At the time of the upgrade, EZDK had been producing one million tons of flat steel per year - ranging from low- to medium-carbon and HSLA grades to limited quantities of API and dual-phase steel. They were looking to get into more added-value products such as thicker API-X70 material, silicon steel, and dual- and multi-phase steel. Moreover, they also wanted to produce thinner 1.0-millimeter gauges to extend the portfolio beyond their then standard 1.2-millimeter thickness. They called upon SMS group’s reliable expertise to tackle the project.
In a first phase the SMS group experts conducted an on-site assessment. The aim was to identify key improvement potentials and establish a holistic plan for the modernization of EZDKs new CSP® plant. Our team went to work and executed the modernization project according to the master plan that brought everything up to date and replaced all control panels, the local operating units, and the HMI system in the CSP® system. They pre-tested and optimized the X-Pact® electrics and automation of the CSP® system with our tried-and-true X-Pact® Plug & Work concept before it was put into operation.
At our test center in Hilchenbach, we tested and optimized the automation system before installing it at the EZDK site, using realistic 3D simulation technology that captures all mechanical systems, the drive technology, and the entirety of the plant’s processes. Using the 3D design data of the plant, our simulation reproduced the dynamic, kinematic, and technical procedures in highly resolved detail. Meanwhile, our experts trained the EZDK operating and maintenance staff on the virtual plant – an invaluable operational advantage for our client, whose teams became intimately familiar with the new systems and could hit the ground running after the shutdown.