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Siemens safeguards the "China's First Furnace"
2020-03-06
Siemens Safeguards the 'China's First Furnace'
The entire automatic coal blending device of the project is managed unmanned on the production site, with all operations and monitoring conducted in the central control room. The system uses a distributed computer monitoring and management approach, mainly composed of two sets of Siemens S7-300 PLCs, two sets of WinCC V6.0 monitoring software and industrial control computers, 48 sets of SIMOVERT MASTERDRIVES 6SE70 engineering frequency converters, 24 CFC-200 loop controllers, 3 sets of OSM and other control units forming a SCADA system based on a TCP/IP 100M fiber industrial Ethernet ring network.
Project Background
With the rapid development of science and technology today, especially the widespread application of control technology, industrial IT technology, database technology, and network technology, the requirements for industrial process control in modern enterprises are becoming increasingly higher. Fully automatic metering and batching control systems are commonly used across various industries. They are the primary link in finished product production, especially in industries requiring continuous feeding. The process control of batching directly affects product quality and is a prerequisite for enterprises to achieve optimal economic benefits.
Although different industries have varying process characteristics and batching control requirements, the goals of high reliability, advancement, openness, maintenance-free operation, and scalability are consistent. For example, in the coal blending and coking production process of steel plants, it is necessary to blend bituminous coal, fat coal, gas coal, lean coal, coking coal, and poor coal in appropriate proportions. This process is called automatic coal blending and is one of the important links in the entire coking production. It is of great significance for producing high-quality coke, rationally utilizing coal resources, and controlling production costs.
"China's First Furnace"
The project partner's 7.63-meter coke oven is known as "China's First Furnace." It is an advanced and environmentally friendly stamp charging coke oven with an annual production capacity of 1.15 million tons, ensuring the partner produces 3 million tons of high-quality stainless steel molten iron annually. To make the coal blending ratio more accurate and realize the intelligence, digitization, and networking of the automatic coal blending device, and to provide accurate data sources to the enterprise's real-time and management databases, after repeatedly comparing the advantages and disadvantages of popular automation solutions in the market, the partner finally chose Siemens SIMATIC automation product solutions.
Siemens Automation Product Solutions
The entire automatic coal blending device of the project is managed unmanned on the production site, with all operations and monitoring conducted in the central control room. The system uses a distributed computer monitoring and management approach, mainly composed of two sets of Siemens S7-300 PLCs, two sets of WinCC V6.0 monitoring software and industrial control computers, 48 sets of SIMOVERT MASTERDRIVES 6SE70 engineering frequency converters, 24 CFC-200 loop controllers, 3 sets of OSM and other control units forming a SCADA system based on a TCP/IP 100M fiber industrial Ethernet ring network.
Key devices such as PLCs, frequency converters, controllers, and distributed I/O use Profibus-DP protocol communication to ensure high real-time performance and dynamic response. Profibus communication speed can reach up to 12 Mbit/s, and the bus cycle time of an 8-node network system can be as fast as 0.2 ms. Profibus has surpassed 10 million installed stations worldwide in manufacturing and process automation, far exceeding any other fieldbus standard. Its node device market share is currently the highest globally. It is the only fieldbus worldwide that can be applied in a standardized way across all fields and throughout the entire process chain.
This system architecture fully leverages Siemens Simatic automation product resources, featuring high reliability, strong anti-interference capability, and flexible scalability. It can independently complete data acquisition, precision control, and monitoring interlock of equipment.
The upper computer WinCC V6.0 configuration software acts as the HMI, monitoring real-time data and alarms through operation screens, achieving real-time curves and historical trends of production process parameters.
Display
alarm records, recipe management, production statistics, various data archiving, and safety interlock protection. At the same time, VBA programming is used to realize Excel report output, printing, and preview functions.
The system needs to monitor over a thousand analog and digital I/O control points including weight, speed, position, material shortage, material blockage, belt slip, motor start/stop, current, torque, and speed. It has 48 PID closed-loop control circuits and 2 sets of remote monitoring system operation stations. The entire system connects to other coking process sections and the plant-level management network of the coke company via Ethernet through a fiber optic switch, achieving integrated control management.
Project Operation and Feedback
China's First Furnace - The partner's 7.63-meter coke oven was successfully put into operation in July 2008. The entire coal blending system operates reliably, with stable performance, easy operation, high automation level, and significantly improved coal blending accuracy and coke quality stability. It not only reduces coal and energy consumption but also greatly improves production efficiency, laying the foundation for the partner to achieve an annual stainless steel production capacity of 3 million tons, becoming the world's largest modern stainless steel enterprise by capacity.
Through the design and implementation of this automatic coal blending project, the partner further deepened their understanding of Siemens Simatic automation products. The system uses industrial Ethernet and Profibus-DP fieldbus to realize mutual communication among field instruments, PLCs, distributed I/O, operation/engineering stations, and frequency drives, improving data transmission reliability and anti-interference capability, reducing a large number of cables, greatly reducing on-site installation and commissioning workload, shortening project implementation cycles, and improving work efficiency and project quality.
At the same time, Siemens Simatic automation products have a long product chain, excellent performance, wide coverage, high popularity, rich and frequently updated website content, complete documentation, and quick technical service response from the partner, all of which bring great convenience to the partner's actual work.
06 Mar,2020
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