Advanced process optimization systems with closed-loop operation to optimize production, real-time data collection and analysis improve operational efficiency and reduce errors. Integration with SAP accelerates decision-making and reduces costs.
Primetals has received an order from turkish steel company Kardemir to upgrade and implement process optimization systems at its sinter plants in Karabük, Türkiye. The project covers an upgrade of the existing Level 2 systems at sinter plants No. 1 and 2 and the installation of a new Sinter Optimizer system at sinter plant No. 3.
According to Primetals, this advanced solution will digitalize Kardemir's sinter production through real-time data collection, automated production data analysis, and AI-driven automated process control.
The new process automation systems will enable closed-loop operation of all three sinter plants using a digital knowledge base built on operational best practices. This will stabilize production, improve efficiency, reduce error rates, and give operators greater transparency, Primetals said.
“This project represents a key milestone in Kardemir’s digital master plan and reinforces our commitment to smart manufacturing and operational excellence,” said Sefa Çetinkaya, Operational Technologies at Kardemir. “The new Level 2 system, with its robust and secure architecture, will help us achieve seamless data integration and intelligent decision-making. By harnessing advanced technologies like data analytics, the Industrial Internet of Things (IIoT), and artificial intelligence, we will continue to drive innovation and enhance our production capabilities.”
According to Primetals, a key feature of this project is the integration of the Level 2 systems with Kardemir’s SAP infrastructure. This ensures a smooth flow of data between the Sinter Optimizer and SAP, providing critical production insights for faster, more informed decisions. The integration will optimize steel plant automation, speed up decision-making based on real-time data, and help reduce operational costs.
Continuous Sinter Process Optimization
The Sinter Optimizer features an expert system connected to a digital knowledge base, enabling fast, fact-based decisions and standardized corrective actions. It performs small, frequent control actions based on a standardized control philosophy, ensuring 24/7, shift-independent operation. The system calculates raw material setpoints, crucial for achieving the desired chemical composition of the sinter product, and evaluates the impact of moisture on specific raw material mixes.Pocess models predict product quality hours before lab data is available, while multiple Level 2 control loops ensure consistent product quality.
Source: Primetals Technologies
