tools provided in your account control panel.
You are entitled to restrict or object to our use of your data, while retaining the right to use your personal information for your own purposes. You have the right to opt out of data about you being used in decisions based solely on automated processing.
Feel free to contact us if you have any concerns or questions about how we handle your data and personal information.
Zensor NV Data Controller
This policy is effective as of 14 May 2018.
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A cookie is a small piece of data that a website stores on your device when you visit, typically containing information about the website itself, a unique identifier that allows the site to recognise your web browser when you return, additional data that serves the purpose of the cookie, and the lifespan of the cookie itself.
Cookies are used to enable certain features (eg. logging in), to track site usage (eg. analytics), to store your user settings (eg. timezone, notification preferences), and to personalise your content (eg. advertising, language).
Cookies set by the website you are visiting are normally referred to as “first-party cookies”, and typically only track your activity on that particular site. Cookies set by other sites and companies (ie. third parties) are called “third-party cookies”, and can be used to track you on other websites that use the same third-party service.
Types of cookies and how we use them
Essential cookies are crucial to your experience of a website, enabling core features like user logins, account management, shopping carts and payment processing. We use essential cookies to enable certain functions on our website.
Performance cookies are used in the tracking of how you use a website during your visit, without collecting personal information about you. Typically, this information is anonymous and aggregated with information tracked across all site users, to help companies understand visitor usage patterns, identify and diagnose problems or errors their users may encounter, and make better strategic decisions in improving their audience’s overall website experience. These cookies may be set by the website you’re visiting (first-party) or by third-party services. We use performance cookies on our site.
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Targeting/advertising cookies are used in determining what promotional content is more relevant and appropriate to you and your interests. Websites may use them to deliver targeted advertising or to limit the number of times you see an advertisement. This helps companies improve the effectiveness of their campaigns and the quality of content presented to you. These cookies may be set by the website you’re visiting (first-party) or by third-party services. Targeting/advertising cookies set by third-parties may be used to track you on other websites that use the same third-party service. We use targeting/advertising cookies on our site.
Third-party cookies on our site
Our third-party privacy promise
We review the privacy policies of all our third-party providers before enlisting their services to ensure their practices align with ours. We will never knowingly include third-party services that compromise or violate the privacy of our users.
How you can control or opt out of cookies
If you browse websites from multiple devices, you may need to update your settings on each individual device.
Although some cookies can be blocked with little impact on your experience of a website, blocking all cookies may mean you are unable to access certain features and content across the sites you visit.