As part of the modernization project, the plant’s basic and process automation systems will be completely renewed. The existing basic automation system will be replaced with the SIMATIC S7-1500 platform to improve spare parts availability and strengthen long-term system support.
The new process automation system will use AI technologies supporting physical models to improve strip thickness and flatness targets. The modernization is expected to support KG Steel’s production capabilities across its broad product range, including galvanized and tinplate steel as well as pre-coated metal products marketed under the “XTONE” brand.
AI and virtualization to support production processes
The project will also include an upgrade of the human-machine interface (HMI), enabling operators to monitor plant processes more effectively. In addition, all servers are planned to be virtualized. This is intended to improve system resilience, enable faster recovery following potential failures and simplify lifecycle management.
Process optimization measures, including an advanced pickling model, are expected to contribute to maintaining consistent product quality and improving operational efficiency.
Production disruptions to be limited during commissioning
A “shadow mode and transition” approach will be used during the transition to the new automation systems. Primetals Technologies will connect the new system to the plant environment while the existing system remains operational. This will allow production data and system configurations to be transferred to the new system ahead of the main shutdown, helping accelerate the commissioning process.
Following completion of the modernization, KG Steel is expected to increase plant availability, minimize downtime and improve efficiency by accelerating rolling processes in the entry section. The new infrastructure will also allow additional digital solutions to be integrated in the future without requiring major system replacements.
South Korean steel producer KG Steel manufactures cold-rolled and galvanized steel, tinplate steel and coated metal products under the XTONE brand.
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