Steel Times International Digital January February 2019 by Quartz Business Media

INNOVATIONS

INDUSTRY NEWS ROUND-UP

ROBOTICS AND STEELMAKING

IRONMAKING

A bumper edition of Innovations – 18 pages of contracts and products

Four pages of global steel industry news

Tebulo develops a new reel-hole fixation robot for cold-coiled steel

Re-hydrated burnt lime improves sinter, says SAIL

www.steeltimesint.com Digital Edition - January/February 2019 - No.11

LIBERTY’S POWDERED METAL INITIATIVE

CMI Industry Metals processes innovation into value The strong commitment to a culture of creative thinkers helped us to provide innovative and profitable answers to the needs of our clients. Resolutely oriented towards the future, innovation forms an inherent part of our engineering. While growth is not an option, the challenge is to remain agile and focus on generating sustainable progress. This is what we have done for the past 200Â years.

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CONTENTS DIGITAL EDITION - JANUARY/FEBRUARY 2019

INNOVATIONS

INDUSTRY NEWS ROUND-UP

ROBOTICS AND STEELMAKING

IRONMAKING

A bumper edition of Innovations – 18 pages of contracts and products

Four pages of global steel industry news

Tebulo develops a new reel-hole fixation robot for cold-coiled steel

Re-hydrated burnt lime improves sinter, says SAIL

www.steeltimesint.com Digital Edition - January/February 2019 - No.11

Picture courtesy of: KOCKS. KOCKS 4D EAGLE® proﬁle measurement system currently operating at Georgsmarienhütte (GMH), Germany

2 Leader by Matthew Moggridge, editor. 4 News round-up The latest global steel news.

LIBERTY’S POWDERED METAL INITIATIVE

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com Consultant Editor Dr. Tim Smith PhD, CEng, MIM Production Editor Annie Baker Advertisement Production Martin Lawrence SALES International Sales Manager Paul Rossage paulrossage@quartzltd.com Tel: +44 (0) 1737 855116

10 China update China shores up steel consumption as peak production looms. 14 3D printing Liberty’s powdered metal initiative. 16 Cyber security Leading by example.

Sales Director Ken Clark kenclark@quartzltd.com Tel: +44 (0) 1737 855117

21 Ironmaking Re-hydrated burnt-lime improves sinter. 26 Robotics Less handling thanks to robotics. 32 Rolling Solutions for vertical roll stands. 42 Innovations The latest new products and contract news.

Managing Director Steve Diprose stevediprose@quartzltd.com Tel: +44 (0) 1737 855164

Chief Executive Ofﬁcer Paul Michael SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com Steel Times International is published eight times a year and is available on subscription. Annual subscription: UK £178.00 Other countries: £254.00 2 years subscription: UK £320.00 Other countries: £457.00 ) Single copy (inc postage): £40.00 Email: steel@quartzltd.com Published by: Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, England. Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034 www.steeltimesint.com Steel Times International (USPS No: 020-958) is published monthly except Feb, May, July, Dec by Quartz Business Media Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER send address changes to Steel Times International c/o PO Box 437, Emigsville, PA 17318-0437.

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Digital Edition - January/February 2019

LEADER

You can run, but you can’t hide – from Brexit...

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

I flew out of Heathrow’s Terminal Five on a Saturday evening bound for New Delhi. I hadn’t travelled to India for a long time, 35 years to be precise, and when I got there I felt a great sense of relief; it was so nice to be away from the UK and away from Northern Europe as a whole. India is a whole new ball game and I knew it was unlikely that I would stumble across a Claire’s Accessories or some other global brand name. Alright, I did spot a Subway not far from my hotel, but that was about it. Everything is different in India, there are auto rickshaws, bicycle rickshaws, bullock carts, monkeys, sunshine, happy people – and great food, and I embraced the lot. I had a conference to attend and a meeting the following day, but the meeting was cancelled, giving me time to visit the Red Fort. In between I enjoyed just being away from English newspapers and knife crime and Brexit and all the other negative elements of living in the United Kingdom. I didn’t have to listen to the awful Theresa May or Jeremy Corbyn and, most of all, I didn’t have to pay any attention to the lunacy of Jacob ReesMogg or Boris Johnson. I’ll nail my colours to the mast right now: I voted remain in the referendum.

I’m not bitter about it, but I’m fed up with it. I don’t want to hear about the backstop or ‘no deal’ and I don’t want to listen to “Brexiteers” moaning about free movement and saying ‘let’s make Great Britain Great Again’. Was it ever great? In India I was free of all this rubbish. Outside of business, all I had to think about was getting down for dinner around 8pm and taking maximum advantage of the all-you-can-eat buffet – and oh, did I take advantage! Two helpings every night and the same at breakfast time. And forget about ‘Delhi Belly’, it never happened. But if you’re British, like I am, there’s no escaping the boredom of Brexit, although the truth of the matter is simple: I should have stayed away from the hotel’s business centre. Checking my email was not a good idea if I wanted to escape the misery that is the United Kingdom. But like Gordon Jackson boarding a train in The Great Escape and inadvertantly saying ‘thank you’ in English when he was wished good luck, I clicked on an email from UK Steel – ‘there are no benefits to be had from Brexit’ for the UK steel industry, said Gareth Stace, director-general of UK Steel. You can run, I thought, but you can’t hide.

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NEWS ROUND-UP

• This coming August, ArcelorMittal USA takes over ‘managing duties’ of Hibbings Taconite from ClevelandCliffs Inc, following the latter’s decision to resign its role as the company’s managing partner. While the management changes, the ownership stakes remain the same. Source: Star Tribune, 31 December 2018.

