cs007zen arcelor fos
Post on 03-Apr-2018
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Company profile With the merger of Mittal Steel and the
Arcelor-group in 2006 the world’s largest
company for steel production emerged.
Today ArcelorMittal produces around one
tenth of the steel manufactured throughout
the world. In 2007 the company achieved
a turnover of 76 billion Euro and employed
320,000 workers in more than 60 countries.
In the factory in Fos-sur-Mer, which was
once part of the Sollac Group, 3,300 workers
are employed and 4.5 millions of tons of
steel are produced every year.
Company strategiesThe aim of the group is to expand the use
of ArcelorMittal’s steels worldwide, by
inventing and producing steel solutions for
today and tomorrow with products that
create outstanding value for their customers.
The company constantly tries to improve
its competitiveness by optimizing current
industrial processes and developing new
approaches, to reduce cost and improve
quality. This is exactly what has been
achieved by modernizing the blast furnace
with the qualified help of Endress+Hauser.
Goals of the project • Reduction of production and
maintenance costs
• Digitize the original measurement
procedures and thereby modernize them
• Realization of reconstruction under tight
schedule without delay
• Installation of the PROFIBUS technology
to improve equipment life
Customer challenge/request As it is generally necessary to renew an
outworn blast furnace after two decades
of continuous operation, one of the two
giants installed in the plant at Fos-sur-Mer
was due to be revamped. At least this was
the original plan. However, while assessing
this rebuild the need for new measurement
devices became apparent. Blast furnace No. 1,
it was decided, was about to be digitized.
“If you want to know today, which part of
your car is defective the mechanic boots up
his computer to investigate. That’s what we
want to do in the future, when maintaining
our processes.” said Alphonse Fabiani,
electrical engineer at Fos-sur-Mer.
To control the process of raw iron
production, the automation technologies
and the measuring devices have to be
very robust and reliable to withstand the
extremely rough conditions of the industry.
Successful project execution:Blast furnace Re-vamp
Working hand in hand to upgrade the “old giant”
“We need solutions – not people who simply
pass the book, to others. From Mr. Endress
to the technician on site the Endress+Hauser
team were fully committed.”
Philippe Divol
ArcelorMittal
Results• Cost saving
• 3.5 Mio € profit per day
saved by project delivery
within schedule
• Efficiency
• Flexibility
• Risk reduction
12.06/I.I.
Instruments International
Endress+Hauser
Instruments International AG
Kägenstrasse 2
4153 Reinach/BL
Switzerland
Phone +41 61 715 81 00
Fax +41 61 715 25 00
www.endress.com
info@ii.endress.com
CS 007Z/29/en/10.08
LL/INDD CS2
Solution providedTo meet the requirements Endress+Hauser
took care to offer a complete and optimum
solution. The project scope included not
only the delivery of approximately 1,200
critical field devices from which 400 use
PROFIBUS PA, but also the engineering
of the instrumentation. Additionally
the solution included the construction
planning, commissioning, and specialized
services including training and testing.
Benefits A retrospective view of the project clearly
shows the benefits ArcelorMittal took
out of the work with Endress+Hauser.
In more than 5,000 working hours
Endress+Hauser could prove the quality
of their work which saved ArcelorMittal
both time and cost. The employment of
new and specially qualified workers as well
as their integration and training would
have been far more expensive for the steel
giant than the solution Endress+Hauser
provided. Additionally the cooperation
with Endress+Hauser also reduced risk.
If the tight time schedule had not been
kept, the revamp would have been far
more expensive for the company, if the
production which was stopped for 90 days
in 2007 couldn’t have been started again on
time. What would have resulted would be
immense, extra costs of an average amount
of 3.5 Mio € of profit daily.
Another great advantage they took out of
the technology installed in cooperation with
Endress+Hauser was new the procedures
that could be planned. These new technical
procedures within the factory at Fos-sur-Mer
derived improved financial control
which result in reduced production and
maintenance costs.
Project organizationEndress+Hauser took the consortium
lead and were responsible for total project
management as seen in the table above.
How did Endress+Hauser qualify toprovide this solution to ArcelorMittal?Beside the wide knowledge the
Endress+Hauser group can exhibit,
qualities such as flexibility of the workers
and their ideas, quick reaction to arising
problems and commercial qualities all
helped to convince ArcelorMittal. In
addition to this, the appropriate price
Endress+Hauser offered for the solution
package in combination with the PROFIBUS
technology proposed. The good relationship
that has existed for over twenty years
between ArcelorMittal in Fos-sur-Mer and
Endress+Hauser France,was – of course –
another factor to chose Endress+Hauser
to work with leaving a large part of the
plant looking “blue” (Endress+Hauser
instruments color).
At what stage did ArcelorMittal involveEndress+Hauser into their project?They contacted Endress+Hauser right at
the start in 2003 when they began planning
the revamp of the blast furnace. During the
following days, a contract was signed and
the most suitable design was elaborated
through a close collaboration of the two
companies. The first orders for devices were
placed in July 2006.
How long was the project lifecycle?The first contact ArcelorMittal and
Endress+Hauser had been in 2003 after
which the engineering and planning
followed. The actual project took place
from July 2006 to March 2008.
Are there further projects resulting out of this one?
ArcelorMittal have entered into
negotiations to revamp and renew the
second blast furnace in Fos-sur-Mer. Today
it is certain that there will be an identical
project with the same team working on it,
with exactly the same devices and the same
solution provided, which is a confirmation
for the perfectly matching solution and the
perfect cooperation between ArcelorMittal
and Endress+Hauser.
Siemens
Other participants
Suppliers
Production Center
Endress+Hauser
Third party suppliers
Partnership
Head of consortium
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