Monitoring and adjustments of combustion parameters in reheating furnaces using a digital tool

Improving the energy efficiency of a reheating furnace is not a simple task because it involves a large number of parameters that, most of the time, are connected in a complex way. To be feasible, the evaluation of such a vast number of variables must be supported by digital tools that are embedded with artificial intelligence. The SMS group has developed a digital tool that effectively supports operators and engineers in enhancing energy efficiency within the reheating furnaces of hot rolling mills. This paper presents a quick study case of the use of Viridis Performance, an application of Viridis Energy & Sustainability Suite, in the analysis and correction of the deviations in the air-gas ratio of a reheating furnace. In this study, a production period of 8 hours was evaluated, during which the air-gas ratio presented a significant deviation. Analysis showed that the probable cause of the deviation was a production stoppage where the furnace control was set to manual mode. A reduction potential of 0.26 Gcal/h and a 13 kg/h decrease in CO2 emissions were identified. Viridis Performance would support the process by guiding the decisions of the operator in a way that energy losses would be avoided or minimized. The potential economic savings were also quantified. This task is performed in the system by Viridis Moneybox, which is another application of Viridis Energy & Sustainability Suite. The results showed potential savings of 13 US $/h. In addition to the gains and savings outlined in this study, the utilization of Viridis Performance encompasses numerous other advantages, such as enhanced operational standardization and improved process capability, to name just a few.