• An article in a leading UK broadsheet claimed that cleaning up steel is key to tackling climate change. Globally, the steel industry accounts for 7% to 9% of all direct emissions from fossil fuels, with each tonne produced resulting in an average of 1.83 tonnes of CO2. Source: Financial Times, 1 January 2019.

• Over 35,000 people displaced due to the setting up of ﬁve steel plants by SAIL and RINL were provided employment by the two PSUs. The people were displaced following the setting up of four steel plants by SAIL and by one, the Visakhapatnam steel plant, by RINL. Source: Business Standard. com, 2 January 2019.

• Hans Fischer, head honcho at Tata Steel Europe, said that the company’s Port Talbot steelworks should be able to forge a bright future after Brexit, – but still needs to improve on its ﬁnancial performance. Source: Financial Times, 2 January 2019.

• UK exports of steel to the USA have plummeted 20% since President Donald Trump introduced tariffs on metals coming into the UK. According to a UK tabloid newspaper, British companies sent 73kt less steel to the US in the ﬁrst nine months of 2018 when compared with the same period in 2017. Source: Daily Mirror, 31 December 2018

• Reports that two workplace accidents took place at ArcelorMittal Dofasco in Hamilton, Ontario, Canada, in less than one day appeared online. Accident one happened on New Year’s Day at the company’s Kenilworth Avenue plant. According to Global News a dump-style machine was involved in a collision and a 23 year-old man was extricated from the machine and taken to hospital with serious, but not life-threatening injuries. The following day there was a truck accident and a 26-year-old woman was taken to hospital, treated and released. Source: www.globalnews.ca, 2 January 2019.

• The Indian state of Gujarat is becoming a key state for foreign direct investment from China, Japan, South Korea and Taiwan, with chemicals, automotive and auto parts and steel processing top of the pile. Gujarat has attracted almost $4,000 million of investments over the past four years. Source: The Hindu, 2 January 2019.

• Vivek Bhatia was announced managing director and CEO of thyssenkrupp Industries India, effective 1st January 2019. Source: The Economic Times, 31 December 2018.

Digital Edition - January/February 2019

• A report in the automotive media stated that Mazda Motor Corporation, working with Nippon Steel & Sumitomo Metal Corporation and JFE Steel Corporation, claim to have developed the world’s ﬁrst cold-stamped vehicle body parts made from 1,310 MPa-class high-strength steel. Source: Automotive World, 10 January 2019.

• Zou Jixin has been appointed as chairman of Baowu Group’s Baoshan Iron & Steel Co (Baosteel). Mr Jixin takes over from former chairman Dai Zhihao. Source: Mysteel.net • “We don’t care about just growth – only about proﬁtable growth,” said Nucor’s CEO John Ferriola. He expects the company to have a good year in 2019, according to an interview conducted by the Charlotte Business Journal’s John Downey. Source: Charlotte Business Journal, 6 January 2019.

• Austrian steelmaker voestalpine has announced plans to further expand its additive manufacturing operations into the Asia Paciﬁc region. In 2017 the company extended them in Taiwan and Singapore with a 50 million Euro investment. Source: 3Dprintingindustry.com, 10 January 2019.

• Chinese energy giant Yankuang Group and French energy business Air Liquide have signed a co-operation framework agreement to jointly promote hydrogen energy. The two companies agreed to jointly make plans on the development of hydrogen energy infrastructure and hydrogen fuel cell vehicles in China’s Shandong Province. They plant to build a sustainable hydrogen energy infrastructure network, according to a framework agreement signed in Jinan, Shandong’s provincial capital. Source: Xinhuanet.com, 4 January 2019.

• POSCO chairman Choi Jeong-woo has told the media that his company has no plans to make additional investments overseas in the steel sector, and this means no plans for mergers or acquisitions. The company will continue to look for lithium mines and will make investments if need be; the plan is to secure natural resources for its lithium battery business. Source: Korea Herald.com, 11 January 2019. • Paper thin steel? It’s a reality thanks to Zhang Wanquan who literally made a ‘paper’ plane out of steel in a factory in Taiyuan, capital of China’s Shanxi Province. The steel in question is just 0.02 mm thick, that’s a quarter of an A4 paper’s thickness. Mass production of the product started during H2 2018. Source: Xinhuanet.com, 11 January 2019.

• ArcelorMittal, the world’s largest steelmaker, is working on reducing its energy intensity by 10% over a decade, with 2013 as the base year. Let’s see whether they achieve their objective next year. Source: New York Times. Digital Edition - January/February 2019

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NEWS ROUND-UP

• Poland-based US Steel Košice has reported a pre-tax proﬁt of $359 million, up 10% according to an online report. However, such proﬁts are not expected going forward. According to the company, its European branch faces ‘massive pressures’ that will reduce its production volume in Q1 2019. Source: Spectator.sme.sk, 5 February 2019.

• Kavita Bhutani, an assistant general manager with Steel Authority of India (SAIL) has allegedly committed suicide by jumping into the stairwell outside her 17th floor flat in Indirapuram, India. According to an online media report, Ms Bhutani ‘used a chair to get onto the railing of the lobby and jumped into the shaft, landing on the third floor and dying instantly. Source: Times of India, 9 February 2019.

• German conglomerate (and steelmaker) ThyssenKrupp announced that income before tax fell 33% to EUR215 million (£189m) in the three months to end December 2018. Net sales were up just 2% to EUR9.7 billion. The company blames higher start-up costs for customer projects, higher material costs in China and tariffs on exports to the USA. Source: CityAM, 12 February 2019.

