From control data to real-time resource maps in a steel-making plant

This study measures the resource efficiency of a basic oxygen steelmaking plant and develops visual maps of its resource use using raw energy and material data extracted directly from the control system. Resource efficiency is measured in units of exergy and resource flows are visualised in Sankey diagrams. Both the metric and the visuals are computed in close-to-real time scales, and are presented on a daily basis over a period of two weeks. Results show the highest level of resource efficiency (73.8%, Day 11) occurs not when energy intensity is greatest (Day 14) but instead when both energy intensity and material yields are high. Combining energy and materials into a single metric-resource efficiency-is shown to provide plant managers with a clearer picture of where interventions might deliver the greatest efficiency gains and redefines the concept of best practice.