Ulsan Aluminum completed a comprehensive automation upgrade on its hot finishing mill in Ulsan, South Korea. The company recently issued the final acceptance certificate (FAC) to Primetals Technologies, marking the successful completion of the project.
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 originally supplied the hot rolling mill in 2013, which 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.
Automation Upgrade
The upgrade project covered both basic and process optimization systems (Level 1 and Level 2). The automation servers were virtualized, reducing maintenance requirements and enabling rapid scaling of digital services. 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’ 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. Overall, the automation upgrade has stabilized plant operations and improved maintainability, enhancing IT security, reducing operating costs, and preparing the mill for future challenges.
“The dedication to supporting our plant during demanding situations has further reinforced our confidence in Primetals Technologies as a trusted and reliable partner,” said Jihwan Jung, Hot Mill Engineering & Automation Team leader at Ulsan Aluminum. “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.”
Production Ramp-up
Primetals Technologies implemented a shadow-mode strategy to reduce risk during commissioning. This method runs both the old and new Level 2 models in parallel, which ensures 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 automation upgrade project has further strengthened the partnership between the two companies, who plan to continue their collaboration. Currently, the companies are planning a new basic automation project for Ulsan.