New FS40 system with digital DICU3 control commissioned in just 19 days at South32’s South African site.
ABP Induction has successfully demonstrated its ability to deliver highly efficient project execution with the installation of a state-of-the-art FS40 induction furnace system at South32 Hillside. Equipped with digital DICU3 technology, an emergency UPS tilting system and advanced digital functionalities, the solution enhances both safety and process optimisation – another milestone in the sustainable transformation of the metals industry. It reflects ABP Induction’s commitment to its guiding principle: “Your Partner on the Way to Zero Emission.”
The project was carried out at the globally active mining and metals company South32 Hillside under the leadership of Thinus Mostert, Nikki Wilson, Irfan Yenigelen, Ahmed Rizk and Vitali Herdt. Remarkably, the complete installation was finalised within only 19 days. Several partner companies contributed to this achievement, including MTM Elektries, Sovereign Engineering, SKM Engineering, Philco Systems and Yandisa.
ABP Induction has successfully demonstrated its ability to deliver highly efficient project execution with the installation of a state-of-the-art FS40 induction furnace system at South32 Hillside
Byron McCall, General Manager of ABP South Africa, expressed his deep appreciation for the outstanding performance of the ABP team and subcontractors. He also commended South32 Hillside’s project management team as among the most exceptional project management engineers he has worked with.
South32 is a diversified mining and metals company that generates value through the production of raw materials used across many areas of modern life. Its operations, growth options and exploration programmes span a wide range of commodities and regions. The company’s strategic approach aligns closely with ABP Induction’s philosophy of supporting industry partners in their transition toward advanced, sustainable and digitalised processes.
At the South African site, ABP Induction installed an FS40 furnace system using the digital DICU3 unit to control the rectifier and inverter, along with an S7-1500 PLC and 22-inch HMI for furnace operation
Streamlined furnace charging – powered by charge bucket system
At the South African site, ABP Induction installed an FS40 furnace system using the digital DICU3 unit to control the rectifier and inverter, along with an S7-1500 PLC and 22-inch HMI for furnace operation. The Digital Inverter Control Unit serves as the technological core of ABP’s thyristor-based melting systems. Compared with its predecessor DICU2, DICU3 represents a significant technological leap, enabled by a new processor platform and advanced remote-service capabilities. Being fully M2M-ready, DICU3 enables remote troubleshooting, providing a key step toward Industry 4.0 readiness.
In addition, DICU3 offers exceptional operational reliability. Faster and more precise regulation reduces downtime, compensates for construction-related variations in replacement transformers, and stabilises critical inverter situations more efficiently, protecting semiconductor components from potential damage.
ABP Induction offices established on site
Installing state-of-the-art equipment in converter room, assisted by Irfan Yenigelen
The system installed at South32 also includes a UPS-based emergency tilting system, which significantly outperforms traditional nitrogen-based solutions. The UPS keeps the PLC and DICU3 operational even during power outages, giving operators greater control of the furnace in emergency situations.
The complete technology package improves operational safety while offering advanced features that prepare customers for future-ready processes, particularly in connection with ABP’s TWIN-POWER® technology. This allows simultaneous furnace operations: melting in one furnace while sintering or holding in the other. The benefits include increased inverter utilisation, reduced maintenance and investment costs, and improved environmental performance. These efficiencies are driven by ABP’s PRODAPT® melting processor, which calculates energy demand based on furnace content and ensures optimal energy management for both melting and holding operations.
Fully installed, ready-to-run FS40 induction furnace
Irfan Yenigelen testing equipment during installation and commissioning
ABP Induction
ABP Induction is a leading provider of induction melting and heating systems, aftermarket services and digitalisation solutions for the global foundry, forging and steel industries. ABP maintains sales, manufacturing and service locations in the USA, Germany, Sweden, Mexico, Thailand, India, China and South Africa.
For further details contact ABP Induction on TEL: 011 623 1814/17 or cell number 072 158 1117 or email byron.mccall@abpinduction.com. You can also visit www.abpinduction.com