• Bimlendra Jha, CEO of Tata Steel UK, has resigned, but no reason has been given. The company is in the process of merging with German steelmaker Thyssenkrupp AG to create a 50:50 joint venture. Source: Hindu Business Line, 13 February 2019.

• Ahn Dong-il has been appointed president of the R&D and technology development division of Hyundai Motor Group. Mr Dong-il is a former executive of South Korean steel maker POSCO. Source: Korea Herald, 15 February 2019.

• The biggest U-boat (or submarine) ever built was launched in Kiel by Thyssenkrupp. Named Invincible it will be part of an ongoing submarine programme in the Republic of Singapore. The new boat is one in a series of four of the Type 218SG, a low signature sub with air independent propulsion (meaning it can stay under for longer). Source: The Medi Telegraph, 18 February 2019.

• Strong demand for alloy in India has led to Tata Steel reporting a 54% jump in Q3 proﬁt, offsetting the impact of falling global prices. Source: Asia Nikkei.

• The administrator for the bankrupt Bhushan Power and Steel has issued a letter of intent in favour of JSW Steel who went ‘procedurally a step closer to acquiring the troubled steelmaker’. According to one online report, if JSW’s bid is successful the company will secure a much-needed beachhead in India’s mineral-rich east. Source: Economic Times, 13 February 2019. www.steeltimesint.com

• Vedanta and JSW look as if they’re going to pair up and take one last stab at making a bid for Essar Steel. According to MoneyControl.com the two might have come together and placed a joint bid for the business. At the time of going to press, ArcelorMittal seems like the favourite with Essar Steel’s lenders. Source: MoneyControl.com Digital Edition - January/February 2019

NEWS ROUND-UP

• Car production in South Korea fell 2.1% year-onyear to 4.02 million in 2018, according to the country’s Ministry of Trade, Industry and Energy. The drop was attributed to the closure of GM’s Gunsan plant in May, which had a capacity of 260,000 units/year. Source: SP Global, 18 January 2019.

• ArcelorMittal announces that it will build its ﬁrst desalination plant in Brazil to handle ‘unforeseen water needs’ at its steel plant in Espirito Santo. The objective is to lessen the steelmaker’s dependence on Cesan, the state-owned water utility plant. Source: Reuters.com, 18 January 2019.

• The Finnish Metso Corporation has been contracted by Indian steel giant Tata Steel to build a large-scale iron ore pellet plant for the expansion of the steelmaker’s Kalinganagar operation in India’s Odisha state. The two companies have a history of collaboration over a 25-year period. Source: Chemical Engineering, 17 January 2019.

• The European Commission has restarted its investigation into the ThyssenKrupp/Tata proposed merger and has set a new deadline of 29 April. The case was paused in December last year to await required documentation that both companies failed to submit. Source: SP Global, 15 January 2019.

• Martina Merz is named new chairwoman of ThyssenKrupp’s supervisory board. A mechanical engineer by trade, Ms Merz is also on the supervisory board of Lufthansa and the board of directors of Volvo and Imerys, not forgetting chairwoman of SAF-Holland, a commercial vehicle supplier. Source: Financial Times, 1 February 2019. • Following on from the Christmas Eve 2018 ﬁre at US Steel’s Clairton Coke Works, children in the area are reporting problems with their breathing. The ﬁre damaged pollution controls at the plant and sulphur dioxide levels ‘spiked several times’ leading to the county health department issuing an air quality warning on 9 January 2019. Source: Allegheny Front.org, 16 January 2019.

• JFE Steel, Japan’s second largest integrated steelmaker, claims it will lose 1.4Mt of crude steel output due to problems with its three blast furnaces. Source: Hellenic Shipping News, 4 February 2019. • Nucor-Yamato Steel has taken on SMS group, the German plant builder, to upgrade its number two rolling mill to produce high-strength steel grades. The Arkansas-based plant produces large wide ﬂanges and H-pile sections and the aim is to broaden the range of structural steels. Source: SP Global.com, 22 January 2019. • Annual coal production in Iran will reach 1.6Mt by the end of the Iranian calendar year (20 March 2019). Coal extraction increased 25% between 21 March and 21 December 2018 when compared with the same period in 2017. Source: Tehran Times, 4 February 2019.

CHINA UPDATE

China shores up steel consumption as peak production looms Continued governmental support for steel intensive projects indicates the desire to maintain GDP, writes Will Fray*

* Maritime Strategies International

Digital Edition - January/February 2019

www.steeltimesint.com

CHINA UPDATE

STEEL production has continued at an extremely high pace in 2018. Once more MSI has increased its forecast for 2018 global production and is now expecting 1,812Mt of crude steel to be produced globally, up 39Mt tonnes from our previous forecast. This is almost entirely accounted for by a 31Mt increase in our forecast for China’s production, now amounting to an 8.8% year-on-year increase. Last year, production cuts that were forced on steel mills to control pollution, brought steel output down by 6.8% quarter-on-quarter in Q4. This year, although we are factoring in a slowdown into our forecast, we’re expecting less of an impact with implied production down 5.9% quarter-on-quarter. The main reason for this is a shift in focus for the Chinese government towards supporting economic growth under current difficult circumstances. Maintaining consumption Over the past year our main argument for slowing Chinese steel consumption has been that, in an aim to reduce levels of indebtedness, the government would reduce credit availability to State Owned Enterprises (SOEs). Tighter cash flows for SOEs would in turn mean less

