Case Study: International Steel Producer reduces emissions spikes and achieves six-month payback with STATISTICA

International Steel Producer - Customer Case Study

An international steel producer operating one of the USA’s largest coke facilities needed to reduce particulate emissions, avoid fines, and lower production and maintenance costs. Because multiple coking oven batteries share emissions stacks, opacity sensors captured aggregated signals from many ovens, so the key challenge was predicting emissions spikes and tracing them back to the specific oven causing the problem.

STATISTICA (Enterprise Server, Quality Control, ETL and Monitoring & Alerting Server) automated data extraction and applied multivariate statistical process control and model‑based monitoring to identify relationships (for example, coal moisture to final coke temperature), detect signature patterns of developing faults, and alert staff by oven. The targeted analytics eliminated guesswork, enabled preemptive repairs that reduced emissions and fines, and delivered cost savings that paid for STATISTICA within six months.