Steel mini-mill

an electric arc furnace melt shop and a continuous caster in one material flow, over opc ua eight devices and 122 tags operator view on 4017 , opc ua on 5027 what it demonstrates a process upset becoming an energy bill slag foam collapses, the arc radiates at the panels instead of into the bath, meltdown stretches, the heat taps late, the tundish runs down, and the melter pushes a higher transformer tap to protect the casting sequence the billed 15 minute demand peak moves with it, and that peak sets the charge for the month a breakout seen before it happens the mould thermocouples lag the shell by seconds reading the lag rather than the level is what turns a breakout into a slowdown copper the melt shop cannot refine out residual copper arrives with the scrap and cannot be removed downstream, so the grade a heat can be sold as is decided at the scrap yard batch and continuous in one flow this is the only solution here that is both at once, and the coupling is the demonstration the furnace melts a heat as an isa 88 batch the caster runs a strand continuously a ladle furnace joins them the caster is the pacemaker, and the melt shop is sized to run about a minute ahead of it, so a delay upstream propagates rather than being absorbed nothing in the cost chain is a rule that says if fault then cost the numbers come out of the process model litmus edge as an aggregator the mill also demonstrates republishing northbound with the edge's own opc ua server enabled, the full chain runs simulator, to edge opc ua client driver, to devicehub, to edge opc ua server, to an mes client browsing the address space that is the only place in this set where litmus edge is shown as an aggregator rather than as a collector what it puts on litmus edge eight devicehub devices covering the furnace, ladle furnace, caster, tundish, mould, scrap yard and utilities, with 122 tags over opc ua a digital twin model and instance per unit analytics groups behind the specific energy, demand charge, cast rate and grade compliance figures deploy services steel minimill image us docker pkg dev/litmus customer facing/litmus solutions/steel minimill demo 0 1 0 container name steel minimill demo restart unless stopped ports \ target 4017 published 4017 protocol tcp \ target 5027 published 5027 protocol tcp environment \# fill these in edge url "${edge url }" edge api token "${edge api token }" sim host "${sim host auto}" apply on start "${apply on start 1}" edge verify tls "${edge verify tls 0}" http port "4017" opcua port "5027" protocol "opcua" speed "6" seed "7" log level "info" edge url=https //10 0 0 5 edge api token=your token sim host=10 0 0 9 docker compose up d open http //localhost 4017 configuration variable default what it does edge url the docker host litmus edge to configure edge api token unset token for that edge or a username and password, or a client id and secret sim host auto address the edge polls to reach this solution apply on start 1 configure the edge on startup edge verify tls 0 1 checks the edge's certificate speed 6 6x real time, so a 40 minute heat is watchable in about seven seed 7 makes a run repeatable set speed to 1 to demonstrate breakout detection on the edge the row 1 to row 2 thermal lag is about six seconds, and a speed multiplier divides the polls across it what you see across the top the heat in progress and its phase, specific energy, the billed demand peak and what it costs, tap to tap time, mill demand now, furnace share of it, cast rate and grade compliance below, the mill itself the furnace with its electrodes regulating and the scrap pile melting into the bath, the ladle furnace, and the tundish feeding the mould with the strand withdrawing at cast speed faults include slag foam collapse, a tundish level excursion, a mould friction rise towards a breakout, and a scrap charge carrying high copper removing it docker compose down use clean up in the solutions provisioner # to remove what it created on the edge support support\@litmus io mailto\ support\@litmus io