Unlocking operational excellence: A steel manufacturer’s journey with Bosch Digital Twin Industries
Solving unpredictable failures and process interruptions through our Integrated Asset Performance Management solution.
The challenge
The steel manufacturer’s industrial exhauster, a critical asset for extracting and transporting coke oven gas, was plagued by unpredictable failures. The root causes of these issues were multifaceted, ranging from clogging due to tar deposition to frequent bearing and rotor bar failures, exacerbated by a lack of historical fault signature data. These breakdowns resulted in significant losses, including the flaring of valuable coke oven gas, energy imbalances, and costly process interruptions.
The solution
Recognizing the need for a comprehensive and proactive approach, the steel manufacturer partnered with Bosch Digital Twin Industries to implement their state-of-the-art Integrated Asset Performance Management (IAPM) solution.
The team has deployed hybrid models for real-time monitoring of tar deposition on the impeller and generated synthetic data to enable failure predictions and maintenance planning. This resulted in tremendous cost savings.
The result
Substantial cost savings were achieved by preventing coke oven gas waste and minimizing process disruptions.
Key features and benefits
Real-time monitoring
BDTI deployed hybrid models to continuously monitor tar deposition on the impeller, enabling real-time visibility and proactive maintenance to prevent clogging.
Failure prediction
Leveraging synthetic data generation and advanced algorithms, Bosch’s solution provided accurate failure predictions from day one, allowing for early intervention and minimizing unplanned downtime.
Comprehensive diagnostics
BDTI implemented early fault detection and alert mechanisms on issues such as eccentricity, rotor bar breakage, bearing faults, gear wear, pitting, and lubrication using its IAPM solution.
Actionable insights
The digital twin technology yielded actionable insights on the industrial exhauster’s performance, enabling data-driven decision-making and optimized maintenance schedules.
Scalability
Encouraged by the success of the initial implementation, the steel manufacturer has scaled the solution across its remaining coke oven plants, further amplifying the benefits and driving operational excellence across its facilities.
Unlocking efficiency and profitability
Bosch Digital Twin Industries’ solution has enabled the steel manufacturer to unlock new levels of efficiency, productivity, and profitability. By harnessing the power of digital twins, real-time monitoring, and predictive sensor data analytics, it has transformed its coke oven operations, setting a benchmark for industry-leading practices.
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