In 2021, Jindal Stainless Ltd. embarked on an ambitious project aimed to enhance production capabilities to enable the production of both hot- and rolled stainless steel coils by installing a Direct Reduction Annealing and Pickling (DRAP) line at their Kalinganagar facility. The challenge was to synchronize multiple sophisticated components in a highly complex processing line.
ABB provided advanced control and automation systems, including the Ability™ System 800xA platform, AC 800PEC and AC 800HI controllers, and digital twin technology for seamless implementation. This ensured precise synchronization and optimal operation of the DRAP line.
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.
Advanced diagnostics and data insight capabilities also translated to significant reductions in downtime and maintenance costs, ensuring the processing line operates at peak efficiency.