Today
Investigate after the excursion
- CEMS and environmental systems measure and report regulated sources.
- Teams investigate exceedances after they appear.
- Process, equipment and environmental data are often analysed separately.
Predict emission risksbefore compliance becomes a problem.
CEMS and environmental systems measure emissions, but the cause often sits in the production process. INSUS connects emissions with process and equipment data to flag developing risks and contributing conditions for environmental and operations review. It does not replace CEMS or make regulatory determinations.
01
Emission limits are only part of the problem.
02
The cause is often inside the production process.
03
Environmental and operations teams keep the decision.
The problem
Emissions compliance isharder than reading a CEMS value.
Steel production generates emissions across coke ovens, blast furnaces, BOF, EAF, reheating, rolling and material handling. Plants may already run CEMS and hold large volumes of operational data, but monitoring often identifies problems only after an exceedance. Without connecting emissions to the process conditions behind them, teams spend time reconstructing what happened instead of acting earlier.
01Multiple emission sources across the plant
02Exceedances often flagged after the fact
03Process causes hard to reconstruct later
- 01Multiple emission sources across the plant
- 02Exceedances often flagged after the fact
- 03Process causes hard to reconstruct later
The shift
From reactive compliance monitoringto earlier emissions guidance.
CEMS and existing environmental systems stay in place. What changes is whether emissions are reviewed together with the operating conditions that influence them.
With INSUS
See the risk and contributing conditions earlier
- Emissions measurements are combined with process, fuel and equipment data.
- Developing emission trajectories and abnormal patterns are flagged for review.
- Contributing factors help teams prioritise investigation and corrective action.
How it works
From emissions and plant datato a reviewed risk flag.
This fits OptiStudio as process-linked emissions decision support beside existing CEMS and environmental systems. Day one is advisory. It does not replace CEMS, certify compliance or change plant controls automatically.
Connect
Bring emissions and plant data together
Read-only links to CEMS, DCS/SCADA, historians, environmental measurements, process parameters, fuel and energy data, production records and available equipment or laboratory information for the selected source.
Understand
Link emissions to process conditions
Learn relationships between emissions and operating variables such as furnace conditions, fuel consumption, gas flows, temperatures, production rates and equipment behaviour on this plant.
Predict
Flag developing emission risks
Forecast near-term emission trajectories and identify abnormal patterns that may indicate developing compliance risk or process instability, subject to data quality and model performance.
Advise
Explain contributing factors for review
Surface likely contributing process or equipment factors and route alerts to environmental, operations or maintenance teams. Investigation and corrective action stay with plant staff.
Verify
Compare predictions with actual events
Log alerts against actual emission events and operating outcomes. Track false positives openly and refine the source-specific model with the environmental and operations teams.
Getting started
Start with one high-impactemission source.
For steel plants that already run CEMS and hold process historian data for a selected source such as a blast furnace, EAF, BOF or coke-oven area. Delivered through OptiStudio as process-linked emissions decision support. Expert Services can help with data assessment and validation. Advisory only. No CEMS replacement. No new sensors by default.
- What we need. Relevant CEMS measurements, DCS/SCADA and historian data, environmental measurements, process parameters, fuel and energy information, production data, and available equipment or laboratory information for the selected source.
- What you see first. Emission trends, predicted trajectories, alerts for potential excursions and analysis of operating conditions associated with elevated emissions, validated against actual events.
- How it grows. After validation, the approach can expand across additional sources and pollutants. Reporting support can help assemble evidence packs for review. Submission and regulatory sign-off stay with the plant.
Related for steel
Other steelstarting points
Emissions guidance sits beside slag, yield and furnace energy work on the same steelmaking operation.
- 01Predictive Slag ManagementPredict slag chemistry and behaviour during the heat so metallurgists can review adjustments before foaming, slopping or carryover escalates.
- 02Steel Yield Loss PredictionPredict yield-loss risk across melting, casting and rolling from process, quality and material data.
- 03Steel industryThe wider picture for steel plants: slag, yield, furnace energy, scheduling and emissions compliance.
Questions steel plants ask us
Emission problems are often investigated after an exceedance. This use case connects CEMS with process data to flag developing risks and contributing operating conditions for earlier review.
No. CEMS remains the source of direct emissions measurements. INSUS adds an intelligence layer that links those measurements with DCS/SCADA, historian and process data.
CEMS, DCS/SCADA, historians, environmental measurements, process parameters, fuel and energy data, production information and available equipment or laboratory records for the selected source. No new sensors by default.
No. Day one is advisory. Alerts and contributing-factor analysis support investigation. Critical operational and compliance decisions remain with plant teams.
Only where suitable existing sensor or environmental data supports it. Computer vision is used only if image data already exists. Additional instrumentation is a separate plant decision.
Through OptiStudio as process-linked emissions decision support. Expert Services can support data assessment, integration and validation with your environmental and operations teams.
Models are source- and plant-specific. Prediction quality depends on data completeness and how well process signals explain emission behaviour. The system does not certify compliance or submit regulatory reports.
Steel · Emissions monitoring and compliance
See emission risk while there is still time to act.
Use CEMS and the plant data you already record to flag developing emission risks and contributing process conditions. Environmental and operations teams keep the decision.