Scientists from South Ural State University are working with the Magnitogorsk Iron and Steel Works to improve the energy efficiency of the enterprise’s power plants by introducing smart energy efficiency management systems. These systems operate using the Internet of Things technology: information from hundreds of smart sensors enters the system and is processed online, which prevents energy overruns and equipment breakdowns.
Scientists have worked out an optimizing technical and economic model of the station. In an automated “advisor” mode, it makes it possible to carry out a comprehensive calculation of the optimal load distribution between power units and the optimal load of the station. This model considers the current technological limitations, the technical condition of the equipment, the cost of energy resources consumed, and energy products generated.
‘The system under development consists of the following subsystems: a subsystem for collecting technological parameters; a subsystem for online energy performance monitoring and the state of the power unit; a subsystem for continuous vibration monitoring; a subsystem of data integration into external automated enterprise management systems. Depending on its type, from 25 to 100 parameters are provided for one power unit,’ explains Dmitry Schneider, project manager.
An automated system of digital twins will be able to determine the current values of the main energy indicators. It will help identify instances of additional costs of energy resources and subsequently analyze their causes. Also, it will make it possible to clarify the energy characteristics of power units based on actual operation data, considering their state, conditions, and operating modes.
Economically, the project is expected to result in increased efficiency of power units and reduced risks of unscheduled repairs and power plant equipment downtime. The project is expected to pay off within two years.