Primetals Technologies has successfully completed a comprehensive automation modernization project at Ulsan Aluminum’s hot finishing mill in South Korea, strengthening plant performance, operational reliability, and future digital capabilities. The project recently achieved final acceptance, confirming the successful deployment of upgraded automation systems and process optimization technologies.
The modernization covered both Level 1 and Level 2 automation systems, introducing advanced digital infrastructure designed to improve operational stability, reduce maintenance requirements, and support future scalability. The project represents a significant milestone in Ulsan Aluminum’s efforts to enhance manufacturing efficiency while maintaining high-quality production standards.
One of the key achievements of the upgrade was the virtualization of automation servers. This development reduces hardware dependency, lowers maintenance needs, and enables faster deployment of digital services. In addition, the process automation database was migrated from Oracle to Microsoft SQL Server, simplifying system support while reducing software licensing costs.
The project also introduced a new Level 2 human-machine interface that provides operators with enhanced visibility into production processes and improved decision-making capabilities. Diagnostic monitoring tools supplied by Primetals Technologies further support ongoing performance tracking, operational transparency, and quality assurance.
To strengthen cybersecurity and future readiness, the software environment was upgraded to current industry standards, including enhanced IT security measures and improved antivirus protection. These improvements help ensure long-term system reliability while supporting evolving digital manufacturing requirements.
A critical aspect of the project involved minimizing operational risk during commissioning. Primetals Technologies adopted a shadow-mode implementation strategy, allowing legacy and new Level 2 systems to operate simultaneously before the final transition. This approach enabled engineers to validate process models, optimize rolling schedules, and ensure smooth integration without disrupting production.
Following the plant’s planned five-day annual shutdown, the hot mill resumed full three-shift production immediately after commissioning. The first aluminum hot strip produced under the new system met all required quality specifications and was ready for commercial delivery, demonstrating the effectiveness of the upgrade.
Jihwan Jung, Hot Mill Engineering and Automation Team Leader at Ulsan Aluminum, highlighted the strong collaboration between the two organizations throughout the project. He noted that Primetals Technologies’ support during critical operational phases reinforced confidence in the company as a trusted technology partner.
Established in 2017 as a joint venture between Novelis and Kobe Steel, Ulsan Aluminum supplies flat-rolled aluminum products to industries including automotive manufacturing, beverage packaging, and specialty applications. The company operates with an annual production capacity of approximately 400,000 tonnes.
Primetals Technologies originally supplied the hot rolling mill in 2013 as part of a capacity expansion programme supporting automotive sheet production for Asian markets. The facility processes aluminum slabs with entry thicknesses ranging from 25 to 60 millimetres and produces finished strip products between 1.8 and 6 millimetres thick.
The successful automation upgrade not only improves operational efficiency but also lays the groundwork for future digital transformation initiatives. Both companies are already exploring additional automation projects, reflecting a growing partnership focused on enhancing productivity, product quality, and manufacturing competitiveness in the global aluminum industry.