spending on infrastructure projects. With construction making up nearly two thirds of steel consumption in China, slowing infrastructure spending would mean slowing steel consumption. In practice, actual events have underlined the difficulty in forecasting Chinese steel production. Although the government continues to emphasise their concern over debt (including setting targets of two percentage point reductions in debt at all SOEs by 2020), there have been few signs of slowing consumption. Indeed, we forecast consumption growth of 8.7% yearon-year in 2018. While there are concerns over the validity of some of the official statistics, implied consumption calculated using reported production, stock changes and trade corresponds to a sharp 9.6% year-on-year increase for the year to September. There are other indications of high consumption in China. For example, rebar prices in China were sustained at historic highs this year until very recently (prices have dropped sharply since mid-November as many traders face concerns that winter cuts won’t be as severe as they’d previously expected). Other signs of high consumption come from anecdotal evidence provided by many reports of highly steel-intense projects

continuing in China, including motorways and metro lines in Mongolia, and a rail line to Tibet. Continuing investment Clearly the government is providing support for infrastructure projects despite their concerns over debt. The trade war with the US has put pressure on Beijing to provide GDP growth at levels the nation has come to expect, despite risks to earnings from exporting manufactured goods. Following the model that has worked so well for them in the past, they are investing in infrastructure to stimulate the economy. Recent announcements supporting further investment, support our view that strong consumption will continue into 2019, although growth will register at a much slower 2.2% year-on-year. However, we do believe that the argument for slowing consumption, as China works to solve its debt problem, is a good one and we expect consumption to peak in 2019, as infrastructure spending slows. By 2022 consumption will have fallen to 797Mt. Production will peak in 2020, the year after peak consumption, as infrastructure projects in neighbouring countries, as part of the Belt and Road Initiative (BRI), support exports of steel products.

Fig. 1: Global incremental steel production. (Source MSI)

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Digital Edition - January/February 2019

CHINA UPDATE

Fig. 1 places incremental Chinese steel production into context against the rest of the world. Should Chinese growth fall as expected, there will be little to compensate from elsewhere; on the other hand, upside risks to our view on China are highly significant in terms of global steel output. Shipping costs set to rise MSI’s main interest in tracking the global steel markets is to better understand the dynamics of dry bulk trade – over 50% of global dry bulk trade is related to steel markets (iron ore and coking coal being the two major components). Trade analysis is one element in a rigorous analytical process to ultimately forecast vessel charter rates (and values). In this context, what does peak Chinese steel output mean for shipping costs? This is a complex question to answer, but one which MSI’s proprietary market models are designed to tackle, and have been doing so for over 30 years. Our dry bulk model incorporates analysis of all dry bulk cargoes and a projection of the bulker fleet and also incorporates the dynamics of the shipbuilding market, which, in itself, is driven by sectors including those other than dry bulk. The supply/demand fundamentals and a

range of operating/capital cost drivers and fleet efficiency factors determine the charter hire rate for a vessel; in addition to vessel charter rates, fuel costs and other voyage factors (including ballasting) determine $/ tonne freight rates. One important policy change on the horizon will place significant upwards pressure on $/tonne freight rates: new fuel regulations imposed by the International Maritime Organisation (IMO) starting in 2020. From 1 January 2020, vessels will be forced to either install mechanical systems called ‘scrubbers’ to extract sulphur oxides from the exhaust, or switch from consuming standard 3.5% sulphur content bunker fuel in their engines to 0.5% low sulphur fuel. Both solutions come at a cost: scrubbers cost in the region of $1-4m to install while low sulphur fuel bunker in Rotterdam currently costs $774/tonne, compared with $515/tonne for standard 3.5% bunker fuel. The financial implications of IMO 2020 regulations are stark. Consider the modern Panamax bulker benchmark vessel used by the Baltic Exchange in its calculation of the Baltic Panamax Index (BPI). This vessel consumes 32 tonnes of fuel per day: at today’s prices, the fuel bill would be an additional $8,300/day burning low sulphur

marine gasoil rather than standard 380cst heavy fuel oil when laden. This compares with the current TCE spot rate for the vessel of $12,000/day. The uptake of scrubbers has been low – though it has increased in recent months as shipowners bet on falling prices for high sulphur fuel oil after 2020, which they can burn using a scrubber. Anecdotally, waiting lists to fit scrubbers are long, up to 18 months for one leading manufacturer: accordingly, MSI estimates up to a maximum 15% of dry bulk vessels will have fitted scrubbers by 1 January 2020. It is clear that a large majority will be using low sulphur fuel. As is clear from the above, fuel prices will be key, and will more than offset the negative factors associated with peak Chinese steel. Fig. 2 shows MSI’s $/tonne freight forecast on an indicative route, coal shipments from the Brazilian port of Bolivar to Rotterdam in the Netherlands, under a number of LSFO price premium scenarios over MSI’s Base Case for Heavy Fuel Oil, of between 25% and 100%. Clearly, while we believe $/day dry bulk vessel charter rates are near a peak, $/tonne freight rates still have significant room to increase as shipowners look to pass on the higher longterm cost of fuel. �

Fig2. $/T Freight Bolivar-Rotterdam under a range of LSFO/HFO price premiums

Digital Edition - January/February 2019

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KNOW-HOW FOR TOMORROW

3D PRINTING

Liberty’s powdered metal initiative International steel and industrials group, Liberty, has launched a multi-million programme to develop a new generation of powder metals aimed at revolutionising component manufacturing.

