Advanced Water Analysis Automation at Salzgitter Flachstahl GmbH
Salzgitter Flachstahl GmbH, a key player in the steel production industry, processes around 32,000 samples every year as part of its operational analytics efforts. These samples are sourced from a variety of facilities within the company and play a crucial role in monitoring production streams and the performance of various equipment. The majority of the samples, approximately 18,000 annually, are focused on water analysis. These analyses cover a range of water types, including cooling water, condensates, degreasing solutions, and wastewater. The company also conducts thorough analysis on drinking water, which is supplied both to its industrial area and to the local public.
The ability to manage such a high volume of samples while maintaining accuracy and efficiency is vital for the company, especially given the complexity of water treatment and the necessity of ensuring compliance with regulatory standards. In recent years, Salzgitter Flachstahl GmbH has made significant strides toward automation to expedite this process. The goal is to process samples more quickly, accurately, and with minimal human intervention, reducing the risk of error and improving the overall efficiency of the analysis process.
Focus on Automation and Robotics in Water Testing
A major development in this direction is the integration of a robotic system known as the SP2000, which is designed to streamline the water sample analysis process. This robot system is capable of autonomously handling up to 90 water samples at a time. The process begins when sample containers from various plants are placed into predefined racks on the robot, which is programmed to carry out all necessary preparatory steps, such as opening and closing containers, dilution, pipetting, and filtration. These steps are all crucial to the analysis and are performed automatically, ensuring precision and consistency across all samples.
The SP2000 robot works in tandem with advanced analysis techniques to test a wide range of parameters, including pH value, conductivity, chloride content, acid and base capacity, turbidity, and coloration in water samples. Additionally, the system can perform sequential biochemical oxygen demand (BOD) testing, which is a critical parameter in water quality monitoring.
Integration with Laboratory Information Management Systems (LIMS)
Once the robot has completed its analysis, the results are processed and calculated via a Laboratory Information Management System. This system stores the data and makes it readily accessible to operators for use in production control and monitoring. This integration ensures that data is not only accurate but also available in real-time, allowing for timely decision-making and action in the production process.
The laboratory follows strict standards to ensure that all tests and analyses comply with the necessary regulations. By utilizing advanced automated systems and software, Salzgitter Flachstahl GmbH ensures that its water quality tests are both efficient and precise, providing critical insights into the overall health of its production processes and supporting the company’s commitment to environmental responsibility.
Key Takeaways:
• Salzgitter Flachstahl GmbH processes approximately 32,000 samples annually in the field of operational analytics, with a focus on water analysis.
• About 18,000 of these samples are analyzed in the "Water" department, covering a variety of water types, including cooling water, condensates, degreasing solutions, wastewater, and drinking water.
• A high degree of automation is employed to process these samples more efficiently and accurately.
• The SP2000 robotic system autonomously handles up to 90 water samples at a time, performing sample preparation steps like opening containers, dilution, pipetting, and filtration.
• The system analyzes critical water parameters such as pH, conductivity, chloride content, acid and base capacity, turbidity, coloration, and biochemical oxygen demand.
• Data from the analyses is stored and processed via a Laboratory Information Management System (LIMS), ensuring real-time availability for production control.
• The testing processes are performed in compliance with all necessary regulations, ensuring accuracy and reliability in the results.
