How automation orchestrates efficiency in metals processing lines

In metals processing, the smallest variations can significantly impact quality. Frederik Esterhuizen, Global Business Line Manager for Metals, and Deng Bo, Global Product Manager for Processing Lines, at ABB’s Process Industries division, explain.

^{_{This article was first published in the March 2025 issue of Steel Times International}}

In the world of metal processing, the journey from raw material to a high-quality finished product is an intricate series of steps. While the metallurgical processes themselves—annealing, pickling, galvanizing—take center stage, the unseen maestro behind peak performance is often the control and automation system.

The quality of processed metal is determined by the quality of the technology used in its processing. Surface characteristics, flatness, and strip tensions must be perfectly monitored and controlled to produce a flawless product. Ensuring each element of the processing line is synchronized and operating harmoniously is the exact job that the control system is there to do. It dictates the precise speed and tension of the metal strip as it travels through numerous stages, from unwinding to coiling. This seemingly simple task becomes critical when dealing with materials of varying thicknesses, widths, and material grades.

The power of precise control

Control and automation systems act as the central nervous system of processing lines, silently ensuring efficient and consistent operation. At the heart of these systems lie sophisticated control algorithms that constantly monitor and adjust strip speed and tension throughout the line. These algorithms consider multiple factors, including material properties, line configuration, and real-time feedback from sensors positioned along the line.

By maintaining continuous monitoring and precise adjustments, ABB's control systems, including ABB Ability™ System 800xA distributed control system (DCS) with the Roll@xA and the ABB Ability™ Manufacturing Operations Management for metals software solutions, as well as digital twin solutions, contribute to reduced product defects, improved productivity, and material savings. Consistent tension throughout the line minimizes the risk of breaks, tears, or uneven coiling. Optimized speed settings ensure the line operates at its peak capacity without compromising quality. These improvements translate to significant cost reductions for metals manufacturers.

One prime example of this efficiency in action is the recent implementation of ABB’s advanced processing line solutions based on the aforementioned DCS, for Jindal Stainless Ltd. at their Kalinganagar facility. This complex project, commissioned in 2023, underscores how automation can transform a metal processing line, driving productivity while maintaining superior quality.

Share this page

How can ABB technologies improve your processing line performance?

Talk to an expert

Frederik Esterhuizen, Global Business Line Manager for Metals at ABB’s Process Industries division

Deng Bo, R&D Manager, North Asia Cluster, Metals, and Global Product Manager for Processing Lines, ABB Process Industries

^{^{ABB control and automation systems act as the central nervous system of processing lines, silently ensuring efficient and consistent operation.}}

Jindal Stainless Ltd. case study: orchestrating success through automation

Project brief

In 2021, Jindal Stainless Ltd., one of India's leading stainless-steel producers, embarked on an ambitious project to install a Direct Reduction Annealing and Pickling (DRAP) line at their facility in Kalinganagar, Odisha. The DRAP line was designed to enhance the company’s production capabilities by enabling the processing of both hot- and cold rolled stainless steel coils—earning it the moniker "Combo Line."

The project was a collaboration between Jindal Stainless Ltd. and ABB, with ABB providing the advanced control and automation systems required to manage this complex processing line. ABB’s comprehensive solution included the Ability™ System 800xA automation platform, incorporating the high-end AC 800PEC controller for process control and the AC 800HI controller for safety functions. In addition, ABB implemented low- and medium-voltage line drives, auxiliary drives, and advanced mathematical setup models for inline tandem mills, ensuring precise synchronization and optimal operation. The project team worked diligently from 2021 to 2023, utilizing digital twin technology for in-house testing, which enabled seamless system implementation.

Challenges and solutions

One of the primary challenges faced in this project was the need to commission a highly complex processing line equipped with advanced technology, including a 3-stand S6-high inline tandem cold mill, degreasing section, furnace section, scale breaker, shot blaster, pickling section and 2-high skin pass mill. This required precise synchronization of multiple sophisticated components, such as the automatic roll change device, the auto sequences for entry and exit sections, and micro tracking for section setpoint handling, all while maintaining high-speed operation and quality output.

