The project included revamping the existing 130-ton AOD converter No. 1 and installing a new 130-ton AOD converter No. 2, resulting in significant improvements in production efficiency, flexibility, and operator safety. State-of-the-art primary and secondary dedusting systems, along with waste heat recovery technology, ensure the meltshop meets the latest emissions and efficiency standards.
The addition of the second AOD converter gives Aperam greater flexibility, allowing for optimized treatment times and the development of advanced steel grades. With the new AOD converter, Aperam can also use more cost-effective raw materials, further optimizing production costs.
Primetals Technologies equipped both converters with its patented Vaicon Autofix, an automated AOD converter suspension system. Traditionally, plant personnel manually operate the locking elements that connect the converter vessel to the trunnion ring. Vaicon Autofix eliminates the need for manual intervention during vessel exchanges, improving safety and reducing exchange times to less than one hour, thereby boosting overall plant availability. In addition, Primetals Technologies installed the Vaicon Damper, a vibration-reduction system that addresses strong bath movements. This system reduces vibrations by more than 50 percent and minimizes wear on equipment and foundations.
Substantial Emissions Reduction
For the new AOD converter No. 2, Primetals Technologies supplied and implemented a waste-heat-recovery-ready system that cools hot off-gas from the converter using a two-stage heat exchanger. The recovered thermal energy, available as hot water, can be used for future industrial applications such as power generation or district heating. This system will help reduce carbon emissions, supporting Aperam’s leadership in sustainable steel and alloys production.
Sofie Vantilt, Steel Plant Manager at Aperam Genk, commented: “The completion of this major upgrade marks a new chapter for Aperam Genk. With the second AOD converter and advanced environmental technologies now in place, we can operate with greater flexibility, produce more sophisticated grades, and further reduce our environmental footprint. This investment is fully aligned with our vision to be the leading value creator in a circular economy of infinite, world-changing materials.”
Enhanced Process Control
The meltshop now features an extensive automation solution, including basic automation (Level 1), process automation and optimization (Level 2), and the Asset-Life Expert (ALEX) condition monitoring system, ensuring improved process control and plant availability.
The AOD Optimizer, a process control and optimization system, enhances efficiency and metallurgical precision in stainless steelmaking. AOD converters must handle great variability in process conditions due to diverse charging mixes, large mass build-up, and the production of a wide range of specialty stainless steel grades. The AOD Optimizer addresses these challenges using hybrid process models based on first-principle calculations and dynamic control algorithms.
The ALEX system is a centralized condition monitoring solution with a web-based user interface which provides a clear overview of the plant’s status and actionable recommendations, enabling fast, informed decision-making. ALEX is scalable and adaptable, allowing users to integrate operational and maintenance expertise and customize the system for specific plant requirements. To ensure the system remains aligned with evolving operational and maintenance needs, Aperam signed a service contract for the condition monitoring system.
Primetals Technologies’ scope of supply also included transfer cars, a semi-automatic ladle transfer crane, and an extension of the existing material handling system.