THE initial £10m project in partnership with the Materials Processing Institute and Atomising Systems Ltd (ASL) is designed to create a new range of powder alloys ideal for 3D printing of precision components, leading to lighter, more efficientlymanufactured parts with zero waste, and open the door to mass customisation of complex steel products. Even simple applications of the technology could achieve huge savings for end-users, claims Liberty. For example, these materials could halve the weight of aircraft seat buckles, saving over £2million in fuel costs over the lifetime of each plane, and 3D printing with these materials would allow affordable tailoring of artificial limbs to achieve a perfect fit for each patient. Liberty will be developing a new generation of powdered steels that contain properties that overcome the barriers to 3D printing found in existing powder metals. The world market for powder metals generally is estimated to be £8billion a year, but the application of powders for 3D printing is still in its infancy. With part-funding from Tees Valley Combined Authority, Liberty is establishing the new development facility at the Materials Processing Institute on Teesside in the UK, which will be equipped with the latest vacuum induction atomiser designed to achieve higher purity metal powders. Longer term aims Liberty’s longer-term aim is to establish a £60 million powder metals production plant on Teesside, feeding a network of advanced manufacturers and helping to make the UK an international leader in manufacturing with powder metals. The company’s Teesside initiative has followed on from its leadership of the Digital Edition - January/February 2019

Government-backed CASCADE initiative, which brought together component makers and big-name end-product manufacturers such as Rolls Royce, Jaguar Land Rover and Siemens, to develop a strong UK supply chain for powder metals. Dr Simon Pike, Liberty’s technical director

commented: “This project will be a very significant step forward for the international metals industry, building on the excellent foundations laid by the CASCADE. We’re confident it will unlock many other exciting opportunities for advanced industries over the coming years.” www.steeltimesint.com

3D PRINTING

Dr Pike said that multiple applications had already been identified for such materials in the aerospace, automotive, energy and industrial equipment markets. “This is a disruptive technology that will produce powder metals capable of changing the face of component manufacturing in the UK and internationally.” Chris McDonald, CEO of the Materials Processing Institute, said: “The Institute has enjoyed a very successful and longstanding partnership with Liberty, and we are delighted to be supporting this powder metals project. Our collaborative expertise and the capabilities within advanced materials at the Institute will be integral to the success of the project, as well as the continued development of additive manufacturing processes.”

New generation powder alloys He added: “Currently available powder is limited to stainless steel and tool steel which is high-cost and not that suitable for the additive manufacturing process, so we will be developing a new generation of powder alloys with finer grains that provide www.steeltimesint.com

better mechanical properties making them stronger, tougher and more formable as well as being ideal for 3D printing.” He explained that the material created could be used to produce near perfect components without the need for further refining of any kind.

Exciting project Tees Valley Mayor Ben Houchen, said: “We have invested £4.6million in this exciting project to keep Tees Valley ahead of the game in this potentially huge new global market. Investment in new technologies is vital to create high-skilled jobs for local workers and this project paves the way for a whole new industrial cluster in the region. The fact that a company like Liberty has chosen Tees Valley shows the importance of backing the job creators, innovators and entrepreneurs to develop future-proof industries like this one.” The vacuum induction atomiser is scheduled to be commissioned in 2019 by the world leading supplier ASL and, in line with Liberty’s GREENSTEEL strategy, plans are being drawn up to install a wind turbine at the site to power the equipment. � Digital Edition - January/February 2019

CYBER SECURITY

Leading by example

Digital Edition - January/February 2019

www.steeltimesint.com

CYBER SECURITY

Cybersecurity and risk management are topics now elevated to board level, and a chief concern of investors, officers and regulators alike. Data breach stories are as common as coffee shops, and it’s hard to find someone who hasn’t personally experienced some form of cyber crime themselves. Hyperbole aside, cyber risk now contributes to the overall mix of fiduciary responsibilities assigned to officers and board members of companies, regardless of the size. By Mark Sangster*

ROI has become less about Return on Investment, and more about Risk of Incarceration. Perhaps at a stretch, the sentiment sticks. Boards and senior executives are being held accountable for cyber attacks and damaging data breaches in terms of law suits, toppled stock values, financial losses and terminations. Board members are now tasked with familiarising themselves with the risks associated with growing cyber crime, emerging technologies and regulatory obligations, and even privacy laws in multiple jurisdictions and levels of government. Once armed with at least enough knowledge to be dangerous, boards must afford their executive team with the budget, resources and people to protect the longevity of the business and its clients. And perhaps the most difficult issue is finding a common language by which they can communicate with their security teams to determine if resources are allocated appropriately and security initiatives are aligned to risk goals. In a recent independent study of 1,250 global security and business leaders, CEOs, board members and technical executives

unanimously predict a major cyber attack in the next two to five years. Over 60% of respondents assume a major event will occur. Interestingly, 77% of CEO and board respondents consider their organisation prepared for such an event. As expected, technical leaders are approximately 20% more likely to predict an attack and are 10% less optimistic than their business peers in their organisation’s preparedness. Business leaders now fear consequences of a major cyber attack more so than regulatory retaliation. Operational disruption and reputational damage are of greater concern than potential financial losses and regulatory penalties. This trend reflects a shift from a compliance-centric security approach (avoiding punishment) to a more self-actualised mindset determined to reduce the risk of business-altering outcomes to protect the organisation, its investors and clients. As a result, “the CISO is the least interesting person to the board, until they are the most important person” is a thing of the past. Most boards are now strongly familiar with security budgets, strategies and policies, technologies, and current

security and privacy risks. Line of sight to the board is also direct. Almost half of the surveyed security officers report to the board of the CEO, a third report to the CIO (which is problematic), and a small handful now report to a privacy or data officer. It is also imperative that boards align business objectives and risk tolerances with security and information technology programmes. A firm’s risk comes down to a finite set of factors including industry participation (think finance and healthcare), adoption of emerging technologies that bring competitive gain, but introduce new and sometimes undetermined risk, and the maturity of their security programmes designed to mitigate such risk. Not surprisingly, 64% of respondents predict a year-over-year increase in security budgets; while only 5% predict a reduction. The average firm spent $1–2.5 million on information technology, with one-third spending more than that. Most firms spend 11 – 30% of that budget on security, with a wide spending range between $110,000 and $750,000. Perhaps the greatest challenge boards face is communicating with

