EVA 1 & EVA 2 Single-Bar Tempering Systems for Georgsmarienhütte GmbH
Project Overview
Georgsmarienhütte GmbH, a leading steel company in Lower Saxony, has commissioned two state-of-the-art single-bar heat-treatment facilities (EVA 1 and EVA 2). With a total investment of 21.5 million euros, the company has built one of the most advanced facilities in Germany for the production of high-quality, heat-treated steel bars made from recycled material.
Single-bar heating: The heating process for premium-quality steel
EVA systems operate using a precise heat treatment process: Steel rods made from recycled scrap are heated to up to 880°C depending on their material properties, then quenched and tempered to 550–700°C. This process makes the material both stable and ductile—ideal for high-stress applications in wind turbines, the automotive industry, aerospace, and agriculture.
The Assignment
Georgsmarienhütte GmbH needed two plants for the production of high-quality, heat-treated steel bars from recycled scrap, with the following requirements:
- Full digital integration into existing production systems
- Real-time monitoring of all process-related data
- Complete traceability of every single rod
- Compliance with international quality standards (AIAG CQI-9, ASTM A1100)
- Seamless integration into the existing infrastructure (brownfield project)
- 100% electric operation using green electricity
This complex automation solution was to be implemented in collaboration with ITG Induktionsanlagen GmbH, which served as the general contractor.
Control Technology and Digitalization: Our Solution
ROTH implemented the complete control systems and digitalization for both EVA plants:
Central control room with highly automated process control
Both systems are controlled from a central control room with minimal manual intervention. This enables rapid adaptation to various material parameters and ensures maximum safety through continuous process monitoring.
PLC Programming for Precise Process Control and Integration of Equipment
The programmable logic controller was custom-programmed for precise process control, integration of all auxiliary units (cooling systems, recooling unit, air extraction and purification system), integrated fire protection, and safe process operations with redundant safety systems.
Level 2 integration with real-time data transmission and an order management system
Full integration into the GMH Level 2 system enables real-time transmission of all process-relevant measurement values, a connection to the customer’s fully digitized order management system, and automatic data collection for quality assurance and traceability.
Full traceability and HMI user interfaces
Each rod is tracked throughout the plant with full traceability and documented process data. After leaving the plant, the bars are sorted into bundles. The highly digitized HMI interfaces provide an intuitive and transparent display of all process parameters and real-time visualization using Siemens WinCC. Compliance with AIAG CQI-9 and ASTM A1100 is ensured.
Brownfield Integration and Project Management
The project was implemented as a brownfield integration into the existing infrastructure. Close collaboration between ROTH, ITG, and the on-site project teams resulted in detailed project planning despite limited space, optimal integration into existing production systems, and the successful commissioning of both plants with minimal disruption to ongoing production.
Results: Production Capacity, Quality, and Sustainability
Production Capacity and Efficiency
- Annual production of over 35,000 metric tons
- Significantly less warping thanks to optimized heat treatment processes
- Partial Reduction in the Number of Trial Proceedings
Quality and Sustainability
- Full traceability and compliance with the highest industry standards (AIAG CQI-9, ASTM A1100)
- 100% electric operation using green electricity
- Recycling Scrap Metal Instead of Mining Raw Materials
- A milestone on the path to climate neutrality by 2039: ITG and ROTH are helping Georgsmarienhütte GmbH achieve its key climate goals
Automation and Digital Transparency
- Highly automated process control with minimal manual intervention
- Central Control Room for Efficient Operation
- Digital transparency across all production steps
This NDR article provides further insights into the project.
