By Saber Sadeghi – Project Manager, Smart Water and Gas Systems

In the era of the Fourth Industrial Revolution, smart technologies are a fundamental pillar of digital transformation. By integrating innovations such as the Internet of Things (IoT), artificial intelligence (AI), and big data analytics, industrial processes can now be monitored, controlled, and optimized with unprecedented precision and speed. This is especially important for energy-intensive sectors like steel, where intelligent resource management not only reduces operational costs and boosts efficiency but also supports sustainable development goals.

Mining and steel industries, as economic engines, are among the largest consumers of water and energy. Recognizing the importance of resource efficiency, Sangan-Khorasan Steel Mining Industries Company (SSMIC) has taken a significant step toward smart monitoring and control. The implementation of an intelligent dispatching room enables real-time monitoring, consumption pattern analysis, and waste identification. The system uses precise sensors and advanced communication networks to collect real-time data and, through analytical processing, generates actionable strategies for reducing consumption and increasing efficiency.

This project not only leads to cost reduction and improved resource management transparency, but also reflects the company’s commitment to social responsibility and environmental protection. In a world of increasingly limited natural resources, smart energy is not an option but a strategic necessity for survival and competitiveness in the steel industry.

Smart Energy at SSMIC: An Inevitable Evolution

As one of the largest pellet producers in Iran’s “mining Asaluyeh,” SSMIC plays a central role in the national steel supply chain. The company not only provides essential raw materials to Mobarakeh Steel Company, one of Iran’s major industrial hubs, but also serves as a vital component in the steel production cycle. Ensuring the sustainability of its production is therefore of high importance. Electricity, water, and gas are among the most vital infrastructure elements required to guarantee this continuity.

Due to the geographical location of SSMIC and the significant challenges in securing energy in the region, maintaining operational stability demands a smart structure. This includes the establishment of an intelligent dispatching system to manage supply and consumption of energy carriers.

Phase 1:
Implementation of SCADA and dispatching systems to allow remote monitoring, observation, and command via automation.

Phase 2:
Online monitoring from supply sources to consumption points. This includes systems for supply, transfer, storage, and distribution of water, electricity, and gas — supported by modeling, soft sensors, and efficiency metrics tracking.

Phase 3:
Intelligent resource and consumption management through data mining, forecasting, validation, optimization, smart decision-making tools, alarms, knowledge management, crisis planning, and operator training.

Smart Water and Gas Management System Project

SSMIC implemented this system using the EPC method. According to project manager Saber Sadeghi, the company has now taken operational steps toward energy digitalization. The system enhances the reliability and sustainability of the water supply, reduces water and energy waste, flattens electricity demand peaks, and institutionalizes knowledge management within site utilities. The estimated return on investment is under two years.

Key Outcomes:

Increased water supply reliability: Monitoring reservoirs and real-time consumption helps prevent unexpected outages.
Reduced water and energy loss: Optimization and waste elimination generate significant savings.
Electricity demand flattening: Intelligent control of pumps and load during peak hours reduces pressure on the power grid and cuts energy costs.
Integrated knowledge management: Operational data analysis supports informed decision-making.

1. A) Key Project Steps

• Assess and collect network data
• Review existing monitoring equipment
• Develop physical and hydraulic models using WaterGEMS and Pipeline Studio
• Prepare updated instrumentation maps (P&ID and Instrument Map)
• Recommend optimal sensor types and locations
• Procure and install sensors
• Calibrate models and develop mathematical/soft-sensor network models
• Build hourly and daily consumption forecasting structures
• Deploy DVR and DSS systems
• Design and equip the monitoring room
• Deploy dispatching systems
• Integrate software systems and complete delivery

1. B) Project Summary

Workshop setup
Completion of the assessment phase, system design, and supervisory approvals

Instrumentation and Equipment Installation:

• 44 pressure gauges (Hoggler)
• 20 flow meters (Euromag)
• 3 online turbidity meters (E&H)
• 112 industrial valves (Vog)
• 112 solenoid actuators (Arad)
• 3 water quality analyzers (E&H)
• 2 instrumentation panels (Siemens)
• 8 PLC panels (Siemens)
• 3 power quality analyzers (Behrad)
• 9 chemical and hydrostatic level meters (E&H)
• 4 barriers and RTUs

Software and System Development:

• Develop and program data acquisition systems with bidirectional communication
• Develop real-time monitoring software
• Deploy telemetry network and APN
• Customize and implement Sahand platform
• Configure and launch servers (HP G10)

Monitoring Room Setup:

• Build and equip the control room
• Install and launch the video wall
• Final system review, commissioning, and operator training