- Modernized automation at Ulsan Aluminum’s hot finishing mill enhances IT security, reduces operating costs, and prepares the mill for future challenges
- Simplified maintenance boosts long-term efficiency
Primetals Technologies has completed a comprehensive automation upgrade, covering both basic and process optimization systems (Level 1 and Level 2), at Ulsan Aluminum’s hot finishing mill in Ulsan, South Korea. Ulsan Aluminum recently awarded Primetals Technologies the final acceptance certificate (FAC), marking the successful completion of the project.
Stabilized Mill Operations
The automation servers were virtualized, reducing maintenance requirements and enabling rapid scaling of digital services. The basic automation upgrade has stabilized plant operations and improved maintainability. The process automation system database was migrated from Oracle to Microsoft SQL Server, lowering license costs and simplifying support. A new Level 2 human-machine interface (HMI) provides better operator guidance and increased transparency, while Primetals Technologies’ diagnostic plug now enables ongoing performance monitoring and quality assurance.
As part of the migration, the software was optimized according to the latest standards. The plant now operates with up-to-date software, enhanced IT security, and improved antivirus protection.
“The dedication to supporting our plant during demanding situations has further reinforced our confidence in Primetals Technologies as a trusted and reliable partner. We believe this experience demonstrates the company’s strong dependability and serves as an important foundation for a continued and strengthened partnership between our companies,” said Jihwan Jung, Hot Mill Engineering & Automation Team Leader at Ulsan Aluminum.
Immediate Production Ramp-up
To reduce risk during commissioning, Primetals Technologies implemented a shadow-mode strategy, running both the old and new Level 2 models in parallel. This ensured model optimization and consistent pass schedules before the final switchover.
After the planned five-day annual shutdown, the mill resumed three-shift production immediately. The first aluminum hot strip produced fulfilled all quality requirements and was immediately ready for sale. The successful project has further strengthened the partnership between the two companies, and a new basic automation project is already in planning.
Supplying Aluminum Flat-Rolled Products
Established in 2017 as a joint venture between Novelis and Kobe Steel, Ulsan Aluminum supplies flat-rolled aluminum products to the automotive, beverage can, and specialty markets, with an annual capacity of 400,000 tons.
Primetals Technologies originally supplied the hot rolling mill in 2013. The mill was added to an existing hot reversing twin-coiling mill to increase throughput as part of an expansion into automotive sheet production for the Asian market. Entry thicknesses range from 25 to 60 millimeters, with exit thicknesses ranging from 1.8 to 6 millimeters.
Part of the teams from Primetals Technologies and Ulsan Aluminum after the successful automation upgrade.
The first coil produced after Primetals Technologies’ modernization at Ulsan Aluminum.
Primetals Technologies, Limited, headquartered in London, United Kingdom, is a pioneer and world leader in the fields of engineering, plant building, and the provision of lifecycle services for the metals industry. The company offers a complete technology, product, and services portfolio that includes integrated electrics and automation, digitalization, and environmental solutions. This covers every step of the iron and steel production chain—from the raw materials to the finished product—and includes the latest rolling solutions for the nonferrous metals sector. Primetals Technologies is a Group Company of Mitsubishi Heavy Industries, with around 7,000 employees worldwide. To learn more about Primetals Technologies, visit the company website www.primetals.com.
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