Aperam Stainless Steel Meltshop in Genk Running with Enhanced Reliability After Major Upgrade by Primetals Technologies

• Aperam, a global player in stainless, electrical, alloys, and specialty steel, has successfully completed an extensive upgrade project in partnership with Primetals Technologies
• Existing argon-oxygen decarburization (AOD) converter revamped and new 130-ton AOD converter installed at the Aperam site in Genk, Belgium
• The revamp has significantly increased production flexibility
• Advanced dedusting and waste heat recovery systems drastically reduce emissions

Aperam’s stainless steel meltshop in Genk, Belgium, is operating with enhanced reliability following a comprehensive upgrade by Primetals Technologies. The project included revamping the existing 130-ton AOD converter No. 1 and installing a new 130-ton AOD converter No. 2, resulting in significant improvements in production efficiency, flexibility, and operator safety. State-of-the-art primary and secondary dedusting systems, along with waste heat recovery technology, ensure the meltshop meets the latest emissions and efficiency standards.

The addition of the second AOD converter gives Aperam greater flexibility, allowing for optimized treatment times and the development of advanced steel grades. With the new AOD converter, Aperam can also use more cost-effective raw materials, further optimizing production costs.

Primetals Technologies equipped both converters with its patented Vaicon Autofix, an automated AOD converter suspension system. Traditionally, plant personnel manually operate the locking elements that connect the converter vessel to the trunnion ring. Vaicon Autofix eliminates the need for manual intervention during vessel exchanges, improving safety and reducing exchange times to less than one hour, thereby boosting overall plant availability. In addition, Primetals Technologies installed the Vaicon Damper, a vibration-reduction system that addresses strong bath movements. This system reduces vibrations by more than 50 percent and minimizes wear on equipment and foundations.

Substantial Emissions Reduction

For the new AOD converter No. 2, Primetals Technologies supplied and implemented a waste-heat-recovery-ready system that cools hot off-gas from the converter using a two-stage heat exchanger. The recovered thermal energy, available as hot water, can be used for future industrial applications such as power generation or district heating. This system will help reduce carbon emissions, supporting Aperam’s leadership in sustainable steel and alloys production.

Enhanced Process Control

The meltshop now features an extensive automation solution, including basic automation (Level 1), process automation and optimization (Level 2), and the Asset-Life Expert (ALEX) condition monitoring system, ensuring improved process control and plant availability.

The , a process control and optimization system, enhances efficiency and metallurgical precision in stainless steelmaking. AOD converters must handle great variability in process conditions due to diverse charging mixes, large mass build-up, and the production of a wide range of specialty stainless steel grades. The AOD Optimizer addresses these challenges using hybrid process models based on first-principle calculations and dynamic control algorithms.

The ALEX system is a centralized condition monitoring solution with a web-based user interface which provides a clear overview of the plant’s status and actionable recommendations, enabling fast, informed decision-making. ALEX is scalable and adaptable, allowing users to integrate operational and maintenance expertise and customize the system for specific plant requirements. To ensure the system remains aligned with evolving operational and maintenance needs, Aperam signed a service contract for the condition monitoring system.

Primetals Technologies’ scope of supply also included transfer cars, a semi-automatic ladle transfer crane, and an extension of the existing material handling system.

About Aperam

Aperam is a global player in stainless, electrical, alloys, and specialty steel, as well as recycling and renewables, serving customers in over 40 countries. Since January 1, 2022, the business has been organized in four primary reportable segments: Stainless & Electrical Steel, Services & Solutions, Alloys & Specialties, and Recycling & Renewables.

Aperam has a flat stainless and electrical steel capacity of 2.5 million tons in Brazil and Europe and is a leader in alloys and high-value specialty products, with operations in France, China, India, and the United States. The main European production sites for stainless steel are Châtelet and Genk in Belgium, and Gueugnon and Isbergues in France. In Genk, Aperam produces hot- and cold-rolled AISI 300 and 400 series grades in coil form. The AOD line No. 1 was originally supplied by Primetals Technologies in 2002. For further information, please refer to Aperam’s website at .