Based on ABB's extensive experience with similar projects, including their previous work with Jindal Stainless Ltd. on the hot- and cold rolled annealing and pickling lines in 2010-11, ABB delivered a control system that included features such as accurate load share control of driven rolls, tension control across the line, and advanced thickness control solutions. These features ensured that the processing line could operate smoothly, even under the demanding conditions of producing both hot- and cold rolled coils.

^{_{The direct reduction annealing and pickling line (DRAP) at Jindal Stainless Ltd. in Kalinganagar, Odisha, India equipped with advanced ABB automation and control systems}}

Technical innovations

The DRAP line was outfitted with several technical innovations that set it apart from other solutions available in the market. Key among these was the rollable weld system, which allowed for seamless transition through the inline 3-stand tandem cold mill and the inline skin pass mill. The system featured an auto-sequence for the tandem cold mill roll change device and a 4-roll carousel stand that enabled roll changes without reducing line speed. These advancements were made possible by ABB’s advanced Direct Torque Control (DTC) technology for AC drives and a wide range of metals standard for processing line control.

These innovations improved the efficiency and reliability of the processing line and enhanced the final product's quality. Within six months of the commissioning process, Jindal Stainless Ltd. started producing 2BD surface quality stainless steel ideal for use cases such as pipes and tubing, a new product developed specifically for the DRAP line.

Beyond control: advanced diagnostics and data insights

ABB's control and automation systems extend beyond maintaining optimal speed and tension. They provide a wealth of data and insights that empower operators to proactively manage the processing line. The system continuously monitors equipment health and performance, identifying potential issues before they can lead to downtime. This proactive approach allows for implementing preventive maintenance strategies, maximizing equipment lifespan and minimizing unexpected disruptions.

By analyzing historical data and real-time performance metrics, the system can identify trends and patterns. This information can be used to further optimize control settings, identify areas for improvement, and even predict potential issues before they occur. In the case of Jindal Stainless Ltd., these capabilities translated to significant reductions in downtime and maintenance costs, ensuring the processing line operated at peak efficiency.

Collaborative approach and seamless integration

One of the strengths of ABB's control and automation solutions lies in their ability to integrate seamlessly with existing equipment, regardless of brand. This allows metal manufacturers to leverage advanced automation without the need for a complete line overhaul. ABB's systems harmonize the various elements of a processing line—from older equipment to newer technology—into an efficient, well-coordinated production line. This collaborative approach ensures that companies can maximize the value of their existing assets while improving overall performance.

For Jindal Stainless Ltd., this meant integrating the new DRAP line with existing infrastructure at their Kalinganagar facility, creating a cohesive system that operated efficiently and effectively. The result was a processing line that not only met but exceeded the customer’s expectations, driving productivity and product quality to new heights.

The future of metal processing: evolving for efficiency

The world of processing lines is constantly evolving, with new materials and processes emerging all the time. ABB remains at the forefront of this evolution, continuously developing and refining its control and automation solutions.

The intricate world of metal processing demands consistent, high-quality results. By leveraging advancements in areas like artificial intelligence and machine learning, ABB is exploring ways to further optimize control strategies, predict potential issues with even greater accuracy, and unlock new levels of efficiency. Through sophisticated algorithms, advanced diagnostics, and seamless integration capabilities, ABB empowers companies like Jindal Stainless Ltd. to achieve optimal speed, tension, and overall line performance. These technologies are poised to revolutionize the way metal processing lines operate, driving even greater productivity and quality in the years to come.

The big picture

While ABB's advanced automation and control systems are transforming the way metals are processed, the broader implications extend beyond the steel mill. For customers buying metals or consumers purchasing the end product, these operational gains mean better quality and reliability in everyday items. Whether it’s the steel in home appliances, automotive parts, or industrial equipment, improved consistency and durability are guaranteed. By enhancing efficiency and minimizing defects, ABB’s technology not only lowers costs for manufacturers but also ensures that consumers benefit from longer-lasting, higher-quality products.

Additionally, the automation-driven improvements in energy efficiency and sustainability contribute to reducing the environmental impact of metal production. For consumers who are increasingly conscious of the carbon footprint of the products they buy, this represents a significant step forward. Metal manufacturers who adopt these systems are not only boosting their competitiveness but are also helping to shape a more sustainable future for the global supply chain, where innovation leads to more responsible production and consumption practices.

To summarize, companies that embrace these technologies today position themselves to meet the challenges of tomorrow, producing higher-quality products more efficiently and sustainably.