Pyrometallurgy process control system in a ‘greenfield’ project
How can a control system be effectively designed and implemented in a new factory — even under demanding market conditions?
We deliver comprehensive industrial automation projects for new production facilities. Building a modern control system in a greenfield project includes system design, electrical cabinet fabrication, equipment supply, software development, and full installation commissioning. It is a demanding task that requires extensive engineering effort, experience, and high technical competence.
Greenfield projects enable the implementation of best practices already at the plant design stage, but they also require precise planning, solution standardization, and effective coordination of multiple suppliers.
Goals
- Design and commissioning of a supervisory control system
- Definition of standards for modern automation solutions
- Rapid implementation of the control system
Challenges
- Disrupted supply chains for components
- Development of new process control algorithms
- Strict safety requirements
Solutions
- Siemens S7-1500 controllers
- AVEVA System Platform
- Modern IT infrastructure, including redundant servers and a storage array
- Delivery of electrical control cabinets
- Communication based on fiber-optic ring network architecture
Benefits
- Precise control of production process parameters
- Improved operator comfort
- Standardization of equipment supplier requirements
- Reduction of spare parts inventory
Control of pyrometallurgical processes in demanding conditions
Pyrometallurgical processes require precise control, especially where efficient recovery of elements is critical. In cooperation with the investor, we developed control algorithms that enable effective process management and ensure high quality of final products.
By combining modern technical solutions with the experience of our engineering team, we ensured stable system operation and full control over critical process parameters.
Optimization of equipment systems and standardization of solutions
In industrial plants, package-unit equipment with dedicated control systems is often used. For the investor, it was important to reduce the variety of solutions in order to simplify maintenance operations and lower spare parts inventory costs.
From the very beginning, we supported the investor in this area. We coordinated with suppliers to minimize the number of types and models of delivered equipment. We also enforced appropriate communication solutions, such as network segregation, connection to fiber-optic ring networks, and communication based on Profinet.
Safety in harsh operating conditions
In the metallurgical industry, where operating conditions are particularly demanding, the safety of production personnel remains a top priority. Therefore, we designed and implemented an advanced safety system that improves operator comfort and enhances employee protection.
Support for maintenance teams
To support maintenance teams, we implemented an intuitive diagnostic system. The solution monitors equipment operation in real time and reports any potential irregularities. This enables faster response to issues, reduces downtime, and improves maintenance planning efficiency.
Summary
Designing and commissioning a control system for a newly built factory under conditions of limited component availability was a significant engineering challenge. Logistical and supply chain constraints could have impacted the project schedule; therefore, coordination of activities, standardization of solutions, and ongoing collaboration with the investor and suppliers were critical.
Thanks to the commitment of our team, the investor, and our technology partners, we successfully completed the project and commissioned the production facility within the planned timeframe.
The investor’s awareness that high-quality hardware and software are the foundation of long-term reliable operation enabled the implementation of modern and stable control system solutions. Advanced fault and failure diagnostics allow for fast issue identification and effective resolution.
The system was also designed with integration into higher-level business systems in mind, enabling efficient and secure data exchange.
Thanks to modern technological solutions and the experience of our engineering team, we deliver demanding industrial automation projects — from concept and detailed design, through panel fabrication, up to full system commissioning.
