Case Study: Tata Steel achieves quicklime production efficiency and energy savings with AnyLogic

Optimizing Quicklime Production Operations

Tata Steel wanted to improve efficiency at its lime plant by optimizing the limestone feeding circuit used to supply quicklime for steelmaking. The company suspected the circuit was underutilized, causing unnecessary machine running hours and higher energy use, and turned to AnyLogic simulation software to help find a better production schedule without risking supply or quality.

Using AnyLogic, Tata Steel built a discrete-event simulation model to test scenarios, identify bottlenecks, and analyze buffer stock and shift schedules. The project revealed key constraints in Bin 2 and Weigh Feeders 3 and 4, enabled part of the circuit to be shut down for up to 10 hours per day, and delivered measurable daily electricity cost savings while improving overall equipment utilization.

Tata Steel