Smart Manufacturing for a Sustainable Steel Future
The iron and steel industry supports essential sectors such as automotive, construction, and infrastructure. However, it faces urgent challenges: achieving decarbonization, improving energy efficiency, ensuring a stable supply of high-quality steel and optimizing production processes.
Yokogawa leverages its expertise in measurement, control, and AI-powered digital technologies to accelerate digital and sustainability transformation in the steel industry. Backed by a global support system, Yokogawa delivers timely support and works across the ecosystem to enable sustainable steel production and enhance operational efficiency.
Your vision for a smart and resilient steel manufacturing—realized with Yokogawa by your side.
Key Industry Challenges and How Yokogawa Responds
Reducing Carbon Emissions and Enhancing Energy Efficiency
- Emissions monitoring
- AI-enabled energy optimization
Ensuring a Stable Supply and Optimizing Production Processes
- Predictive monitoring
- Safety instrumented systems
- Process automation
Driving Cost and Operational Efficiency
- Cost and resource optimization
- Streamlined operations
Yokogawa's Solutions
Sustainability Maturity Assessment
Assess and improve sustainability performance with an industry-aligned framework.
Solutions
- Evaluate sustainability maturity across operations
- Generate actionable insights for improvement
Benefits
- Clear baseline for sustainability initiatives
- Actionable roadmap to guide continuous improvement
Greenhouse Gas Emission Visualization and Management
Visualize, manage, and reduce Scope 1 and 2 GHG emissions in compliance with international standards.
Solutions
- Provide reliable emissions data based on actual measurements, fully compliant with international standards
- Monitor all energy consumption across the plant and optimize GHG emissions in real time
Benefits
- Informed decision-making toward achieving carbon neutrality
- Clear visibility into emission hotspots and operational inefficiencies
Real-Time Gas Composition Monitoring
Continuously analyze process gases to improve combustion control and energy efficiency.
Solutions
- Monitor oxygen concentration in exhaust and furnace gases
- Integrate gas analysis with control systems for feedback
Benefits
- Improved energy efficiency and fuel control
- Reduced manual inspection workload
- Timely adjustments to combustion and fuel ratios
KPI-Driven Operational Decision Support
Visualize purpose-driven KPIs to promote continuous improvement and agile decision-making.
Solutions
- Identify gaps in process and performance
- Integrate purpose-driven KPIs for real-time response
- Support improvement cycles through operational dashboards
Benefits
- Better data-based decision-making
- Sustained knowledge transfer across teams
- Greater agility through structured action loops
Wireless Temperature Monitoring for Large Outdoor Facilities
Monitor coal yard temperatures continuously with a reliable, low-maintenance wireless system.
Solutions
- Extend coverage with long-range wireless communication up to 2 km
- Monitor temperatures without wired installation
Benefits
- Reduced field labor and maintenance effort
- Reliable ignition prevention through continuous sensing
AI-Driven Vibration and Temperature Monitoring
Monitor equipment health in real time and support predictive maintenance using AI-driven wireless technology.
Solutions
- Monitor vibration and temperature wirelessly using ISA100
- Apply AI analysis to enable condition-based maintenance
Benefits
- Continuous tracking of equipment health
- Forecasting of maintenance needs and avoidance of downtime
Fire Risk Monitoring for Conveyor Systems
Enable continuous, fiber-optic-based fire risk monitoring with meter-level precision.
Solutions
- Detect abnormal heat using distributed fiber-optic sensors
- Monitor conveyor cones continuously, 24/7
Benefits
- One-meter accuracy for localizing heat anomalies
- Damage mitigation and reduced patrol costs
Application Note: Conveyor Belt Fire Detection
DTSX3000 Distributed Temperature Sensor
Centralized and Collaborative Operations Management
Break down silos and drive innovation through and an integrated, unified operations environment.
Solutions
- Design and implement a unified operations platform and KPIs
- Optimize control room ergonomics and workflow structure
- Provide consulting on roles and change processes
Benefits
- Enhanced collaborative and situational awareness
- Centralized, informed decision-making across facilities
Integrated Operations Center (Yokogawa Integrated Solutions Blog)
Condition-Based Decoking Optimization
Maximize furnace efficiency and stable steel production by optimizing decoking timing based on real-time coking conditions.
Solutions
- Calculate coking buildup using model-based estimates
- Monitor coil conditions to identify the optimal time for decoking timing
Benefits
- Reduced frequency of decoking
- Improved furnace efficiency and stable steel production
Digital Permit to Work and Risk Control
Standardize and streamline work authorization to ensure safety and compliance across frontline operations.
Solutions
- Embed expert knowledge from permitting experience
- Simplify control navigation through intuitive icons
- Issue digital permits with hazard safeguards
Benefits
- Assured hazard control with proper authorization
- Continuous improvement through shared learning
- Flexible adaptation to site-specific safety rules
Resources
First generation CENTUM had contributed to the production of high-quality steel product at the NSSMC's Yawata Works for 33 years.
Yokogawa had pursued innovation of process control technology with the customer during the decades.
The Japan Steel Works, LTD., Muroran Plant uses the Control and Measurement Station CX2000, UP series program controllers, and UT series digital indicating controllers for operation of its heat treating furnaces.
A furnace for heating slabs needs to be operated under low oxygen conditions at high temperatures of 1000°C and above to prevent oxidation of the steel. The measurement of oxygen concentrations in the furnace is essential in this process. (AN 10M01F01-03E)
To technology in iron & steel industry is continuously improved to obtain the best possible performance. The improved plant performance gives rise to the higher quality improvement and lower cost, and simultaneously environmental friendly plant operation.
A belt conveyor fire detection solution employing the DTSX distributed optical fiber temperature sensor can greatly reduce crises that can threaten a company's survival.
News
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Press Release | Corporate Feb 20, 2023 Yokogawa Enters into Partnership with Radial Software Group to Provide AI-powered Viewport Software Worldwide
- Giving customers a single view of all their technical data -
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