SMS Group Revives PT Krakatau Steel’s Hot Strip Mill with Complete Automation Overhaul
SMS Group, a global leader in plant engineering for the metals industry, has successfully upgraded the automation system at PT Krakatau Steel (PTKS) in Cilegon, Indonesia. This transformation of hot strip mill no. 1 marks a pivotal moment for PTKS, as the mill resumed production after a prolonged shutdown, rolling its first sellable coil in December 2024. The completion of this ambitious project is vital in helping PTKS re-enter the competitive market for hot-rolled coils.
Comprehensive System Overhaul
In a strategic move aimed at revitalizing its operations, PTKS opted for a complete renewal of its automation systems, rather than just replacing damaged parts. This extensive overhaul covered the mill’s entire electrical and automation infrastructure, ensuring that PTKS would benefit from next-generation technology while preserving the existing DC drives used in key units, such as the slab sizing press, roughing mill, and down coiler. SMS Group facilitated the smooth integration of these old drives with the new state-of-the-art automation systems, resulting in a seamless transition without compromising efficiency or production.
Advanced X-Pact® Automation Technology
At the heart of the upgrade is SMS Group’s X-Pact® process automation control technology. This advanced suite of solutions includes Level 1 and Level 2 automation systems designed to enhance mill control, diagnostics, and overall performance. The X-Pact® ProBAS platform is built on X-Pact® Embedded controllers, which provide extensive connectivity and open interfaces, supporting flexibility and ease of integration with the existing plant infrastructure.
One of the standout features of this upgrade is the inclusion of Sinamics DC drives paired with Simotion-based drive control software, which ensures consistent high production standards while maintaining top-tier efficiency and quality.
Technological Process Models for Enhanced Performance
The modernization includes the introduction of several technological models that will significantly improve the mill's operations:
• X-Pact® Pass Schedule Calculation (PSC®): This model optimizes the roughing and finishing stands, ensuring precise pass schedules to increase output and minimize material waste.
• X-Pact® Cooling Section Control: This model automates the strip cooling process, ensuring uniform cooling rates for improved strip quality and coiling temperature consistency.
• X-Pact® Profile, Contour, and Flatness: This model guarantees stable rolling processes and precise control over strip thickness and flatness tolerances, crucial for meeting stringent quality standards in steel products.
These systems work together to enable the production of high-quality steel products with a wide range of properties and dimensions, making the mill adaptable to a variety of market needs.
Operational Challenges and Achievements
The project was no small feat, considering the complexity of implementing a new automation system on existing machinery. Utomo Nugroho, Director of Infrastructure and Operations at PTKS, praised SMS for its commitment, saying, “SMS group acted like a partner in every sense. It was a huge challenge to put a new automation system on the existing machinery, but we are delighted to have achieved our goal of starting up the plant by the end of 2024.”
The collaboration between SMS Group and PT Krakatau Steel goes back decades, with their partnership dating to the 1980s. SMS had previously helped PTKS with the delivery of the original hot strip mill and supported the commissioning of hot strip mill no. 2 in 2016/17. With this new automation upgrade, the relationship has been further solidified, ensuring PTKS is poised for future success.
Future-Proofing the Mill for High-Quality Production
The upgraded hot strip mill is designed to handle a variety of products, including general structural steels, tubes, pipes, and automotive grades. The mill’s annual capacity stands at 2.4 million metric tons, with the ability to process strip thicknesses from 1.8 mm to 25 mm and widths from 600 mm to 2,080 mm.
Thanks to the cutting-edge automation technology, PTKS is now better equipped to meet the growing demand for high-quality steel products, providing precise and consistent results across a wide range of industries. The newly upgraded mill will also enable PTKS to regain its market share and re-establish itself as a leading producer of hot-rolled coils in Indonesia.
KEY TAKEAWAYS:
• Automation Overhaul: SMS Group completed a comprehensive upgrade of the automation system at PT Krakatau Steel's hot strip mill in Cilegon, Indonesia, improving mill control and production quality.
• State-of-the-Art Technology: The new system includes X-Pact® automation technology, featuring Level 1 and Level 2 systems, and Sinamics DC drives for precise, high-quality production.
• Technological Models: Advanced models such as the X-Pact® Pass Schedule Calculation and X-Pact® Profile, Contour, and Flatness ensure stable rolling and precise control over strip thickness and flatness.
• Production Capacity: The upgraded mill has an annual capacity of 2.4 million metric tons and can handle a wide variety of steel products, including automotive grades and structural steels.
• Strategic Partnership: The long-standing partnership between SMS Group and PT Krakatau Steel was further solidified with the successful completion of this project, setting the stage for PTKS's return to the Indonesian market.
• Future-Ready Systems: The upgraded automation ensures that PTKS is now equipped with a future-ready system capable of meeting growing demands for high-quality, diverse steel products.
