The Application Of Simulation Modeling at ArcelorMittal Dofasco

Scott Baylis
Senior Specialist

Danny Pavan
Senior Specialist

Automation Technology Solutions

ArcelorMittal Dofasco

Copyright ArcelorMittal 2011

Computer Simulation Modeling What is it?

The methodology for using computer models to:
Imitate the operation of real-world processes or facilities. Draw conclusions about their performance.

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Computer Simulation Modeling Why to use it?

Model Complex Dynamic Systems
You can incorporate the variables, interactions and rules that define a system.

Model Random Variability over Time

You can model variation over time by describing system behaviors using probability distributions.

What-if Analysis
You can run experiments to estimate key performance measures for proposed solutions and alternative system designs.

Visualization of the system

You can provide an animated visual representation of the system.
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Demonstration
The Problem with Averages - Simulation versus Calculation Averages Model
Grabau, M.R. (2001) Averages kill (or how to sell business process simulation). In Proceedings of the 2001 Winter Simulation Conference (pp 1263-1265).

Hot Metal Delivery to Electric Arc Furnace Model

Objective:
With a new practice of delivering hot metal to the Electric Arc Furnace determine if additional transporters or ladles are required. (Model Demonstration)

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Hot Metal Delivery to Electric Arc Furnace Model

Sample Results Objective:
With a new practice of delivering hot metal to the Electric Arc Furnace determine if additional transporters or ladles are required.

Outcome:
A single transporter and a single hot metal ladle was capable of servicing EAF requirements for hot metal. The purchase of an additional transporter was not required.

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Computer Simulation Modeling Summary

Simulation modeling provides the unique capability of creating Dynamic, Visual representations of Complex real-world systems that includes the inherent Random Variability of the systems.

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Simulation At ArcelorMittal Dofasco

Computer simulation modeling has been employed for over 30 years.

Current team is three simulation specialists. Where ever possible we utilized the simulation methodology in our capital projects evaluation process.

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Simulation At ArcelorMittal Dofasco

Model Development
Models are designed to answer specific questions. Defining the system to be modeled is a collaborative effort between:
simulation specialists process experts IT specialists (system input data) decision makers

Models are the translation of the system definition into the simulation software. Model scope and detail as well as the level of animation detail are dependant on questions to be addressed. Typically simulation development is an iterative process. Model > Simulate > Learn > Revise
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Simulation At ArcelorMittal Dofasco

Flexsim Software
Powerful and flexible tool that allows for large scale model customization, visualization and analysis of a wide array of processes. Rapid prototype model development. New users can build simple basic models very quickly.

Experienced users can develop more complex, sophisticated models relatively quickly.
The 3D graphics are integrated with model development. can be tailored to needs visual verification enhanced credibility, understanding, acceptance Multiple specialist are able to simultaneously develop portions of the same large, complex models.
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Simulation At ArcelorMittal Dofasco

Sample Simulation Projects

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Sample Projects
Hot Mill Slab Yard Logistics Capability Study
Slab Storage Yards, Transfer cars, Cranes, Hot Mill Depiler, Reheat Furnace Charge Tables and Entry Doors

Objective:
Determine if existing slab handling equipment is capable of performing all slab sorting and delivery responsibilities at increased throughput levels and to help identify potential bottlenecks and logistics improvement strategies. (Model Demonstration)

Outcome: Determined that slab handling equipment is capable at targeted

production rates and anticipated future warm charge levels. Identified opportunities to develop strategies to balance crane work loads.

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Sample Projects
Crane Results

Central Shipping New Axial Wrapper Evaluation

Coil storage racks in adjacent buildings, Truck/transporter access lanes, Axial Wrapper, Coil Preparation Area, transporter decks, customer trucks, Coil Stacker Work Cranes Elements Summaries

Objective:

Determine if the cranes in adjoining buildings are capable servicing a proposed coil axial wrapper at target throughput rates while maintaining adequate service levels for incoming customer truck and coil transporter deck traffic. (Model Demonstration)

Time Series Analysis of Crane Utilization

Utilization Distribution from multiple model runs

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Sample Projects
Central Shipping New Axial Wrapper Evaluation
Elements Summary

Axial Wrapper Performance Results

Coil storage racks, Truck access lanes, Axial Wrapper, Coil Preparation Area, Utilization transporter decks, customer trucks, Cranes Work Distribution

Objective:

for multiple model runs

Determine if the cranes in adjoining buildings are capable servicing a proposed coil axial wrapper at target throughput rates while maintaining adequate service levels for incoming customer truck and coil transporter deck traffic.

