Automated System of Record and Control over Materials Acceptance, Stocking and Blending in the Ore Stockyard of the Blast-Furnace Shop of OJSC «Zaporozhstal» (SARC OS)

Technologies /

Technologies and Automated Control Systems for the Processes of Sintering and Blast-Furnace Production

Automated System of Record and Control over Materials Acceptance, Stocking and Blending in the Ore Stockyard of the Blast-Furnace Shop of OJSC «Zaporozhstal» (SARC OS).

The system’s purpose is:

to reduce the coke consumption for iron production in the blast-furnace shop due to reducing the variations of basicity and iron content in the sinter;
to improve the materials blending in the ore stockyard of the blast-furnace shop;
to carry out continuous on-line control over the materials charging into the stack;
to carry out timely correction of the materials consumption when charging into the stack;
to increase the staff responsibility.

The system provides for automated record and control over the materials acceptance and stocking in the ore stockyard, carries out automated calculation of the stack process values (Fig. 1), and percentage of different components in it (Fig. 2).

The system implementation gives the possibility of on-line control over the materials store in the ore stockyard, of keeping the logs of the process equipment operation and raw materials unloading.

The system consists of the database server and three workstations (Fig. 3): workstation of the ore stockyard chief, workstation of the deputy chief of the blast-furnace shop in charge of the burden, workstation of the deputy chief of the sintering plant in charge of the burden.

Communication between the system’s components placed far away from each other is carried out through the factory information network. The workstation of the ore stockyard chief is connected to the system through telephone line (high-speed modems are used).

Application software developed by RPC «Donix» is situated on the application server of the Department of Automated Control Process Systems which gives the possibility of on-line maintenance and new users’ connection to the system.

Fig. 1 The stack log.

Fig. 2 Graph of materials content in the stack.

Fig. 3 The system structure.

The database server of the system was assembled based on Intel server platform (2 Intel Xeon processors 2.8Gz, 1Gb DDR ECC, RAID of the 5^th level 4HDD x 80Gb with warm reboot function, server control system, reserved power supply with warm reboot function).

An APC Smart-UPS RM 1500 VA is used to provide the uninterruptible power supply of the server.

The server is equipped with the following Microsoft software: Windows 2003 Server MS SQL Server 2000.

The server processes the inquiries from all the workstations connected to it (it is possible to connect new users) and ensures data storage for at least 5 years.

The workstation of the ore stockyard chief was designed for operation in the conditions of high dustiness. The workstation equipment is installed in Ritall cabinet (ensures the equipment safety IP65) with a remote terminal and consists of an Advantech computer based on Intell Pentium-4 2266 processor of an industrial version, APC UPS, Zyxel 841 modem, HP 1320 printer and switching equipment. The workstation of the ore stockyard chief works under control of Windows XP Professional.

The workstations of the deputy chiefs of the blast-furnace shop and the sintering plant in charge of the burden consist of a personal computer under control of Windows XP Professional.

Zyxel modems are used to provide communication through the dedicated telephone line.

APC equipment is used to provide the telephone line and Ethernet protection.

DLink devices are used as network concentrators.

The following Microsoft software was used for the system development: Windows 2003 Server, MS SQL Server 2000, Windows XP Professional and Borland C++ Builder 6.0 language.

The system is implemented at:

Zaporozhye Integrated Metallurgical Works "Zaporozhstal"

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83102, Ukraine, Donetsk, Kuibysheva Str. 44

Phone: +38 062 388-91-20
email: donix@donix-ua.com