Digitalization of electric melting furnace operation
Efficiency and sustainability: Successful digitalization of electric melting furnace operation
Starting situation
Technological transformation for CO2-reduced production | Our customer, Flumroc AG, a leading manufacturer of stone wool, has replaced two coal-fired cupola furnaces with a single electric melting furnace in order to significantly reduce emissions. The new furnace now supplies both production lines, significantly increasing energy efficiency. The long-standing partner company IMT AG took on the complex software adaptation.
Due to the sophisticated connectivity of system components, a preliminary project was carried out to determine the feasibility and precise cost estimate. This changeover represents an important step towards environmentally friendly and efficient production and significantly reduces the company's ecological footprint.
Challenges before the project
Before the project began, several challenges had to be overcome to ensure a successful transition. Key considerations included:
- Data integrity: it was critical to maintain the integrity and accessibility of historical production data during the transition. The risk of data loss needed to be mitigated to maintain continuous quality control and operational insights.
- Timing of implementation: The project timeline was critical. The switch to the electric furnace had to be planned during a period of low production demand to minimise disruption to Flumroc's operations.
- System compatibility: It had to be ensured that new software components could be smoothly integrated into Flumroc's existing infrastructure without requiring extensive downtime or retraining of staff.
These challenges shaped the strategic planning and execution of the project to ensure that the transition to a more sustainable production method was both smooth and effective.
Project objectives
The aim of the project was to minimize CO2 emissions during stone melting using a technologically advanced electric melting furnace and to increase the efficiency of the production processes. Innovative, future-proof components were implemented for this purpose. Data recording and validation were improved to ensure process quality, while old server systems were replaced with modern solutions that increase performance.
In addition, the digitalization of processes was driven forward to reduce manual activities and existing outdated systems were migrated on the basis of the IMT EAF platform. These measures contributed to a more sustainable and CO2-reduced production.
Technical implementation
The technical implementation was based on the IMT EAF framework, which enabled the seamless migration and integration of existing systems. Technologies such as .NET 8.0 Core, Blazor, WPF and Microsoft SQL Server were used. By using the IMT EAF Framework based on .NET 8.0, cross-platform applications were developed that allow flexible integration. WPF was used to create user-friendly desktop interfaces, while Blazor was used to develop reactive web applications.
Blazor is a modern web framework developed by Microsoft as part of the .NET ecosystem. It enables developers to create web applications with C# that build on existing .NET technologies. Blazor facilitates the creation of rich, responsive user interfaces with real-time web capabilities. This technology was used at Flumroc AG to optimise operational control and data visualisation of the production line.
The existing software components were successfully migrated and optimised, including the adaptation of the production parameters and their distribution to the new line constellations. The connection of the control systems via OPC UA (Open Platform Communications Unified Architecture) ensured secure and reliable communication. In addition, data recording was switched to the Wonderware Historian Server in order to further optimise data storage and analysis. With the IMT EAF Framework as the central base component, standardised data processing and improved interoperability were achieved. This centralisation not only simplifies operations and standardises the platform for controlling production parameters, but also improves the accuracy of process adjustments required in real-time production environments.
Results
The project led to a significantly improved digitalization of the production lines, optimized existing structures and improved processes. The use of the IMT EAF framework provided a cost-effective solution for developing customized applications with extensive performance features. In addition, the availability and quality of the data were significantly increased.
The iterative approach made it possible to react quickly to feedback and increase the acceptance of the new systems. Particularly noteworthy is the use of Blazor, which supported the development of user-friendly web applications and created interactive, powerful solutions in the area of data analysis that optimally met the requirements of the users.
Would you like to know more about how we use innovative technologies such as the IMT EAF framework to increase efficiency and sustainability in the industry? Contact us - together we will develop a solution that suits you.
