Digital transformation in metallurgical engineering

Over the start of industrialization, several changes in production patterns have taken place, promoted by the introduction and application of new technologies. the world has already seen three paradigm shifts, known as industrial revolutions. Currently, a fourth transformation is in progress named digital transformation. Digital transformation is the integration of digital technologies in all areas of business in order to produce new values to the organization. The fourth industrial revolution also called Industry 4.0., brings a new concept of industry, based on a digitalization of production processes and combination of internet-oriented technologies. This allows the connection between smart sensors, machines and IT systems across the whole production value chain. The implementation of these cyber-physical systems will bring a series of improvements, such as an improve in operational efficiency, customer service, inventory levels and profit margin. Industry 4.0 is not only about the integration of new technologies, but it will also change the organization (Sánchez, 2019). The term digital transformation has been extensively defined depending to the industrial sector adopting it. Vial (2019) has offered the following definition:” improve an entity by triggering significant changes to its properties through combinations of information, computing, communication, and connectivity technologies”. The digital transformation disruptive technologies already represent a US$350-billion market, which by 2025 could grow to over $3.2 trillion. The definition of the “digital metallurgy” varies among organizations, it is however possible to define a set of core technologies that represent the DT in the metals industry including: Autonomous equipment, full automation, remote or unmanned control: This includes the use of robots in hazardous activities and remote operation to improve the safety of operators. The use of autonomous equipment, such as cranes are expanding rapidly. Steel ladle crane, cast iron torpedo car or copper electrorefining plant overhead crane are few recent examples of autonomous equipment. These can significantly reduce the collision risks, reduce OPEX by increasing the equipment utilization due to the continuous operation and increase the productivity. Internet of Things, smart sensors, artificial intelligence, machine learning and real-time big data: IoT is a network of objects, such as sensors, equipment, machinery who can interact, exchange data and coordinate. Development of smart sensors allows real-time capture of data from machines and equipment across the operation. (Deloitte, 2017). Predictive analytics has already demonstrated its potential to revolutionize the operational model, in terms of speed, cost, and ease of implementation. It uses advanced, self-learning algorithms to select through large volumes of data and identifying patterns. Steel surface inspection, strip weld inspection and solid waste inspection are the current examples of the IoT combination with machine vision sensors and machine learning. Predictive Maintenance through receiving the real data information of equipment vibration or motor circuit analysis are examples of transmission equipment PM. Augmented and virtual reality and digital twinning: Augmented and virtual reality, along with digital twinning are tools that will enhance the design and construction of metallurgical projects, and the extraction and processing operations. Digital twinning refers to the construction of a digital model of the physical operation or a process. This is possible using the operational information of the process, using the real-time data generated from the sensors connected across the operation. With the digital twin of the metallurgical process, it is possible to perform simulations, predict potential failures or downturns in performance. Thus, the digital twin establishes a useful tool to improve operational planning and reduce operational costs, by modeling the production processes. The future of the digital transformation is still undetermined; however, the technology is evolving quickly and to date, the significant applications of digital transformation in the metals industry and its connected value chains have appeared.