EVRAZ ZSMK introduced a "digital twin" on blast furnaces, reducing costs and increasing production efficiency
| Customers: Western Siberian Metallurgical Plant (EVRAZ ZSMK) Project date: 2025/06 - 2025/12
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2025: Introduction of a "digital twin" on blast furnaces
EVRAZ ZSMK has implemented an innovative digital project "Model for managing air heaters of blast furnaces No. 1 and No. 3." The introduction of an intelligent system of automatic gas supply for hot blast preparation has improved working conditions and made it possible to achieve significant resource savings. The confirmed annual effect of the project amounted to 78 million rubles. EVRAZ announced this on January 20, 2026.
The project is aimed at optimizing the key stage of blast furnace production - heating air, which is then supplied to the furnace for smelting cast iron. Previously, the adjustment of gas supply depended on the experience of gas operators, which could lead to temperature fluctuations and fuel overspend. A system based on the principles of a "digital twin" analyzes many parameters (required energy, current temperature, blow flow) in real time and automatically calculates the ideal gas-air ratio, independently controlling the valves.
In addition to developing software and algorithms, the equipment was modernized: three outdated valves on gas pipelines were replaced, integration with an automated process control system was carried out.
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