交流提纲／Outline

• N-SIDE 公司介绍

• 钢铁企业危机与挑战

• 智能决策优化系统的功能特点

• 产购销一体优化实例

• 总结

• Highlight of N-SIDE

• Challenges for steel industry

• Intelligent decision optimization

• Case studies

• Summary & Conclusions

供应链Supply Chain

能源管理Energy Management

工业过程Process Optimization

全球主要客户

钢铁行业面临深度危机Industry-wide severe crisis

钢铁企业

Steelmaker

产能过剩

Excess capacity

市场动荡

Market volatility

需求下降

Declined demand

钢铁企业想要在严重危机中生存，唯一可持续的战略就是成为低成本的制造商。

The only sustainable way for a steel company to survive from this severe

crisis is to become a low-cost producer.

提升成本竞争力所面临的挑战Challenges of improving cost competitiveness

智能决策优化系统及其功能

财务计划

公司总体利润最优、成本最低或产量最大

采购成本 生产成本 能源成本 收益

原料采购优化

产品组合优化

生产过程优化

产量为目标的生产资源配置优化

能源优化

时序为中心的生产排程优化

智能决策优化系统

公司战略目标（例如 EBITDA）

原材料市场价格和可获得性的变化

产品市场需

求和价格的变化

供给侧

需求侧

• 原材料动态评价• 选购方案及最优采购量

• 基于“极限边际价格”的协商议价

• 制定中间产品外销外购策略

• 基于“边际成本”计算产品盈亏，寻找最优产品组合和生产路径

• 进行原材料厂间分配，计算最优配煤配矿比

• 确定各生产单元最优生产量及操作点

• 合理回收废料，减少资源浪费• 确定生产瓶颈，提高投资回报

• 计算全流程能量平衡，合理分配利用焦炉高炉转炉煤气，减少天然气使用量

• 计算硫氧化物、氮氧化物和二氧化碳排放量及排放成本

• 编制各生产单元的成本预算报表和利润预算报表

• 按照公司战略目标的要求，计算公司最优总体利润，最小成本或最大产量

Intelligent decision optimization system functions

Financial planning

Profit, cost or production optimization

Procurement cost Production cost Energy cost Revenue

Raw

Material

purchase

optimiza-

tion

Process Optimization

Resource allocation

optimization, focusing

on production volume

Energy

optimi-

zation

Advanced scheduling, focusing

on time and sequence

Intelligent decision

optimization system

Corporate strategic goal

（e.g. EBITDA）

Changes in raw

material market

price and

availability

Changes in

product market

demand and

price

Supply Demand

Product

profile

and mix

optimiza-

tion

• RM dynamic

assessment

• Optimal selection

& purchase plan

• Price negotiation

based on “Limit

Marginal Price”

• External purchase

or sale strategy of

intermediate

product

• Identify profitable

products and

optimal production

routes based on

marginal cost

• RM allocation and optimal

blending

• Optimal operating point and

production level for each unit

• Waste recovery

• Production bottleneck

identification for higher ROI

• Complete energy balance,

optimal allocation of COG, BFG

& LDG with reduced

consumption of NG.

• Calculation of SOx, NOx and

CO2 emission and penalty cost

• Cost and profit report for each unit

• Achieve max profit, min cost or max

production based on corporate

strategic goal

智能决策优化系统特点intelligent decision optimization system features

敏捷生产

Agile manufactur-

ing

精细管理

Delicacy management

智能决策

Intelligent decision making

协同优化

Collaborative optimization

预案比较

Scenario comparison

指标分析

KPI analysis

开放平台

Open platform

全流程优化，多部门协同

9

在市场条件变好的情况下，我们是否应该增加产量？哪种产品将带来最大的利润？什么生产线组合最适合生产这种产品？

在不影响质量的前提下，什么是最优的铁水化学成分组成？

废钢价格的变化对转炉进料量的影响是什么？

我们是否应该增强焦炭强度？其对成本的潜在影响是什么？

基于球团市场的变化（数量和价格），烧结矿的最佳生产量是什么？

我们是否应该生产更多的焦炭来外销，或生产更多的焦炉煤气来降低能源成本？

如何选择原材料，什么是最佳配煤配矿比？

在一定煤气混合限制条件下，如何最优地使用焦炉高炉煤气？

Integrated optimization & collaboration

10

Should we increase the production due to good market condition? Which end product to make for more profit? Which facility route to use?

