Automation technology for high-capacity hot strip mill upgrade

AM/NS Calvert has commissioned SMS group to carry out a major upgrade of the automation control system at its high-capacity hot strip mill in Calvert, Alabama, USA. The aim is to bring the automation technology up to the state of the art and increase the operational efficiency of the hot strip mill. Scheduled to commence in phases from 2025 to 2027, SMS group’s automation solution will elevate the mill to a new technological level, providing modern and reliable high-speed control.
As well as installing advanced X-Pact® Embedded controllers, the core of this upgrade is the X-Pact® ProBAS software platform, which ensures the plant’s high-speed control capabilities. The integration of an EtherCAT real-time Ethernet network for high-speed technological sensors and a Profibus remote I/O system for standard sensors ensures robust and reliable real-time data communication.
This technological advancement provides numerous benefits, including an enhanced graphical programming environment, high-speed control, and improved diagnostic capabilities, which are crucial for maintaining seamless plant operations. The new automation system guarantees digital readiness, which is essential for getting production units and automation systems ready for digitalization with a minimum of effort.
The project continues a longstanding collaboration between SMS and AM/NS Calvert. Over the years, SMS has played a vital role in various upgrade activities at the plant, ensuring that operations remain efficient and aligned with the latest technological advancements. AM/NS Calvert’s decision to partner with SMS underscores the latter’s expertise in delivering advanced technological solutions tailored to metallurgical plant needs.
Matt Korzi, Vice President of Automation, Digital and Service Solutions at SMS group Inc., stated, “As a lifecycle partner of AM/NS, we are committed to ensure a reliable automation solution that not only addresses immediate technological needs of the hot strip mill but also sets a foundation for future operational improvements. Only through trustful cooperation and a lifecycle approach to plant automation, can such a high-capacity hot strip mill produce high-quality products that meet the evolving requirements of the market.” 
AM/NS Calvert’s seven-stand hot strip mill, with an annual capacity of 5.3 million tons, is a key player in the USA, producing flat carbon steel to the highest specifications. The plant serves diverse markets, including automotive, construction, pipe and tube, service centers, and the appliance/HVAC industries, making this upgrade pivotal for maintaining its competitive edge.