Metals The Bedrock of an Economy
Published on : Thursday 05-09-2024
Metals are integral to virtually everything we make, process, or consume, says Mukund Pant.
While not glamorous or new-age, metals form the bedrock of economies. Ever since the industrial age dawned, metal consumption has increased at a staggering pace. From infrastructure to cars and from industrial goods to consumer electronics, metals are integral to virtually everything we make, process, or consume. The world’s appetite for metals is in no danger of being exhausted. The only changes will be in consumption patterns – in terms of which metals see increasing demand and what new quality parameters are imposed as we learn more about sustainability.
Metal analysis – The whys and wherefores
To most laypersons, steel is ‘steel’, or at best, they may see ‘stainless steel’ as distinct from ‘normal steel’. Very few know that there are over 150 grades of stainless steel alone! This situation is not unique to stainless steel or even steel in general; it holds true for all metals. Each grade has varying concentration ranges for key elements that it’s made of. Each of the dozens of elements that a metal consists of imparts a certain quality to the metal – some desirable, and others undesirable – leading to each grade displaying unique characteristics, making it suitable (or unsuitable) for different uses, based on the use-case.
Not only does metal testing provide the ability to ensure that the metal in question adheres to all grade requirements, but it also enables producers to optimise raw material costs and drive profitability levels by carefully controlling the concentration of expensive alloying elements.
The imperatives from metal testing – for quality, profits… and research!
We can already see that from a quality perspective, testing solutions need to offer exceptional accuracy across a wide range of elements. There are also two other very critical requirements from metal testing.
Speed: Given the energy-intensive nature of metal-making, speed and productivity are critical for any setup. A melt can’t be held for too long while the Lab decides whether quality requirements are met. The testing solution, therefore, needs to deliver highly accurate results in as short a time duration as possible.
Range of analysis: Firms are constantly working to find newer grades and alloys to improve material characteristics, reduce costs, and reduce environmental impact. To enable such research, the testing solution must also offer very low detection limits and cover all possible elements, ensuring the research is comprehensive.
Why Spark Optical Emission Spectrometers (OES) are the solution of choice
For nearly a century now, Spark OES has been the testing solution of choice for metal industries. There are primarily four main reasons for this:
1. Speed: Spark OES provides highly accurate results in ≤30 seconds, which is faster than any comparable solution.
2. Range of analyses: OES can analyse 60+ elements, including gaseous elements such as N, O, and H in metals. Most elements can be analysed down to sub-ppm (0.0000X%) levels, making it far more versatile than any other testing solution.
3. Value-added features: OES also provides a host of value-added features, including inclusion detection, Carbon Equivalent, and a lot more.
4. Low total cost: OES are fully computer-controlled and come pre-loaded with all the software needed, making them operable by shop floor workers with basic training. This makes them very economical in comparison to comparable alternatives.
OES in the age of Automation, Industry 4.0 and beyond
OES have been around for almost a century – but continue to evolve. From the 1950s through today, every aspect of the OES – barring the underlying physics, of course – has completely transformed. PMT detectors have given way to CMOS detectors, vacuum optics have given way to Argon-sealed optics, and detection limits have gone from hundreds of ppm (0.0X%) to sub-ppm (0.0000X%), but development continues at a frenetic pace, and today, the direction of progress is focused on productivity, value-added information, and connectivity.
Productivity
The focus on automation and productivity has seen two trends emerge:
● Lab automation: All processes, from sample preparation to sparking and report generation, are automated using advanced robotics. These systems, though, are extremely expensive today in relation to accrued savings for all but the highest-productivity plants.
● Immediate transmission of results: Lab reports only begin to add value once the personnel controlling the charge – who may be a full kilometre away – receive the results. To expedite this process, firms now use wireless (previously, these were wired) remote display systems with screens installed near the furnace, to which OES reports are instantly transmitted.