REGULATORY

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Settlement Trends Industry Threat Comparison HIPAA/OCR Violations (# Records + Types)

HIPAA/OCR Mock Response

Downtime Caused by Incidents

Lost Revenue Caused by Incidents

Institutional Vs Peers Threats

Marquee/High Priority

Policy Near Misses

Open High-Priority

(Numbers + Types)

Risk Audit Findings

(# + Duration)

Threat Intelligence (ISACs + Vendor) Training Results

Patching Cadence

(# Complete + AVG. Score)

Incidents Affecting Public-facing

New Regulatory Requirement

Systems Red-Blue Team

(NY DFS + GDPR) Friendly Attack Results

Table 1

Incidents Reported to Media

(# + Duration)

Excercise Results

(# Phished Creds + Reports)

* VP and industry security strategist, eSentire www.steeltimesint.com

Digital Edition - January/February 2019

CYBER SECURITY

BOX 1

Directors must approach cyber risks as an enterprise-wide issue and not simply an IT responsibility.

Directors must understand the legal implications of cyber risks as they relate to their specific business.

Boards should have access to cyber security expertise and establish discussion time and a cadence for cyber security reports.

Boards must provide governance and set expectations for the executives and leaders in the business to establish a security programme that aligns to the risk management objectives of the board.

Board must establish a risk profile, identifying risks to avoid or eliminate, risks to mitigate through security programmes and insurance, and risk that must be accepted.

technical leaders. They struggle to assign risk tolerance, understand resource requirements, and measure and report security progress. Only a third of respondents are confident their security teams have access to the appropriate resources, and that the organisation is spending adequately on security. Similar confidence rates are associated with an organisation’s ability to monitor and report on cyber security programmes (34%), confidence that cybersecurity programmes align to business objectives (33%) and that high-profile assets are adequately secured (33%). In fact, a meagre 29% of respondents indicated that their highvalue or high-profile information is not adequately protected. Business is in desperate need of a Rosetta Stone to translate the ones and zeros of security into dollar signs and risk management vocabulary of fiduciary officers. Much like other aspects of fiscal responsibility, boards must establish a regular cadence of discussion around cyber security and risk management and develop a dashboard that focuses on business objectives rather than the minutiae of information technology. For example, a board dashboard should include the following in Table 1 (see previous page). The National Association of Corporate Directors (NACD) published and updated a Cyber-Risk Oversight Handbook as part Digital Edition - January/February 2019

BOX 2

•

Conducting a third-party risk assessment to identify attack vectors, target assets, and likely business consequences.

•

Inventory assets, such as core data and protected non-public data, such as financial information and employee records.

•

Identify and harmonise legal or regulatory obligations to establish end-state standards for a cyber security programme.

• Identify the legal obligation of clients. •

Establish a regular cadence for cyber security planning (twice a year), and monthly reporting using a standardised dashboard.

• Establishing an incident response plan and run a mock scenario with board participation.

of their Director’s Handbook Series. The reference provides five key pillars that directors should apply (see box 1). In addition to the NACD recommendations, boards should consider six further points (see box 2). As data breaches and cyber attacks continue to plague businesses and affect consumers, boards will be held accountable for meeting prescriptive regulations, while preserving brand, protecting operations and avoiding financial losses. In the future, organisations will likely move to a security and risk management paradigm driven by a focus on the client. In this state, brand and reputation will form the barometer by which a company’s security performance is ultimately measured. Protecting the client will mean by extension, protecting their data and services, avoiding operational disruption and the resulting financial losses. Mark Sangster is a cybersecurity evangelist who has spent significant time researching and speaking about peripheral factors influencing the way that legal firms integrate cybersecurity into their day-today operations. In addition to Mark’s role as VP and industry security strategist with managed cybersecurity services provider eSentire, he also serves as a member of the LegalSec Council with the International Legal Technology Association (ILTA). � www.steeltimesint.com

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IRONMAKING

Re-hydrated burnt-lime improve sinter The addition of hydrated lime solution to the sinter mix â&#x20AC;&#x201C; rather than dry lime during mixing â&#x20AC;&#x201C; improved granulation during the mixing process and tumble strength after sintering. It also increased line productivity by improving bed permeability and hence vertical sintering speed in addition to improving combustion efficiency and reducing the amount of lime needed. By S T Selvam, B N Pathak, S Dhara, U K Mondal and S Parida IT is well established that additions of burnt-lime (CaO) as binder to the raw materials on the sinter line increases productivity of the sinter plant. In the conventional method, dry fines of burntlime are added to the belt conveyor carrying the raw materials to a mixing/balling drum, where water is also added to aid mixing and balling. However, hydration of the burnt-lime is incomplete in this method and hence bonding of the raw materials is not fully achieved. A new system adding burntlime as pre-hydrated liquid has improved the effectiveness of bonding, leading to significant increases in both quality and quantity of the sinter produced through improved sinter bed permeability.

