Improving the efficiency of the longitudinal rolling process in the iron and steel factory in Misrata

Abstract

This research paper aims to enhance the operational and production efficiency of the longitudinal rolling process at the Misurata Iron and Steel Factory, addressing key challenges such as high energy consumption, inconsistent product quality, and increased downtime. The study employed a mixed-methodology approach, combining quantitative analysis of historical operational data with the application of Finite Element Method (FEM) computer simulation for the rolling process. Analytical results showed that 60\% of product defects were attributable to roll wear, and the roughing stand consumed 45\% of the total line energy. Based on the simulation outcomes, optimal operating parameters were identified, including modifications to the roll pass geometry, a 35^\circ\{C} reduction in reheating temperature, and synchronized speeds. The proposed recommendations demonstrated the potential for significant improvement, achieving a 9.5\% saving in specific energy consumption, an 11% increase in Overall Equipment Effectiveness (OEE), and a 57% reduction in the product defect rate. These findings support a shift towards intelligent and sustainable operation, thus strengthening the factory’s competitive advantage.