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Improved sustainability for Tata Steel


Tata Steel invested in a new evaporative cooling system for the Basic Oxygen Steelmaking (BOS) plant in South Wales, which would produce steam and generate electricity. The 10MW reduction in energy consumption will improve sustainability and power an estimated 20,000 homes.

Iconsys was asked to design, supply, install and commission a new plant-wide control system to regulate the complete process.


Our Solution

The full turnkey control system from Iconsys comprised:

  • Upgrade of existing 11kv switchgear protection circuits
  • 2x 11kv:690V transformers
  • 1x 690V distribution board
  • 14x ACS800 low harmonic AC drives
  • 2x active harmonic filters
  • 3x Rockwell Contrologix PLC systems
  • intouch SCADA station upgrade for the power plant/energy control
  • ifix SCADA nodes for Converter 1 & 2 control rooms

    The whole plant PLC, SCADA and drive system was connected on a high-speed Ethernet FO network, which included communication converters to legacy Eurotherm hardware.



  • Increased production output
  • Reduced energy usage – 10MW of energy saved enough to power an estimated 20,000 homes
  • Recycle and reuse process gas


Client Feedback

“By equipping our BOS plant with a state-of-the-art evaporative cooling system, we will improve Port Talbot’s productivity and energy efficiency. We will also build on the ability to recycle and reuse process gases that our Energy Recovery plant brought us.”

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iconsys enhance performance through integration of automation technologies.
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