The productivity of a sinter machine is directly related to the permeability of the raw material mix and hence depends to a great extent on the effectiveness of mixing and granulation/balling of the raw materials. Burnt-lime is an established intensifier in sinter making, releasing heat when in contact with water, this heat being very conducive in improving the balling/ granulation effect on the raw materials mix. As a binder, burnt lime promotes the quasi particle property of the raw-mix. It helps to increase throughput of micro fines. In addition to the binding property, burnt lime also reduces the coke breeze rate on the sinter line should un-calcined limestone (CaCO3) be added instead of

burnt lime during sintering. The use of burnt lime also reduces the crushing and screening load of harder raw limestone and hence saves energy. However, when burnt-lime is added as dry fines, the lime does not fully hydrateswhen it comes into contact with water in the mixing/balling drum, causing poor granulation and balling of the raw-mix, thus the effectiveness of lime in the raw-mix is reduced. This lowers the permeability of the raw materials significantly, both in the raw-mix bunker and in the sinter bed resulting in low productivity of the sinter machine and increased consumption of burnt lime to compensate for its lower effectiveness. An alternative method of adding burnt-

Fig 1. Schematic of experimental pot sintering unit

Fig 2. Schematic for production of hydrated lime on an industrial scale

The authors are with the R&D Centre for Iron and Steel, Steel Authority of India Ltd Ranchi â&#x20AC;&#x201C; 834002, India. Contact: stselvam@rdcis-sail.com www.steeltimesint.com

Digital Edition - January/February 2019

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IRONMAKING

Raw materials

Tot Fe

SiO2 Al2O3 CaO MgO LoI

Parameters Value

62.1

2.3

2.0

5.0

Bed height (mm)

450

LD Slag

10.8

1.6

47.2

3.5

Suction (mm wc)

450

Lime stone fines

1.6

8.2

2.0

43.7

4.1

Coke rate (kg/t)

Dolomite fines

1.5

7.9

1.9

27.5

17.7

Mill scale (kg/t)

13.47

49.68

23.47

5.76

0.62

LD Slag (kg/t)

Mill scale

1.0

Sinter return fines %

Burnt lime

0.7

2.4

1.2

2.5

Bulk density(t/m3)

1.9

Coke breeze

Ash

Water of total charge %

17.8

1.2

0.7

Burnt-lime (g/lit) of water

Iron ore fines

Ash

Table 1. Analysis of raw materials for sintering

lime was thus sought to fully utilise the binder, reduce consumption and hence lower the cost of producing sinter. The R & D Centre for Iron and Steel (RDCIS) of Steel Authority of India Ltd (SAIL) has successfully developed an efficient alternate method of adding the burnt-lime using laboratory scale pot sintering experiments. Following successful development of the new method, RDCIS constructed a pilot plant in an industrial sinter plant to experiment and confirm its technological benefits on an industrial level. Laboratory trials Knowledge previously established for fine particles in water indicates that the iso-electric point differs between particles and also that the surface charge can be affected by the pH of the solution. These phenomena can be applied to the sintering process by spraying milky state lime solution into the iron ore mixture to observe the effects. The chemical analysis of the raw materials is given in Table 1. The raw material composition for the pot sintering test was obtained by charge calculations with the help of established charge calculation models. An experimental design was prepared and experiments carried out and repeatedly tested. The process parameters used are given in Table 2. Pot sintering experiments were carried out using the raw materials mix of Table 1 and maintaining the parameters recorded in Table 2. The pot sintering unit is shown schematically in Fig 1. The unit consists of a replaceable sinter pot of internal diameter 310mm and is connected to a vacuum chamber (wind box). Necessary suction for this unit is provided by an exhauster controlled by a butterfly valve. The waste gas is cleaned in a scrubber where water is continuously sprayed for cooling and for dust suppression. The under grate suction is measured with the help of a digital pressure meter. www.steeltimesint.com

7.8 0 to 50

Table 2. Parameters for pot sinter tests

Trials with lime-water solution All the raw materials: iron ore fines, lime stone fines, dolomite fines, coke breeze, mill scale and return sinter fines, were proportioned by charge calculations and thoroughly mixed in the mixing/balling drum. The required amount of water was added to the mixture and fed into the rotating drum to form micro granules. This sinter mix was charged into the sintering pot over the grate bar. 2kg of sinter of size 10-25mm was charged onto the grate bars. Then the exhauster/blower is switched on to create a vacuum below the pot. The air filtration velocity at the required suction (mm wc) is measured. The top layer of sinter mix is ignited by burning LPG in an ignition hood above the top layer. Suction is maintained at the required level (150mm wc) during ignition and afterwards the valve of the blower is adjusted to create the required value of suction for the experiment. When combustion of the top layer starts the ignition with LPG is stopped. The sintering flame front travels downward through the hearth layers. When the exhaust gas temperature reaches a maximum, the sintering process has been completed. The sinter product is then left to cool for about an hour, followed by screening. To assess the quality of the finished sinter 15kg (of size +10mm40mm) undergoes a Tumbler Index test. Samples of size (+5mm to - 40mm) are recovered for chemical analysis. The laboratory experiments were carried out using various limewater No.

