I4MS 2015: Enhancing digital transformation in manufacturing SMEs I4MS 2015 will explore the progress achieved by the I4MS initiative and the impact participation has had on SMEs. To date I4MS has achieved over 80% industrial participation. An initial participation of 80 SMEs has now grown to 150 as momentum continues to build. Success is also evident with SME participation in projects leading to the adaption of new technologies and approaches. I4MS phase two will take this success further through additional projects supported by a budget of approximately EUR 35 Mn. At I4MS 2015 participating SMEs will present their experiences, results achieved and impact made. They will explain how they have benefited and what the adaption of innovative ICT has meant for their business. European support does not just exist at EU level. Action at regional level supported through programmes such as Smart Specialisation present the good opportunity to reach out to and involve the diverse landscape of European SMEs. At I4MS 2015 participants will be introduced to a new activity designed for such outreach – digital innovation competence centres – and an outlook towards the next stage of I4MS. I4MS is a EUR 77 Mn initiative of the 'Factories of the Future' partnership designed to support the adaption of innovative ICT by SMEs. Through seven integrated projects in four key areas, I4MS brings manufacturing SMEs directly into research and innovation projects, introducing them to innovative technologies and supporting the adoption of such technologies.

1. Enhancing Digital Transformation
in Manufacturing SMEs
22nd of May
Brussels
2015
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2. Fortissimo Experiment 402
Isabella Mazza
Ergolines Lab s.r.l.
Cloud-based simulation of continuous casting
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3. INDEX
1. WHAT WE ACHIEVED
2. HOW WE DID IT
3. HOW I4MS HELPED
4. HOW WE WILL TAKE IT FORWARD
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4. ERGOLINES PRESENTATION
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 4
Ergolines is based in Trieste, Italy
Technologies for
Steel Continuous Casting:
• ELECTROMAGNETIC STIRRERS
• SENSORS
• INSTRUMENTATION
44 Countries

5. WHAT WE ACHIEVED
1. THE CHALLENGE
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 5
INDUSTRIAL PROBLEM:
SLAG TRANSFER
 LOWERS STEEL QUALITY
 BREAKOUT AFFECTS:
 SAFETY
 PRODUCTIVITY
Continous Casting
LADLE
TUNDISH
CASTING
STRAND

6. WHAT WE ACHIEVED
1. THE CHALLENGE
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 6
INDUSTRIAL PROBLEM:
SLAG TRANSFER
 LOWERS STEEL QUALITY
 BREAKOUT AFFECTS:
 SAFETY
 PRODUCTIVITY
Continous Casting
OUR SOLUTION:
DESIGN OF
SLAG DETECTION SYSTEM
LADLE
TUNDISH
CASTING
STRAND

7. WHAT WE ACHIEVED
2. WHY HPC?
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 7
SLAG TRANSFERSTEEL POURING INTERRUPTED
BEFORE COMPLETE EMPTYING
STEEL WASTED = 1 TON/LADLE
COSTLY REMELTING NEEDED
DEMAND FOR SLAG
DETECTION SYSTEM
NEW BUSINESS OPPORTUNITY

8. WHAT WE ACHIEVED
2. WHY HPC?
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 8
SLAG TRANSFERSTEEL POURING INTERRUPTED
BEFORE COMPLETE EMPTYING
STEEL WASTED = 1 TON/LADLE
COSTLY REMELTING NEEDED
EXTREME CONDITIONS
LIQUID STEEL @ 1500 °C
FIELD EXPERIMENTS
NOT FEASIBLE
DESIGN REQUIRES
CFD SIMULATIONS
HUGE COMPUTATIONAL LOAD HPC
DEMAND FOR SLAG
DETECTION SYSTEM
NEW BUSINESS OPPORTUNITY

9. WHAT WE ACHIEVED
3. FORTISSIMO EXPERIMENT 402:
“CLOUD-BASED SIMULATION OF CONTINUOUS CASTING”
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 9
• End User
 Ergolines Lab s.r.l. (Italy)
• HPC Resource
 Arctur d.o.o. (Slovenia)
• Objective
 Exploit HPC to solve an industrial challenge :
Prevent slag transfer
• Activities
 HPC based CFD simulation of slag transfer
 Experimental model validation

10. HOW WE DID IT
4. Rationale
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 10
• Objectives
• Correlate vibrational signal with fluid dynamics
• Numerical Model
• Emptying mechanisms
• Experiments
• Single Phase Model (STEEL only)
• Double Phase Model (SLAG + STEEL)
• Performance Criterion
• Experimental validation of numerical models
 Vortex
 Drain Sink
 Dedicated Laboratory System

11. 6. Software used & Simulations
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 11
HOW WE DID IT
• Simulation time = 322 s = 5 minutes
• Computation time = 183.5 days = more than 6 months
Successful experimental validationSoftware: OpenFOAM 2.2.0

12. HOW I4MS HELPED
11. I4MS-enabled Achievements
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 12
• to achieve accurate results
 Transient simulations
 very fine geometrical discretization
 small time steps
ELEVATE COMPUTAIONAL TIME:
6 months to simulate 5 minutes
• High quality results:
successful experimental validation
MODEL RELIABILITY
• Complex phenomena, huge computational load CRUCIAL ROLE OF
CLOUD HPC

13. 13. Economic Impact
I4MS 2015: Enhancing Digital Transformation in Manufacturing SMEs · 22nd of May · Brussels 13
Exploitable output: know-how for new product Slag Detection System
Target Market Segments: Steel Continuous Casting
Benefits for Ergolines: reduced time-to-market, new business opportunity, internationalization
Benefits for End-users = Mini Mills:
• Increased Steel Yield: save up to 60% of 1 t wasted steel /ladle= 0.6% of production
• +0.6% Increased Productivity: save 6000 tonnes of steel /year/ 1 Mt produced
• Reduced Remelting costs: 100 €/t X 6000 t/year = 600.000 €/year saved
• Reduced Energy costs of remelting: 500 kWh/t X 6000 t/year = 3 GWh/year saved
HOW WE WILL TAKE IT FORWARD
High Quality
High Velocity

14. THANK YOU
FOR YOUR ATTENTION
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