What is the best S content in hot metal, taking into account the trade off between coke production cost (cheaper coal with high S content) and desulfurization cost?

Does desulfurization station have enough capacity to treat high-S hot metal?

Similar question to Si content in hot metal.

Should we increase MnO in sinter in order to reduce consumption of FeMn at SMS?

Should we increase coke strength? What will be the cost impact?Depending on pellets availability

and price, what will be the best production level for sinter?

Should we produce more coke for external sale, or more COG to reduce energy bill?

Which raw material to choose, and at what blend ratio?

How to distribute internal gases given the gas mixing constraint?

精细化管理，智能化决策

•数百个决策变量，其可能影响整个钢铁生产过程的方方面面

•许多钢企已开发多种过程模型，但是通常的做法是运用反复试验的方法进行仿真计算。其很难找到最优点。

•运筹优化技术在以整体利润为目标的前提下，给出最大利润的操作点，并同时满足所有的经济、技术条件以确保生产的可行性。

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优化

仿真

企业成本竞争力

• Hundreds decision variables, which may have impact on various aspects of the entire steelmaking process

• Many plants have developed process models, but common practice is to run model simulations by “trial and error” approach, which is difficult to find the optimal point.

• Intelligent optimization

technology maximizes overall

profit, while satisfying all

technical & economic

constraints to ensure the solution is optimal & feasible.

Delicacy management & intelligent decision

12

Optimization

Simulation

Cost competitiveness

钢铁成本优化系统Steel COst OPtimization (SCOOP) system

一个智能决策优化系统如何帮助提升钢铁企业成本竞争力

How an intelligent decision optimization system can help

improving steel production cost-competitiveness

原料采购优化Raw material procurement optimization

财务计划

公司总体利润最优、成本最低或产量最大

采购成本 生产成本 能源成本 收益

原料采购优化

产品组合优化

生产过程优化

产量为中心的生产资源配置优化

能源优化

时间为中心的生产排程优化

SCOOP系统

公司战略目标（例如 EBITDA）

原材料市场价格和可获得性的变化

产品市场需

求和价格的变化

供给侧

需求侧

• 原材料动态评价• 选购方案及最优采购量

• 基于“极限边际价格”的协商议价

• RM dynamic

assessment

• Optimal selection

& purchase plan

• Price negotiation

based on “Limit

Marginal Price”

原材料价值评估：极限边际价格

15

极限边际价格

• 动态评估原材料的真实价值

• 与供应商议价的有效工具

• 确定最优采购量

最优采购量

Raw material value assessment:

Limit Marginal Price

16

Limit Marginal Price

Computes real value of the raw

material for the process

Dynamic (depends on the rest)

Negotiation tool by comparing

with market price

Optimal purchase volume

用户实例Case study #1

One steel company has two integrated steel production sites with annual production of 9.5 million tons. SCOOP system was implemented in 2009 with SCOOP enterprise version for coordination between sites. Within one year, they continuously increased the usage of one coal according to SCOOP optimization results and achieved significant benefits.

某钢铁企业拥有两个全流程生产厂，产能950万吨。2009年实施SCOOP以及SCOOP企业版用以协调多厂优化。在一年的时间内根据SCOOP优化结果逐渐增加某煤种的使用量.

17

生产过程优化Process optimization

财务计划

公司总体利润最优、成本最低或产量最大

采购成本 生产成本 能源成本 收益

原料采购优化

产品组合优化

生产过程优化

产量为中心的生产资源配置优化

能源优化

时间为中心的生产排程优化

SCOOP系统

公司战略目标（例如 EBITDA）

原材料市场价格和可获得性的变化

产品市场需

求和价格的变化

供给侧

需求侧

• 进行原材料厂间分配，计算最优配煤配矿比

• 确定各生产单元最优生产量及操作点

• 合理回收废料，减少资源浪费• 确定生产瓶颈，提高投资回报

• RM allocation and optimal

blending

• Optimal operating point and

production level for each unit

• Waste recovery

• Production bottleneck

identification for higher ROI

用户实例

Case study ＃2

A cheap but high-S PCI becomes available in the market. One steel company used SCOOP to evaluate the impact of this new PCI on slab production cost to determine whether it should be used and if so, how much is needed.

