Transforming Steelmaking with Cutting-Edge Automation

Primetals Technologies, a global leader in steel plant engineering and automation, has recently achieved final acceptance from Outokumpu Stainless USA for a major Level 2 automation system upgrade at its Calvert, Alabama meltshop and caster. This upgrade encompasses the entire meltshop and casting areas, deploying state-of-the-art process optimization software designed to elevate production efficiency, improve steel quality, and meet stringent market demands. By modernizing critical control systems, Outokumpu is reinforcing its position as a world-class producer of stainless steel.

Subscription Model Shifts Automation Investment Paradigm

Rather than the traditional approach of a large one-time purchase, Primetals Technologies introduced a novel 7-year subscription model with this upgrade. This model spreads out costs into annual license fees, making the investment more manageable and predictable for Outokumpu. Lawrence Bailey, Level 2 Network Administrator at Outokumpu, highlights how this subscription ensures that all automation systems remain current with the latest software updates, advanced algorithms, and security patches. This approach helps the plant continuously adapt to evolving steel production challenges without costly system overhauls.

Comprehensive Optimizer Suite Boosts Process Control

The upgraded automation platform integrates multiple key process optimizers: Electric Arc Furnace, Argon Oxygen Decarburization, Ladle Treatment Station, Continuous Casting, Through-Process Quality Control for the continuous casting machine, and a Ladle Tracker system. These tools work in concert to monitor and optimize steel chemistry, temperature, and flow in real-time, enabling precise control over each production stage. This synergy results in higher product consistency, reduced defects, and enhanced material efficiency.

Driving Sustainability Through Smarter Production

One of the upgrade’s crucial benefits lies in supporting Outokumpu’s ambitious sustainability agenda. By optimizing energy use and minimizing raw material waste, the new automation systems help reduce greenhouse gas emissions and conserve resources. Advanced process models allow operators to lower CO₂ footprints by improving furnace energy consumption and refining process parameters. This sustainable production approach aligns with global efforts to decarbonize heavy industry while maintaining competitiveness in a carbon-conscious market.

Strengthening a Decade-Long Strategic Partnership

Outokumpu and Primetals Technologies have nurtured a collaborative relationship since 2012 when the original meltshop and caster automation systems were installed at the Calvert facility. Over the years, Primetals has provided continuous service support, software upgrades, and operator training, evolving the systems alongside changing production requirements. The new subscription-based model formalizes and deepens this partnership, ensuring a long-term commitment to innovation and operational excellence.

Continuous Improvement for Operational Excellence

With the subscription, Outokumpu benefits from seamless, regular software updates that introduce new features, security improvements, and optimizations without operational disruption. Lawrence Bailey emphasizes that this continuous development model prevents technical obsolescence and allows Outokumpu to maintain peak plant performance. The ability to quickly implement software patches or enhancements improves uptime, reduces maintenance costs, and allows proactive responses to emerging process challenges.

Greater Flexibility to Meet Dynamic Market Needs

The enhanced automation system equips Outokumpu with the agility to swiftly switch between steel grades and customize process parameters to meet diverse customer specifications. This flexibility is essential in the competitive stainless steel market, where quality tolerances are tight and product variety is increasing. Real-time data analytics and predictive modeling empower operators to make faster, data-driven decisions that optimize yield, reduce cycle times, and improve delivery reliability.

Key Takeaways

• Primetals Technologies completed a comprehensive Level 2 automation upgrade at Outokumpu’s Calvert meltshop, delivered under a 7-year subscription model.

• The upgrade integrates advanced process optimizers and quality control systems, enhancing production efficiency, steel quality, and sustainability efforts.

• The subscription model ensures continuous software updates, reduces upfront investment, and strengthens the long-term partnership between Primetals Technologies and Outokumpu.