The project covers the modernization of three LD converters (BOF), four ladle furnaces (LF), and one vacuum degassing (VD) unit. Each converter will have a melting capacity of 120 tons.
With the new system, all production units at Kardemir’s melting plant will be integrated under a single digital architecture provided by Primetals Technologies. The Level 2 process optimization system will collect metallurgical, operational, and planning data on a single platform, forming an integrated structure described as the “steel production backbone.” This setup will enable operators and metallurgists to work through a common interface, while standardized procedures will improve data consistency between shifts and enhance operational transparency.
It was noted that Kardemir’s existing structure, based on different systems and processes, has limited optimization and led to data inconsistencies. The new system aims to eliminate these issues.
The modernization is expected to reduce reblowing rates in the BOF shop, lower energy consumption in secondary metallurgy processes, increase efficiency, and improve overall production performance. Kardemir’s Director of Operational Technologies, Sefa Çetinkaya, stated that significant improvements in steelmaking performance are expected with the unified Level 2 environment, adding that the investment represents a critical step in the company’s digital transformation journey.
The project stands out as a key milestone in Kardemir’s digitalization roadmap and follows previous automation upgrades at the sinter plant.
As part of the fully integrated process optimization system, material and quality databases, shift and user management, production planning tools, and web-based reporting solutions covering all production units will be implemented.
Applications to be included in the system comprise the BOF Optimizer, LF Optimizer, and VD Optimizer. The BOF Optimizer will enhance processes through dynamic process models, end-of-blow calculations, heat tracking, and cost-based material calculations. The LF Optimizer will manage alloy additions, deoxidation, desulfurization, and temperature control through a closed-loop system, reducing energy consumption and improving process stability. The VD Optimizer will manage the vacuum process using advanced thermal and metallurgical models, calculating degassing in real time to enable faster cycle times and cleaner steel production.
With a comprehensive production structure covering ironmaking, steelmaking, and rolling operations, Kardemir has been accelerating its digitalization investments in recent years. This project with Primetals Technologies aims to make the company’s production processes more efficient and sustainable.
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