某钢铁厂使用SCOOP系统来评价一种新的市场上可获得的喷煤对钢坯生产成本的影响。这种喷煤价格便宜，但是含硫量较高。通过SCOOP系统可以决策是否试用，若是，最优使用量是多少。

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S (%) BF1 BF2 BF3

Base case without new

PCI

0.041 0.040 0.042

Alternative case with

new PCI

0.081 0.079 0.082

Financial impact on Difference

hot metal production cost -8.71 €/thm

desulfurization cost +0.66 €/tst

slab production cost -7.34 €/tst

产品组合优化

财务计划

公司总体利润最优、成本最低或产量最大

采购成本 生产成本 能源成本 收益

原料采购优化

产品组合优化

生产过程优化

产量为中心的生产资源配置优化

能源优化

时间为中心的生产排程优化

SCOOP系统

公司战略目标（例如 EBITDA）

原材料市场价格和可获得性的变化

产品市场需

求和价格的变化

供给侧

需求侧

• 制定中间产品外销外购策略

• 基于“边际成本”计算产品盈亏，寻找最优产品组合和生产路径

• External purchase

or sale strategy of

intermediate

product

• Identify profitable

products and

optimal production

routes based on

marginal cost

边际成本和最优生产量的确定Marginal cost & optimal production level

21

售价sale price

边际成本Marginal cost

生产量 production level

总利润Total profit

加入生石灰提高烧结矿产量Quicklime to increase sinter production

高炉使用球团Pellet used at BF

消耗额外的废钢Consumption of extra scrap

购买外部焦炭External coke used

边际成本＝售价, 利润最大方案MC=Price, max profit solution

边际成本>售价, 增加生产量提高销售收入但利润下降MC>Price, inc. production makes higher revenue, but declined profit

转炉使用铁硅合金FeSi alloy used at CV

边际成本<售价，增加生产量获利MC<Price, increase product for profit

800

850

900

950

1000

1050

1100

800 850 900 950 1000 1050 1100Marginalcost[€/t]

Sellingprice[€/t]

用户实例Case study #3

某钢铁企业利用SCOOP计算边际成本并对产品按边际利润排序

A steel company used SCOOP calculate marginal cost and sort all products based on marginal profit.

22

最优产品组合 / Optimal product mix

获利产品 (销售价格>边际成本) -> 扩大生产以最大满足市场需求或至最大产能Profitable product (Price>MC) -> increase production to meet max market demand

无利可图 (销售价格<边际成本) -> 减少生产至满足最小市场需求Non-profitable product (Price<MC) -> reduce production to meet min market demand

-40 -20 0 20 40 60 80 100

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Marginalprofit[€/t]

Products

边际利润 Marginal profit

产品排序

So

rte

d p

rod

ucts

边际成本

Ma

rgin

al co

st

销售价格 Sale price

Steel COst OPtimization (SCOOP) system

结束语Summary & Conclusion

SCOOP成长业绩碳钢、不锈钢生产商及原材料供应商

• 应用于全球15家钢铁企业

• 约涵盖世界10%钢铁产量

• 节约吨钢成本2-5欧元

• 全流程优化，而不是单独考虑各生产单元的局部优化

• 对各生产单元过程及其相关性具有更好的理解，能够在各生产单元之间进行权衡以达到总体利润最大化

• 以极限边际价格为基础对原材料的真实价值进行动态评估并优化原材料的选购

• 通过打破各部门间的独立运营，改善部门间的交流、协作以及信息共享

SCOOP AchievementCarbon steel, stainless steel producers and raw material suppliers

• Applied to world-wide 15+

steel companies.

• ~10% global steel production

• Significant cost savings of 2-

5 Euros per ton

• Integrated optimization of complete value chain,

instead of each individual operation unit.

• Understanding of processes and complex

impacts involving multiple operation units hence

decisions can be made based on appropriate

trade-offs to achieve maximum overall profit.

• Negotiation power gained by assessing true

value of raw materials using LMP.

• Improved collaboration and info sharing of all

stakeholders by breaking down internal “silos”.

网址：www.n-side.com steel.n-side.com邮件：yzh@n-side.com电话：+1.647.680.2378（North America） +86.13810189901（中国）