Comprehensive Modernization of an EBNER HICON® Pusher Furnace
EBNER | DANIEL NEUWEG, Senior Manager Upgrade & Rebuild
Comprehensive Modernization of an EBNER HICON® Pusher Furnace
NOVELIS Korea invests in future-proofed technology through the modernization of a key facility for sustainable aluminum production
At Yeongju in South Korea, NOVELIS Korea is modernizing the HICON® pusher furnace facility that has been in operation since 2005 in cooperation with EBNER. The existing facility is used for heating and homogenizing aluminum ingots and represents an essential part of the production chain. The modernization aims to sustainably increase operational reliability, facility availability, and maintainability while establishing the technological foundation for future production requirements.
The facility is an EBNER HICON® pusher furnace of type STOg w-700/h-265/l-1875 for the heat treatment of aluminum ingots. The originally installed automation system was based on a GE FANUC PLC and had reached the end of its life cycle. As part of the project, the automation, instrumentation, control, and drive systems are therefore being comprehensively upgraded to state-of-the-art SIEMENS S7-1500 technology.
HOLISTIC MODERNIZATION APPROACH
As part of the modernization, numerous core components of the facility are being renewed and upgraded to the latest state of the art. The scope of supply includes, among other things:
- Replacement of the existing PLC control system with SIEMENS S7-1500
- Modernization of the process control system and visualization
- Renewal of the burner control system
- Replacement of sensors and field devices
- Modernization of the hydraulic system
- Optimization of the ingot pusher system
- Upgrade of the pressure-reducing station
- Modernization of the safety system, including protective devices
- Adaptation of the facility architecture to the latest technical standards
The technological benchmark for this project is the latest EBNER pusher furnace that has been operating successfully at the same site since 2023 and serves as a model for key system components.
ON-SITE ANALYSIS CREATES THE FOUNDATION FOR SUSTAINABLE SUCCESS
Before the project commenced, EBNER experts carried out extensive on-site analyses of the existing facility.
During these assessments, various optimization opportunities were identified, and several signs of aging and wear were detected. These issues are now being sustainably addressed as part of the modernization. By taking a holistic view of the facility, a modernization concept was developed that goes beyond merely replacing obsolete components and instead creates the basis for sustainably higher facility availability over the long term.
FOCUS ON AVAILABILITY AND FUTURE PROOFING
One of the key benefits of the modernization is the assurance of long-term spare parts availability. The previously used automation components had already been discontinued or were only available to a limited extent. By migrating to current SIEMENS systems, NOVELIS will receive a future-proof platform for operation, maintenance, and future expansions.
In addition, the new system architecture enables improved diagnostic capabilities, greater data transparency, and more efficient maintenance. The modernization therefore creates the conditions required for safe and economical facility operation for many years to come.
CLOSE COLLABORATION AS A KEY SUCCESS FACTOR
The project was developed through close cooperation between the teams of NOVELIS, EBNER’s local representative office in Korea, and the specialist departments in Leonding, Austria. Numerous technical workshops, joint facility inspections, and detailed coordination meetings were conducted already during the quotation phase to define the optimal scope of modernization.
The intensive collaboration among all parties in-
volved ensured that the modernization could be tailored precisely to the customer’s requirements while also taking future expansion possibilities into account. With the modernization of the HICON® pusher furnace, NOVELIS Korea is taking an important step toward securing its competitiveness and production reliability. The combination of state-of-the-art automation and process technology, increased facility availability, and long-term spare parts security results in a future-proof solution for the aluminum industry.
The project once again highlights EBNER’s expertise in the modernization of existing industrial furnaces and demonstrates how proven facilites can be successfully prepared for future requirements through targeted technical upgrades.
