Energy Management System for Ironmaking Plants, Steel Plants & Rolling Mills

The energy management system assists managers, engineers, and sustainability officers in ironmaking plants, steel plants, and rolling mills, aiming to reduce energy costs, improve operations, and increase sustainability. It enhances operational efficiency through predictive algorithms to optimize energy use at steel plants and rolling mills. Additionally, it integrates the feed-in power of renewable energy sources and calculates the ideal time for energy purchases to cover the required process energy demand.

At the core of the energy management system is a set of predictive algorithms that play a crucial role in optimizing energy use and costs. These algorithms predict market energy prices by analyzing fluctuations and identifying the best times for energy-intensive activities, such as power-on time at the electric arc furnace. This information is sent to the process automation system for scheduling.

The energy management system assesses energy availability from internal and renewable sources, calculates operational needs, and determines the additional energy required from the market. By analyzing real-time data on energy prices and demand, these algorithms ensure that energy is used efficiently and cost-effectively, minimizing expenses and maximizing the use of renewable energy. Energy consumption is monitored within 15-minute intervals to accurately predict and control energy consumption from the grid. This ensures the exact usage of purchased energy at the end of each quarter. This strategic approach allows steel plants and rolling mills to maintain a stable energy supply while minimizing energy costs.

Features and Applications of Energy Management

Battery Energy Storage System (BESS)

The Battery Energy Storage System (BESS) optimizes energy storage and distribution integration with an ironmaking plant, steel plant or rolling mill. It stores excess energy from renewable sources during low-demand periods or buys energy when electricity prices are favorable. This stored energy is released during peak demand, ensuring a stable supply and reducing reliance on external sources during high-cost times. Seamless integration into the power system of a steel plant or rolling mill allows for strategic use of stored energy, reducing costs and enhancing operational availability. Predictive control algorithms determine optimal charging and discharging schedules based on real-time prices and demand forecasts.

Energy Management for a Hydrogen-based DRI Plant

The energy management system application in a hydrogen-DRI plant integrates into hydrogen production operations for direct reduction. Producers must also efficiently produce hydrogen via electrolysis to replace natural gas in direct reduction processes. The energy management system ensures that producers can adjust natural gas and hydrogen levels in the direct reduction process to maintain output by ensuring energy availability is regulated for hydrogen production. The predictive algorithms monitor the electrolyzer operation, ensuring full capacity use when energy costs are low and scaling back as prices increase. With the energy management system and the integration of hydrogen and natural gas procurement strategies, companies gain flexibility regarding the effective purchasing of natural gas and hydrogen production.

Benefits of the Energy Management System

• Energy efficiency: maximizes the use of available energy, reducing waste and improving the overall cost of energy consumption within the steel plant
• Cost reduction: reduces electricity and natural gas costs by optimizing energy use and scheduling energy-intensive operations when energy prices are low, reducing capital and operational expenditures
• Sustainability: accounts for renewable energy sources such as wind and solar, reducing steel production's Scope 2 carbon emissions

Features of the Energy Management System

• Predictive control algorithms: these algorithms forecast energy prices and manage energy flows, enabling plant operators to make informed decisions and strategic plans for production.

• Real-time energy procurement: the system continuously monitors energy prices and adjusts procurement strategies accordingly. This real-time adaptation helps capitalize on price fluctuations and maintain cost-effective operations.

• Battery Energy Storage System (BESS): a robust BESS stores excess energy during low-demand periods and releases it during peak times. This ensures a stable energy supply aligned with operations and enhances energy use efficiency.

• Hydrogen electrolysis integration: this feature allows the plant to produce hydrogen when electricity prices are favorable.

• Dynamic hydrogen management: the system allows for dynamic adjustments in energy use, particularly in the hydrogen-to-natural-gas ratio in the DRI process. This ensures the optimal balance between energy costs, hydrogen production, and natural gas procurement.

• Scalable and modular design: the system is designed to be scalable and modular, allowing for easy integration with existing infrastructure and the ability to expand or modify as operational needs change.

• Renewable energy integration: the system incorporates renewable energy sources such as wind and solar, reducing steel production's carbon footprint and maintaining production availability.