Accurate Estimation of Readiness of Ovens

Theme: Asset Optimization & Predictive maintenance

Expected Pilot Duration - - Months

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Challenge Summary

The challenge is to estimate the readiness of oven through the process parameters. The current estimation is based on heuristics like colour and flame on the coke bed, which is inaccurate and leads to burning loss. Ideal solution is to measure the readiness of the oven through imaging sensors.

Challenge Scenario

The readiness of the oven denotes the completion of coking process in the coke bed which is currently being estimated by visual inspection of colour of the bed – bright yellow coke signifies the completeness of the process.

Absence of flames and clear visibility of coke bed also denotes completeness of process. The real problem occurs when the coke is held for longer time after coking – it starts burning and leading to burning losses. In the manual process, the burning losses are high due to lack of operator training, missing on time detection by operator, etc. Currently, temperature is measured manually through pyrometer.

The solution should be able measure the readiness of the oven by integrating imaging sensors or thermal cameras on the pushing cart (equipment which helps to push hot coke from the oven) on real time. Pushing cart can move around the ovens and inspect the oven readiness. Then, it should be to alert the operator of readiness on time and should have provision to store and analyse the data

Profile of the end users

Production team – Met Coke division

The Production Team is directly involved in managing and monitoring the coking process, from furnace operation to coke production.They possess in-depth knowledge and experience in coke production, including the operational and technical aspects of the coking oven.

Solution Requirements

Reduction in Hours: The current TAT of 53 hours could potentially be reduced, although the specific percentage improvement would depend on the existing process efficiency and other factors.

Improved Predictability: By replacing the current heuristic-based estimation with real-time measurements using sensors, the solution enables better predictability of oven readiness.

Reduction in Burning Losses: The percentage reduction in burning losses would depend on the magnitude of losses in the existing process and the effectiveness of the solution in preventing them.

Real-time Readiness Measurement: The solution should be capable of measuring the readiness of the oven in real time, indicating the completion of the coking process. This can be achieved through the integration of temperature sensors or other suitable sensors.

Alert System: The solution should provide an alert system to notify the operator when the oven reaches the desired level of readiness. This ensures timely action and prevents unnecessary delays or burning losses.

Data Storage and Analysis: The solution should have the capability to store and analyze the data related to oven readiness. This enables the production team to track and evaluate the performance of the coking process over time, identifying areas for improvement.

Automation and Elimination of Manual Intervention: The solution should aim to automate the readiness measurement process, reducing or eliminating the need for manual intervention. This minimizes human error and improves operational efficiency.

Integration of Thermal Cameras / Imaging sensors: The solution may involve the integration of heat vision cameras, or other imaging sensors to accurately measure the readiness of the oven. These cameras would be mounted on pushing cart and should be able to peep into the ovens periodically alerting the readiness. It must be reliable and capable of providing accurate data.

Compatibility and Integration: The solution should be compatible with the existing infrastructure and systems used in the coke production process. It should be capable of integrating with temperature sensors or other required devices seamlessly.

Reliability and Accuracy: The deployed solution should be highly reliable and capable of providing accurate measurements of oven readiness. It should be able to withstand the challenging operational conditions of the coking process.

Robustness: The solution should be robust enough to handle vibrations, fluctuations in temperature, and other environmental factors that are common in the coke production environment. It should be able to operate consistently and effectively under such conditions.

Deployment Constraints: The deployment of the solution should prioritize data security and privacy. Measures should be taken to protect sensitive data related to oven readiness and ensure that it is accessible only to authorized personnel.

Proactive Pushing: The solution should enable proactive pushing, aiming to reduce the cycle time of the oven. This ensures efficient utilization of resources and increases overall production capacity.

Expected Outcomes

1. Operational KPIs/Metrics:

Baseline KPI (Unit of Measurement)	Baseline # (Baseline Period)	Target (Expected)	Expected Timeline to achieve 100% Target
Avg. Oven readiness TAT	53 hours	50 hours	-

2. Qualified Outcomes :

Current State	Target State
Operator Judgement	Automation/Data driven decision making

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