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In the metals industry, reheating furnaces play a critical role in preparing materials for processing, but their high energy consumption presents a costly challenge. By applying AI-enabled Advanced Process Control (APC) models, early tests demonstrated up to 5% energy savings, with further optimization promising even greater efficiency and gas cost reductions.
Challenge: High energy consumption in reheating furnaces, with temperature inconsistencies across multiple heating zones requiring manual interventions. Achieving optimal efficiency without compromising product quality was difficult due to the need for precise temperature control and varying power inputs.
Solution: Implementation of AI-enabled Advanced Process Control (APC) models through the SORBA.ai platform. The APC models dynamically optimize power input and gas flow in real-time across multiple heating zones, reducing manual monitoring and improving energy efficiency. Early testing showed a 5% reduction in energy consumption, with further optimization expected to unlock even greater savings.
