Process Engg > Tools

Batch annealing of cold rolled steel coils is a critical unit operation in the cold rolling mill, having strong influence on key plant performance parameters, namely, energy consumption, productivity and product quality. An integrated Batch Annealing Furnace Simulator (BAFSIMTM) with the capability to predict spatial and temporal evolution of temperature, microstructure and mechanical properties in cold rolled coils during the batch annealing process has been developed. Its potential applications include product development, efficient process optimization and online control resulting in benefits in terms of overall cost reduction, energy reduction, productivity enhancement and quality improvement.

Carburizing Simulator

Carburizing can so strongly affect key plant performance metrics such as productivity, product quality, energy consumption and environmental pollution. Optimizing the process is critical to successful manufacturing/heat treating. Carburizing optimization exercises have traditionally focused on individual performance metrics such as energy consumption, case depth or productivity.

ConSim (Continuous Casting Simulator)

Relying on the traditional trial and error methods to design casting processes is not only time and resource consuming; but could also result in faulty and unproductive casts and processes. This could lead to low quality products and revenue loss.

Our Continuous Casting Simulator is a software tool which enhances multivariable optimization. It helps optimize and enhance the casting process by replicating the process using diverse parameters. Helping meet product quality specifications, it enhances productivity, supports innovation on grades of steel, and reduces time to market. As a part of the engagement, our team of experts will understand the conditions in your plant, cull data from your existing processes, test them with our simulator and recommend parameters that result in optimal and enhanced productivity

Induration and Pelletization simulator

Quality is of utmost importance in the steel industry, at every step of operations. Low quality pellets fed to COREX, MIDREX or blast furnaces can reduce furnace productivity and the hot metal or sponge iron quality. Ensuring high pellet quality requires lower rates of production, which in turn, increases pellet production costs and impacts profitability.

Our offering helps you address these issues by improving the induration machine's productivity, maintaining desirable pellet quality and optimizing fuel usage. Enhancing your profit margins, it can also aid in minimizing gaseous emissions and in adhering to regulatory standards. Using a model-based software tool for multivariable optimization and control, we help you identify the best process operating regime for your induration process.

LFOR (Ladle Furnace On-line Reckoner)

In today's competitive business environment, steel producers worldwide are striving for productivity with consistent quality at the lowest possible cost. Ladle furnaces are a key unit in secondary steel making and contribute significantly towards meeting these objectives.

Now, with LFOR, the steel maker can achieve these goals. LFOR is a model-based on-line advisory system for prediction and control of temperature and chemistry of steel in ladle furnaces. This system has been developed, tested and implemented by Tata Research Development and Design Center (TRDDC), Pune

Optimized Sintering

The ideal sintering environment is one in which a highly productive sintering machine delivers good quality sinter, which adheres to blast furnace specifications, while optimizing factors like energy consumption, sinter bed permeability and granulation. This controls energy usage and minimizes adverse effects on the sinter machine and the blast furnace, ensuring that they support stringent production requirements.

Our model-based process optimization and control solution helps you to create and maintain this ideal environment. We bring a software tool for multivariable optimization, which aids you in controlling various factors that affect your sintering process.

Sponge Iron Rotary Kiln Simulator

Sponge Iron Rotary Kiln Simulator is a tool based on a fundamental mathematical model for direct reduction of iron ore by coal in a rotary kiln. The model uses ore and coal properties such as particle size distribution and chemical analysis along with kiln geometry and air profile as inputs. Heat and mass balances, reactions between different phases are included in the model for predicting the gas and solid temperature and composition profiles along the length of the kiln, degree of metallization and waste gas analysis. A user friendly GUI makes it easier to use the simulator and helps train operators and equips them to derive greater productivity in kiln operations.

The measurement of kiln internal temperature profile becomes inaccurate with time due to accretion. Our simulator can act as a soft sensor to predict the inside temperatures along kiln length and help the plant operators take appropriate decisions to run the plant in an optimized manner.


An indispensable, user-friendly PROCESS EVALUATION AND DIAGNOSTICS TOOL for Minerals and Materials Processing Industries

PREDICT is a software tool developed by Tata Research Development and Design Centre (TRDDC), to assist plant engineers in monitoring and optimizing the plant performance. With the help of a powerful material balancing algorithm, it uses the data collected from the plant (in the form of assays and flow rates) to compute a complete set of data that is balanced, consistent and reliable. PREDICT calculates plant performance in terms of recoveries and distribution of the various components in the output streams in a complex circuit configuration. PREDICT is a user-friendly system that has a powerful graphics environment, menu-driven operations and on-line context sensitive help. PREDICT maintains a database of assays, flow rates and plant performance that enables studies of trends and correlations. It also comprises of a sieve module for analysis of sizewise data. The effect of grind size as well as the plant performance as a function of particle size can be studied with the help of PREDICT.

Rational Design of Performance Chemicals

Pre processing of ores is very important as it can eliminate a lot of unwanted ingredients. This helps in meeting specifications for further processing and enhancing productivity thereafter. Most of the traditional reagent development is done through trial and error. This involves time and money and makes the process expensive. Some off-the shelf products are also used but these have limited impact. Our solution designs a customized reagent for your ore using state-of the art molecular modeling

SecSim (Secondary Steelmaking Simulator)

The nature and type of the steel depends mainly on the conditions and processes imposed on the molten metal during the secondary steelmaking process. The challenge begins with identifying the right parameters to enable the process you follow (Ladle/Tundish) to run at an optimum performance level. Studying the suitability of process and design changes, arriving at the process parameters for optimized plant performance and understanding flow behavior under changed conditions are imperative to developing high quality steel.. However, experimenting with varied processes and designs while arriving at the best parameters, can affect productivity and plant performance.

TCS understands the challenges involved in secondary steelmaking, whatever your manufacturing process.  Using a software tool for multivariable optimization, our solution seamlessly introduces suitable process and design changes without productivity loss.   Our team of experts gathers data from your existing operations and simulates the process using varied parameters to understand the behavior under changed conditions, and then obtains process parameters for optimized plant performance. Our solution also provides a detailed temporal thermal analysis of secondary steelmaking operation.


A user friendly powerful simulation tool for the design and optimization of mineral and material processing unit operations and circuits

SimL8 is a software tool developed by Tata Research Development & Design Centre (TRDDC), a division of Tata Consultancy Services, Pune, for simulating mineral processing plant operations, in particular those involving grinding, classification and flotation. This tool is based on more than 15 years of TRDDC experience in modeling, simulation and optimization of mineral processing unit operations and circuits.
SimL8 has been developed using the state-of-the-art Simulator Development Environment (SDE), a proprietary technology of Tata Consultancy Services

Wire Drawing Simulator

The challenges for the wire drawing industry include right die pass schedule design for a new product to meet mechanical properties which at the same time provides an optimal processing conditions in terms of energy consumption, die life or productivity. While a vast knowledge base and analytical models exist for the process design, a comprehensive tool to look at the whole machine in tandem including deformation and temperatures is needed to push the process design to next level.

Our FEA based simulator takes into account die pass schedule and die details, wire rod properties, machine parameters such as cooling of dies and drum, friction etc to predict loads on the dies, energy consumption, residual stresses and strains in the wire, temperature of the wire, die stress and temperature, chances for wire breakages etc. The tool can be customized for different machines based on their configuration. Wrapped in an optimizer, the tool offers you an optimized process for multiphase wiredrawing. It ensures a better pass design with ability to optimize for diverse targets, thereby minimizing production costs and maximizing profitability