Following a comprehensive upgrade by metallurgical engineering company Primetals Technologies, stainless, electrical and specialty steel supplier Aperam’s stainless steel melt shop in Genk, Belgium, is operating with enhanced reliability.

The project included a revamp of the existing 130 t argon oxygen decarburisation (AOD) converter and the installation of an additional, new 130 t AOD resulting in significant improvements in efficiency, flexibility and operator safety.

Additionally, the implementation of “state-of-the-art primary and secondary dedusting systems”, along with waste heat recovery technology, ensured that the melt shop would meet emission and efficiency standards.

The second AOD converter gives Aperam greater flexibility, allowing for optimised treatment times and the development of advanced steel grades.

Moreover, with the new AOD converter, Aperam can also use more cost-effective raw materials, optimising production costs.

Primetals Technologies also 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; the Vaicon Autofix eliminates the need for manual intervention throughout vessel exchanges, improving safety and reducing exchanges times and boosting overall plant availability.

Primetals Technologies also installed the Vaicon Damper, a vibration-reduction system that addresses strong bath movements. This system also reduces vibrations by more than 50%, lessening wear on equipment and foundations.

Emission Reduction

For the new AOD converter, Primetals Technologies supplied and implemented a waste-heat-recovery-ready system that cools 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 to reduce carbon emissions, supporting Aperam’s leadership in sustainable steel and alloy production.

“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,” Aperam Genk steel plant manager Sofie Vantilt states.

Additionally, she notes that this investment is fully aligned with Aperam’s vision to be the leading value creator in a circular economy.

Enhancing Process Control

To ensure improved process control and plant availability, the melt shop features an extensive automation solution, including basic automation, process automation and optimisation and the Asset-Life Expert (ALEX) condition monitoring system.

The AOD optimiser, a process control and optimisation system, enhances efficiency and metallurgical precision in stainless steel production.

The AOD converters must handle great variability in process conditions as a result of diverse charging mixes, large mass build-up and the production of a range of specialty stainless steel grades. Therefore, the AOD optimiser uses hybrid process models based on first-principle calculations and dynamic control algorithms.

Moreover, the ALEX system is a centralised 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.

According to Vantilt, the ALEX is both scalable and adaptable, allowing users to integrate operational and maintenance expertise, as well as customise the system for specific plant requirements.

To further ensure that the system remains aligned with evolving operational and maintenance needs, Aperam has signed a service contract for the condition-monitoring system.

Primetals Technologies’ scope of supply also includes transfer cars, a semi-automatic ladle transfer crane and an extension of the existing materials handling system.