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Usiminas Boilers

Boiler Control System

Altus supplied the automation technology for the development of a new Boiler Control System at one of Usiminas’ manufacturing plants, one of the largest companies in the Brazilian steel industry.

The project delivered enhanced control over critical process variables such as pressure, temperature, and fuel management, ensuring safer operation, improved energy efficiency, and greater system reliability. As a result, the plant achieved cost savings, optimized resource utilization, and increased overall productivity.

Usiminas Boiler Control System

The Boiler Control System, developed using Altus programmable controller technology, performs load sharing, protection, and load rejection functions for Usiminas’ 45 t/h and 130 t/h boilers. These systems manage the supply of high-pressure, high-temperature steam to turbo-blowers and the thermoelectric plant, as well as process steam to key areas such as the Plate Mill dispatch yard.

The automation also supports coordinated operational actions, including the automatic deceleration of uncoilers in the hot strip mill and the furnace discharge system in Batteries 1 and 2 of Coke Plant 1, ensuring process stability and operational safety across interconnected units.

The project scope further included full instrumentation of the area. Motorola communication radios were deployed to provide Ethernet interconnection between field measurement points and the InduSoft Web Studio supervisory system, enabling reliable real-time monitoring, data acquisition, and centralized control of the boiler operations.

Energy Efficiency

The energy generation optimization achieved through this project saves Usiminas approximately US$ 450,000 per month

Accurate data

The embedded technology in this solution delivers highly accurate data throughout the process

Centralized information

The system also enhances the centralization of all data related to resource use

Online control

With a range of online diagnostics and alarms, the system enables remote monitoring, ensuring continuous oversight

Key benefits of the new system

The system is controlled by four Altus programmable controllers, connected via an Ethernet network with CPU and I/O module redundancy.

Supervision is carried out from a dedicated Supervisory Station, with all PLCs linked to it through Altus AL-3405 communication modules over Ethernet/TCP-IP (IEEE-802.3), as well as the optical transceivers and repeaters used in the project.

The system also features a real-time multitasking processing module, which handles communication with two single-loop controllers for precise boiler temperature control.

Application-specific features

The system includes 784 digital and analog input/output points, all operating in redundancy mode, along with the process control CPUs. These operate within an Ethernet TCP/IP network using fiber optics.

Additionally, the system features remote supervision capabilities for enhanced monitoring and control.