Synopsis of "No Risk" Blast Furnace Reline Project

Situation: A leading North American steel producer operated with an antiquated blast furnace that had throughout the years undergone many technical transformations. Issues: Diminished reliability of existing controls, diminished production, bloated operational expenses, increased safety risks. Requirement: Blast Furnace Controls Upgrade implemented without interrupting existing operations. Technology: Modicon Quantum controllers, GE Series Six controllers, Wonderware, HMIs, Modbus, Modbus Plus, Modbus Ethernet, Serial.

Brock Solutions' Role: Replacing controllers with warm standby units; integrating new controllers into the existing blast furnace’s charging control network; moving charge recipe control from the existing Furnace Top PLC into a new Furnace Charging Master PLC designed for flexible material charging; converting two iron ore pellet bins into new miscellaneous material bins used to charge a quantity of nut coke into the furnace to reduce furnace natural gas and/or coke requirements; implementing the new system based on shadow commissioning mode for parallel testing.

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