Outcome:
Determined that cranes are capable of servicing axial wrapper while Throughput maintaining truck service requirements. performance
Distribution for multiple model runs

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Sample Projects
21 Bay Coil Storage and Shipping
Coil Shuttle Cars, Temper Mill Exit, Cranes, Coil Storage fields , Transporter Deck Locations, Galvanize Line coil consumption

Objective:
Assess cranes capability to service coil movement and storage within the bay under various throughput and bay layout scenarios. Also to test coil storage field capacity allocations (Model Demonstration)

Outcome:
Identified limitations in crane capacity under various material volume and routing scenarios. Also identify areas where planned storage field capacities required modification. Provided follow-up analysis of various solution proposals.

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Sample Projects
Temper Mill Exit Conveyor Staggering
Temper Mill Entry an Exit Indexing Coil Conveyors and Mandrels, New Automated Packaging equipment (Banders and Stencilers)

Objective:
Determine if the practice of staggering coils on the exit conveyor of the Temper Mill in order to physically accommodate new automated packaging equipment would cause unforeseen throughput/bottleneck issues. (Model Demonstration)

Outcome:
Determined that there were no detrimental flow effects or throughput effects using coil staggering practice.

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Sample Projects
Models with Multiple Applications

Sheet Mill A Building Model

#2 CPCM, #1 Batch Anneal, Open Coil Anneal, Coil Transporters, Coil Shuttle Cars

Crane Utilization Project

Objective:
Assess existing cranes capability of servicing coil movement requirements within the bay at expected increased throughput levels.

Outcome:
Determined that a third crane was required to meet projected production demands.

Coil Movement Logistics Evaluation

Objective:
Evaluate existing systems ability to support shorter term increased throughput requirements in order to determine if a significant capital project designed to support longer term goals could be deferred.

Outcome:
Determined that a major $500,000 transporter doors installation expenditure could be deferred.
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Sample Projects
Models with Multiple Applications

Hot Metal Delivery System Model

(Blast Furnaces, Desulph Station, KOBM Pour Pit, EAF Pour Pit, Coffin Facility, Dekish, Railroad System (Locomotives, torpedo cars, logistics logic))

Steelmaking Improvement Project

Objectives:
Determine if Metal Delivery System is capable of supporting targeted increased production levels at #2 Melt Shop. Evaluate multiple torpedo fleet configuration scenarios in support of blast furnace high productivity trials.

Outcomes:
Validated that the Hot Metal Delivery System could support the targeted increased #2 Melt Shop levels. Supported the blast furnace high productivity trials by analyzing multiple operating scenarios to ensure that torpedo car fleet configurations were adequate for the increased production.
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Sample Projects
Models with Multiple Applications

Hot Metal Delivery System Model contd

Hot Metal to EAF Proof-Of-Concept Study
Evaluated feasibility of supplying EAF facility with hot metal under a 3 blast furnace operation.

Key justification to move forward with this initiative.

Precipitated several further analysis requests relative to this proposed operating context: Torpedo Car Puller Study Desulph Bag House Capability Study Fleet Size Analysis Pig Machine Location and Quantity Analysis

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Sample Projects
Models with Multiple Applications

Hot Band Gantry Yard Simulation Model

Hot Mill Coil Exit Conveyors, Gantry Cranes, Coil Storage Yards, Coil Carriers and Tractors, roadways, Coil Decks, coil arrival logic, coil storage logic, exiting coil load logic.

Objective:
Assess Hot Mill exit coil conveyor throughput capabilities at anticipated increased levels.

Outcome:
Determined that exit end of the Hot Mill is capable under normal operating conditions.

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Summary of Benefits
Simulation modeling has provided the capability to answer numerous complex questions.
Specific Outcomes: Cost avoidance. Highlighting of deficiencies in proposed system designs. Productivity improvements. Improved equipment utilization. Efficient allocation of resources. Resolution of material handling concerns.

General Benefits: Avoidance of risk by changing virtual process versus actual processes. Proof-of-concept capabilities. Improved collective understanding of processes. Cost effective evaluation of alternative investment scenarios.
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Thank You

Scott Baylis-Senior Specialist Danny Pavan-Senior Specialist Automation Technology Solutions

ArcelorMittal Dofasco

Copyright ArcelorMittal 2011