Visualization and Control of the Melt Production Process in an Oxygen Converter at the Kremikovtsi Metallurgical Complex
As part of the reconstruction of Converter No. 3 and Waste Heat Boiler KU 100 at the Kremikovtsi Metallurgical Complex, Rotek Ltd. delivered a complete solution for visualization and automated control of the melt production process in the oxygen converter.
The goal was to replace outdated analog instruments and relay logic with a modern, fully automated system built around equipment from Allen-Bradley, a brand of Rockwell Automation and a global leader in industrial automation.
Complete Automation and SCADA Integration
The solution covers three operator stations in the control room: for the converter operator, boiler operator, and technologist. Each station is equipped with industrial HMI panels connected to Allen-Bradley PLCs via reliable industrial networks.
Key functionalities include:
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Real-time measurement and graphical display of over 50 process parameters – temperature, pressure, oxygen flow, blow time, and more;
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Visual and audible alarms for critical and emergency values;
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Safety interlocks with relay outputs to control oxygen injection;
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Curve selection and visualization for converter preheating;
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Technological logbook (melt card) with heat number, steel grade, temperature, composition, etc.;
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Melt history database with reporting and analysis tools;
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Information exchange between operator and technologist stations.
Allen-Bradley – Industrial Quality You Can Trust
Key equipment highlights:
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ControlLogix PLCs – for modular, scalable control;
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PanelView Plus HMI terminals – with custom-designed screens for each process;
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EtherNet/IP and DH485 communication protocols;
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Full support for alarms, data archiving, diagnostics, and remote access.
Rotek Ltd. – Trusted Partner in Heavy Industry Automation
With this project, Rotek Ltd. affirms its position as a leading engineering company in the field of heavy industry automation. The company delivered:
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System design and engineering;
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SCADA software development;
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Operator training;
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Full technical support and documentation.
Conclusion
The Kremikovtsi project is a prime example of how complex industrial processes can be modernized through Allen-Bradley’s high-performance automation technology and the engineering excellence of Rotek Ltd. The result is a safer, more efficient, and fully transparent melt production system that meets the highest industry standards.