Zyfra AI
INDUSTRIAL AI
METALS & MINING
Zyfra AI solutions for Metals & Mining industry
Zyfra AI solutions for
Metals & Mining industry

Traditionally, facilities in Metal & Mining industry are equipped with many sensors and SCADA system. Huge volume of the information is stored on the servers, factory spent money for storing and has nothing in return. Zyfra AI products study and enrich the information and, based on present day integration with SCADA system, manage production facilities really effectively.

We collaborate with leading manufacturers of the industry and help them to improve quality, increase productivity and boost machine availability. The effectiveness of Zyfra AI products was proved on steelmaking, pipe rolling and other complexes.
SOLUTIONS
Steelmaking Engine AI
Heat Treatment AI
STEELMAKING ENGINE AI
BOF Zyfra AI
Product purpose is to reduce the amount (and cost) of ferroalloys per melting and simultaneously align product's chemical components with heat report. Ferroalloys are added into Basic Oxygen Furnace (BOF) and Ladle Furnace (LF) during melting and refinement and this operation is one of the most expensive.

BOF Zyfra AI digital advisor provides recommendations on the optimal absolute amount of ferroalloys to be "dumped" into a melted steel to get desired steel quality with minimal costs. It also reduces the number of chemical composition adjustments needed due to high prediction accuracy.

The heart of the BOF Zyfra AI is a Machine Learning model, trained on the historical data on previous smeltings.

When operational, BOF Zyfra AI obtains real-time process data from SCADA and IT systems, using data on ferroalloys available, current status of smelting and target steel grade. The product is fitted with adapters for connection with any major SCADA and has customizable GUI as well as API.

Existing implementation of BOF Zyfra AI allow to reduce ferroalloys consumptions by 5% and more, thus saving our customers millions of USD per year on ferroalloys costs and productivity increase.
STEELMAKING ENGINE AI
EAF Zyfra AI
EAF Zyfra AI is designated to reduce melting time and power costs per melting and to align semi product's chemical components with technical requirements.

EAF Zyfra AI provide recommendations on the optimal smelting mode, thus allowing to make smelting faster and consume less electricity, keeping steel quality and output volume intact.

Machine Learning model predicts outcomes of the smelting using data on raw materials and process parameters, while optimization model uses these predictions to find optimal process model. Models are being trained on the historical data.

In the operational mode, EAF Zyfra AI obtains real-time process data from SCADA and IT systems, using a wide range of software connectivity interfaces developed. It has customizable GUI to provide efficient operational awareness and decision support to EAF operator, as well as API to allow programmatic access to the recommendations, making fully automated control mode possible.

Implementations of EAF Zyfra AI demonstrated that this solution is capable to reduce Power-On time by 10% and significantly reduce electricity, oxygen and fuel consumption. In most cases, ROI of this solution is less than 6 months.
STEELMAKING ENGINE AI
LF Zyfra AI
Product purpose is to reduce the amount (and cost) of ferroalloys per melting and simultaneously align product's chemical components with heat report. Ferroalloys are added into Basic Oxygen Furnace (BOF) and Ladle Furnace (LF) during melting and refinement and this operation is one of the most expensive.

LF Zyfra AI digital advisor provides recommendations on the optimal absolute amount of ferroalloys to be "dumped" into a melted steel to get desired steel quality with minimal costs. It also reduces the number of chemical composition adjustments needed due to high prediction accuracy.

The heart of the LF Zyfra AI is a Machine Learning model, trained on the historical data on previous meltings.

When operational, LF Zyfra AI obtains real-time process data from SCADA and IT systems, using data on ferroalloys available, current status of smelting and target steel grade. The product is fitted with adapters for connection with any major SCADA and has customizable GUI as well as API.

Existing implementation of LF Zyfra AI allow to significantly reduce ferroalloys consumptions, thus saving a lot on ferroalloys costs and productivity increase. One of the cases demonstrated average savings of 10 000 EUR per day for a single Ladle Furnace installation.
STEELMAKING ENGINE AI
CCM Zyfra AI
CCM Zyfra AI is designated to predict failures of main units of the CCM (continuous casting machine) to avoid outage during casting and to align product's features with technical requirements. CCM outages are one of the main reasons of productivity and quality reduction, as wells as of the growth of the cost of slabs. Based on prediction, CCM operator can change operating mode or use routine break for maintenance of the critical units.

CCM Zyfra AI comes with a wide range of interfaces with major SCADA and IT systems, customizable GUI and API for programmatic access.
Heat Treatment AI
The solution is designed to optimize the area of pipes heat treatment. It's built on models that describe the quality of pipes (mechanical test results) depending on the task, heat treatment mode and historical observations.

The solution takes into account the equipment possibilities and limitations. Recommended modes can be applied automatically or after validation by a person.

A feature of the solution is to take into account all the details of the process specific to a particular production:
- chemical composition of the specific melt;
- furnace condition;
- inaccuracies of sensors and temperature settings;
- cooling water temperatures.

Possible effects from the solution implementation:
- increase in output to 6% per year;
- defect level decrease.
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