Value-added information
An OES stores an immense amount of data that lends itself to a host of value-added information, including:
● Assessment against desired grades/characteristics: The OES can immediately inform users whether the tested sample conforms to a particular grade and also provide detailed information on chemical, mechanical and metallurgical properties.
● Guidance for melt optimisation: OES can compute and provide instant outputs on what changes should be made to the charge to optimise it. This includes guidance on the quanta of each raw material to be added and even the store locations from which to extract the material.
● Statistical process control: OES can generate all manner of statistical process control (SPC) charts to assess performance over extended periods of time. These can also be used in conjunction with other business charts to generate actionable business insights.
Information connectivity
With the shift to Industry 4.0 and beyond, OES makers have rolled out multiple solutions to aid connectivity and “anytime, anywhere” information availability.
● Apps: OES makers offer mobile apps through which business leaders can access their data anywhere in the world to generate customised reports, SPC charts, and a lot more.
● Connectivity with databases: OES makers offer solutions to instantly transmit and write data into any required database or even ERP system that the user wishes to use as a central repository.
● Connectivity with other instruments: OES today are close to supporting a smart or even automated foundry. They can transmit data in any required format to instruments they may be required to integrate with, including furnace controllers, and could, in theory, enable corrections without manual intervention. While this still requires more work, it does seem like an inevitability in the near future.
The future is bright; the future is…
.jpg)
As can be seen, today's OES is far more than merely a testing solution that analyses elemental composition. With a range of solutions, the modern OES lies at the heart of the drive for automation. When it comes to the Indian context in particular, the headroom for growth in this sector is immense. Infrastructure and defence investments will continue growing for decades yet, given the development potential and fiscal and strategic targets. Already blessed with immense natural resources and a young workforce, geopolitical trends have also positioned India well to become a manufacturing powerhouse.
From an OES perspective, penetration of OES usage remains low in India. This has seen a strong upsurge in the current decade. In the coming decade, too, there is no doubt that volumes will continue to rise strongly. As the Indian economy grows and rising prosperity brings with it a rise in production costs, there will also be a shift to more value-added products, and buyers are likely to seek more value and ‘bang for the buck’ from their OES. As a result, we are likely to see more focus on higher-end OES segments and an increased demand for value-added solutions. This promises to make the development journey all the more rewarding for OES makers and, in the end, for everyone who will enjoy the fruits of a bigger and better metals industry.
Mukund Pant is Managing Director, Metal Power Analytical Pvt Ltd, has been instrumental in driving the company's rapid and sustained growth in both Indian and international markets. Under his leadership, MPA has diversified its market presence, expanded its product portfolio, and dramatically increased the scope and scale of the business. Additionally, he serves as Director at Metal Power Pvt Ltd (MPPL), which is an A2LA-accredited manufacturer of Certified Reference Materials. MPPL also provides A2LA- and NABL-accredited material and metallurgical testing services, as well as proficiency testing services.
Mukund holds an MBA from IIM Lucknow and a BE from BIT Mesra. He began his career in management consulting, a field he worked in from 2006 to 2015 at firms including Kearney and KPMG. At Kearney, he led teams on multiple cases spanning business planning, growth strategy, pricing strategy, revenue and profit optimisation, and supply chain management in Consumer Markets, Pharmaceuticals, Energy, and Luxury sectors. Prior to this, at KPMG, he focused on Energy, Education, Consumer and Industrial Markets with cases encompassing entry strategy, business planning, growth strategy, and due diligence.
Mukund is a regular speaker and panelist, contributing to discussions and seminars on quality management, industry analysis, and business strategy. He has also authored multiple white papers and articles on technical and business subjects.
______________________________________________________________________________________________
For a deeper dive into the dynamic world of Industrial Automation and Robotic Process Automation (RPA), explore our comprehensive collection of articles and news covering cutting-edge technologies, robotics, PLC programming, SCADA systems, and the latest advancements in the Industrial Automation realm. Uncover valuable insights and stay abreast of industry trends by delving into the rest of our articles on Industrial Automation and RPA at www.industrialautomationindia.in
.jpg)
