AMI Automation has completed the Factory Acceptance Test (FAT) for Big River Steel’s Level 2 Meltshop system at Plant 1, advancing the plant’s digital integration following the commissioning of the Plant 2 system in December 2024.

The new Level 2 solution covers two Electric Arc Furnaces (EAFs), two Twin-Shell Ladle Furnaces, and one RH Degasser. It delivers operator screens for production scheduling, scrap and material addition tracking, heat and process variable monitoring, reporting, interfaces to external systems, and life-tracking for critical equipment. Real-time process modeling, refined automation logic, and enhanced production insights support consistent, repeatable, high-efficiency melts and stronger data-driven decision-making across the Meltshop as part of AMI’s Digital Operation Technology suite.

The system uses a Windows-based architecture with an Oracle database, SAP Crystal Reports, Kepware for PLC communications, and Microsoft .NET development—providing robustness, scalability, and seamless integration. The user interface aligns with the adjacent Meltshop Level 2 system for a unified operator experience. Software was delivered ready for testing in record time, with immediate technical support and increased reliability.

“The completion of this FAT reflects Big River Steel’s commitment to innovation and operational excellence,” said Eduardo Aguilar, Digital OT Director AMI Automation. “We’re proud to support their continued progress toward a fully optimized, digitally integrated steelmaking operation.”

Despite the tight timeline for the Factory Acceptance Test, the development team successfully met the challenge, demonstrating strong coordination and technical expertise throughout the project.

This achievement underscores Big River Steel’s next-generation manufacturing vision and AMI Automation’s leadership in delivering advanced automation and digital technologies for the steel industry.