Waste management for production of steel electric welding pipes using Data Mining technologies and MES systems

Abstract

The article is devoted to the study of environmental problems in the production of steel pipes and the rational use of waste. The relevance of the study lies in the high resource intensity and waste of pipe metallurgy, the classification of steel production and their subsequent redistribution as the first category of environmental hazard and is assigned to the areas of application of the best available technologies. The aim of the article is to analyze the resource intensity and waste production of steel pipes, to study the existing waste management system and its rationality at Russian enterprises. As the main research methods, the IDEF0 modeling methodology was used to visualize the waste management system and to structurize the model for the production of welded pipes taking into account emissions of pollutants, as well as Data Mining technology in the form of a classification and regression tree for studying trends and local patterns in waste management. The tendency of increasing resource intensity at the enterprise of the pipe industry with relative financial instability is revealed. A visualization of the waste management system in the production of steel pipes is proposed, which makes it possible to distinguish the main functional blocks of the incoming and outgoing parts of the waste balance. A model of the processes of production of welded pipes is structured taking into account emissions of polluting substances into the atmosphere and cleaning methods according to the reference book on the best available technologies ITR 27-2017. Based on the constructed decision tree, knowledge was obtained on the trends in the treatment of steel pipe production waste. In order to reduce the level of rejection in the production of steel pipes and minimize the formation of scrap, a project has been proposed on the automation of technical quality control and the implementation of the MES system. The research was carried out within the framework of the grant of the President of the Russian Federation for state support of leading scientific schools of the Russian Federation, project number NSh-2600.2020.6.

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“…The use of simulation modelling and end-to-end tracking allows controlling the technological process to maintain the specified product quality parameters and reduce costs. The study by Shinkevich & Malysheva (2020) suggests that online analysis of a large amount of data at each stage, the development of a dynamic management of reference information (RI) and mathematical modelling provides a synergistic effect, which reduces operating and technological costs. The level of automation of the largest metallurgical enterprises today can be described as quite high, although it cannot be said that it corresponds to the latest technological trends.…”

Importance of the integrated manufacturing execution system for a metallurgical enterprise

“…The MES system most often covers a wide range of tasks: installation and configuration of rational modes of operation of the enterprise and each of its individual technological processes; maintenance of proper operation of a given mode of activity of the enterprise; provision of the growth of the quality of the manufactured product by reducing costs, emergencies, downtime, etc. ; distribution and monitoring of the status of resources; automation of dispatching of production processes; regular data collection, quality management, maintenance management, performance analysis; production scheduling; document control, human resource management; coordination of technological processes and tracking of finished products [9][10][11].…”

“…The industrial zone is 632 hectares -these are melting shops, administrative buildings, warehouses. The infrastructure allows servicing 13 furnaces with a total capacity of 400 thousand tonnes of alloys per year [10].…”

“…In Tau-Ken Altyn, there is an increase in the production of refined gold by 4 % and refined silver by 46.7 % [10].…”

“…Kazakhstan Metallurgical company Casting increased the volume of copper cathode production by 19 %. The company produces a wide range of products from ferrous and non-ferrous metals: steel billets, grinding balls and rods, reinforcing bars, cathode copper and copper products, bronze, brass, aluminum and lead alloys [10]. Evraz Caspian Steel plant in Kostanay increased the volume of reinforcing bar production by 8 %.…”