Primetals Technologies Completes Major Automation Modernization Project at Ulsan Aluminum Hot Rolling Mill!

Primetals Technologies has successfully completed a comprehensive automation modernization project at Ulsan Aluminum’s hot finishing mill in South Korea, marking a significant step forward in the facility’s digital transformation journey. The project recently achieved final acceptance, confirming the successful implementation of advanced automation technologies designed to enhance operational reliability, improve manufacturing efficiency, and strengthen the plant’s readiness for future digital initiatives.

The modernization focused on upgrading both the Level 1 and Level 2 automation systems that control and optimize hot rolling operations. By introducing a modern digital infrastructure, the project has provided Ulsan Aluminum with a more robust and scalable automation platform capable of supporting long-term production requirements while maintaining the high quality standards demanded by global customers.

A key feature of the upgrade was the virtualization of automation servers, a significant advancement that reduces reliance on dedicated hardware while improving system flexibility and maintainability. Virtualized environments simplify future system expansions, accelerate the deployment of new digital services, and lower ongoing maintenance requirements. The move also enhances operational resilience by enabling more efficient management of critical automation resources.

As part of the modernization effort, Primetals Technologies migrated the process automation database from Oracle to Microsoft SQL Server. This transition simplifies system administration, improves compatibility with modern digital platforms, and reduces software licensing costs. The new database environment also provides a more streamlined foundation for future data analytics, reporting, and operational optimization initiatives.

The project introduced an advanced Level 2 Human-Machine Interface (HMI) designed to provide operators with improved visibility into production processes and real-time operational data. Enhanced graphical interfaces and monitoring capabilities enable production teams to make faster and more informed decisions, contributing to greater process stability and product quality. The upgraded operator environment supports more effective production management while helping reduce the potential for process deviations.

To further strengthen operational performance, Primetals Technologies implemented advanced diagnostic monitoring tools that provide continuous visibility into equipment status, production parameters, and system performance. These capabilities support proactive maintenance strategies, improve operational transparency, and contribute to consistent quality assurance throughout the rolling process.

Cybersecurity and system reliability were also key priorities within the modernization program. The software environment was upgraded to current industry standards and enhanced with modern IT security measures, including advanced antivirus protection and improved cybersecurity frameworks. These improvements help protect critical production systems from emerging digital threats while ensuring long-term operational stability and compliance with evolving industrial security requirements.

One of the most critical aspects of the project was the commissioning strategy employed by Primetals Technologies. To minimize operational risk and avoid disruptions to production, the company utilized a shadow-mode implementation approach. This methodology allowed the legacy and newly installed Level 2 automation systems to operate simultaneously before the final switchover. Running both systems in parallel enabled engineers to validate process models, test operational performance, optimize rolling schedules, and verify production parameters under real operating conditions.

The shadow-mode strategy ensured a smooth transition while significantly reducing the risks typically associated with major automation upgrades. By thoroughly validating system performance before commissioning, the project team was able to maintain production continuity and ensure that all process requirements were met before the final cutover.

Following the facility’s planned five-day annual maintenance shutdown, the hot rolling mill resumed full three-shift production immediately after commissioning. Demonstrating the success of the modernization project, the first aluminum hot strip produced under the new automation system met all required quality specifications and was approved for commercial shipment. This achievement highlighted the effectiveness of the upgraded systems and the careful planning that supported the transition.

According to Ulsan Aluminum’s Hot Mill Engineering and Automation Team Leader, Jihwan Jung, the project benefited from strong collaboration between the two organizations throughout all phases of implementation. He noted that Primetals Technologies provided critical support during key operational stages, reinforcing the company’s reputation as a trusted technology partner capable of delivering complex modernization projects successfully.

Ulsan Aluminum was established in 2017 as a joint venture between Novelis and Kobe Steel and has become a major supplier of flat-rolled aluminum products for industries including automotive manufacturing, beverage packaging, and specialized industrial applications. The company operates with an annual production capacity of approximately 400,000 tonnes and serves customers across domestic and international markets.

The hot rolling mill itself was originally supplied by Primetals Technologies in 2013 as part of a capacity expansion initiative aimed at supporting growing demand for automotive aluminum sheet products throughout Asia. The facility processes aluminum slabs with entry thicknesses ranging from 25 to 60 millimeters and produces finished strip products between 1.8 and 6 millimeters thick, supporting a wide variety of end-use applications.

The successful completion of this automation modernization project demonstrates the growing importance of digital technologies in metals manufacturing. As aluminum producers seek greater efficiency, improved product quality, enhanced cybersecurity, and increased operational flexibility, investments in advanced automation systems are becoming essential for maintaining competitiveness in a rapidly evolving global marketplace.

By upgrading critical automation infrastructure while maintaining uninterrupted production, Ulsan Aluminum has strengthened its ability to meet future market demands and continue delivering high-quality aluminum products to customers worldwide. The project also highlights how digital transformation initiatives can provide immediate operational benefits while creating a foundation for future innovations in smart manufacturing and industrial automation.