The company placed an order covering the upgrade of the existing Level 2 systems at sinter plants No. 1 and No. 2 in Karabük and the installation of a new Sinter Optimization system at sinter plant No. 3.
With this comprehensive project, Kardemir will bring its sinter production onto a digital platform through real-time data collection, automated production data analysis, and AI-powered automatic process control. Thanks to the new Level 2 systems, which will enable closed-loop operation at all three plants, production stability will be ensured, efficiency will be increased, error rates will be reduced, and a higher level of transparency will be created for operators.
Sefa Çetinkaya, Kardemir’s Operational Technologies Manager, commented on the project: “We are excited to enhance our existing sinter Level 2 expert system and to deliver a next-generation solution in collaboration with Primetals Technologies. This project represents an important milestone in Kardemir’s digital master plan and reinforces our commitment to smart production and operational excellence. With its robust and secure architecture, the new Level 2 system will help us achieve seamless data integration and intelligent decision-making processes. By leveraging advanced technologies such as data analytics, the Industrial Internet of Things (IIoT), and artificial intelligence, we will continue to drive innovation and enhance our production capacity.”
One of the most remarkable features of the new system is the full integration of the Level 2 control systems with Kardemir’s SAP infrastructure. Thanks to this integration, a seamless data flow will be ensured between the Sinter Optimizer system and SAP, allowing production data to be quickly analyzed and enabling more informed decisions. In addition, process optimization and data-driven decision-making mechanisms will contribute to reducing operational costs.
The Sinter Optimization Device operates with an expert system connected to a digital knowledge base, enabling rapid, fact-based decisions and providing standardized corrective actions. Through small and frequent control actions, the system allows continuous 24/7 operation regardless of shifts. By evaluating the effects of moisture in raw material mixtures, it ensures that the sinter product reaches the desired chemical composition. Furthermore, process models predict product quality hours in advance without the need for laboratory data, and multiple Level 2 control loops ensure consistent product quality.
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