Lime / water

VSS

Yield, %

(g/lit)

mm/min

(+5mm)

concentrations to match the plant sintering process. The parameters recorded were: (i) sintering time (ii) sintering temperature and (iii) suction. The following parameters were calculated through the experiments: (a) productivity (b) vertical sintering speed (VSS) (c) yield (d) strength. Findings The various parameters obtained through the different experiments in the pot sintering unit are presented in Table 3. Productivity varied from 0.80 to 0.94t/ m2/h, this maximum achieved when limewater was added at 20g/l. There was a direct relationship between lime solution consumption and sinter productivity. The more lime added, the better the granulation strength and the greater the permeability. This resulted in increased air filtration velocity through the sinter and improved vertical sintering speed. However, beyond an optimum consumption of 20g/l, productivity fell, possibly due to increased granule size. The maximum yield of 76.5% was achieved when 30g/l of water was added to the mix and this coincided with the maximum drum tumbler Index of 66%. While the maximum productivity of 0.94t/m2/h can be achieved at a burntlime to water ratio of 20g/l, a higher lime concentration of 30g/l improves yield and strength warranting a slight compromise in productivity. In addition, this increase in lime concentration also improves the flowability of the mix. DTI, % % +6.3mm

Productivity

Balling Index

t/m2/h

11.84

74.56

61.33

0.80

1.27

12.68

74.64

61.33

0.87

1.47

13.85

75.37

63.67

0.94

1.5

13.23

76.5

0.93

1.63

Table 3. Results of pot sintering experiments

Digital Edition - January/February 2019

IRONMAKING

0.25 0.2

with hydrated lime

0.15

without hydrated lime

0.1 0.5

Input data:

Size of calcined line: ~10mm

Ratio of lime in water: 10-50 grams/litre of water

Wind box

Lime addition in lime slaker by manual

Fig 3. Industrial set-up for generation of hydrated lime

Water addition in lime slaker from main header at site

19.8 16.74

Without lime

17.92

Lime-water solution addition rate: 4m3/hr

18.53

Fig 4. Effect of addition of hydrated lime to sinter mix on air filtration velocity

With lime At PMD

Without lime

At Balling Drum

Industrial trials Based on the successful development through pot sintering, an industrial scale trial was installed and commissioned at a sinter plant. This was capable of producing hydrated lime solution at an appropriate feed rate and concentration for addition to the Primary Mixing Drum. The schematic arrangement for the production of hydrated lime solution is shown in Fig 2. Burnt-lime of suitable size and quality was brought from the refractory materials plant (RMP) to the sinter plant in portable 50kg poly-bags each day. This was manually charged into the slaking tank, installed at the +3m level using a mono-rail. Process water continuously flowed into the slaking tank in a controlled manner through a combination of a rotometer and a manual control valve. The feed rate of burntlime and water into the slaking tank was manually controlled to make the required concentration of hydrated lime solution for sintering. The slaking tank is provided with a four-bladed stainless steel agitator to provide continuous agitation to the lime solution, for effective generation of milk of lime (MOL) solution and also to prevent settling of lime particles to the bottom of the tank. The clear slaked MOL solution from the top of the slaking tank was passed by gravity to an inter-connected classifier via a weir. In the classifier, continuously operated racker blades collected any lime Digital Edition - January/February 2019

With lime

Fig 5. Effect of hydrated

trial data analysis.

lime in sinter mix on Balling Index

grit which settled on the bottom of the classifier from where it was removed by a scraper and discharged to a wheeled trolley grit collector placed below the discharge chute. The clear hydrated lime solution was then transferred by gravity to one of two MOL storage tanks. Both storage tanks are provided with agitators to ensure a homogeneous MOL solution. From one of the storage tanks, the MOL is pumped to the primary mixing drum (PMD) # 1 of the sinter plant for mixing with the other raw materials. In contrast to the addition of solid burnt lime to the conveyor, now the burnt-lime and water are combined as MOL. The feed rate of pre-hydrated lime solution to the raw mix inside the PMD was controlled manually through a flow meter with a control valve. Fig 3 shows the industrial plant for the addition of pre-hydrated lime solution to the PMD. Results and discussions Industrial trials were conducted for a fortnight. The aim was to collect the significant process parameters for the sinter machine when using additions of the pre-hydrated lime solution at the optimum concentration ratio of 30g/l, which was established through laboratory experiments. The following are the significant technological benefits achieved through

Effect on Air Filtration Velocity The Air Filtration velocity through the sinter bed was measured using a diverging hood and vane type anemometer on top of the sinter bed. The specific volume of air for sintering is almost constant, so that the sintering rate will depend on how fast the air (air filtration velocity) is blowing through the bed. This is mainly dependent on the permeability of the bed. Due to the improved fluidity of the hydrated lime solution around the particles, the bonding efficiency among them had significantly improved. To measure air velocity, the sinter cake was divided into three sections widthwise and air filtration velocity measured in each section. Fig 4 depicts the effect of hydrated lime solution on Air Filtration Velocity along the length of sinter bed. The average Air Filtration Velocity increased by approximately 8% from the base level (without any addition of hydrated lime solution) from 0.14m/s to 0.15m/s. This increase in air velocity, increased sinter-line productivity. The higher the air filtration velocity, the greater the conductive heat transfer rate inside the sinter bed. Increased air filtration velocity results in an increase in vertical sintering speed; which directly translates into an increase of sinter productivity. Effect on Balling Index Due to limeâ&#x20AC;&#x2122;s natural binding properties and the improved fluidity of the mix, the tendency of sinter-feed particles to agglomerate improves and hence the www.steeltimesint.com

IRONMAKING

strength of individual green granules increases. Due to the addition of hydrated lime solution to the sinter-feed, the average Balling Index increased by 7%, measured both at the PMD and Balling drum outlets (Fig 5). This effect is also evident as a significant improvement in the degree of granulation of the sinter-feed. Effect on other parameters The addition of hydrated lime solution in the sinter-feed has reduced the presence of CO in the waste gas from 0.06% to 0.03%, due to the improved combustion efficiency of the coke in the sinter feed. This has improved the wind main temperature from 113°C to 123°C and the wind main suction from 540mm WC to 453mm WC. From these observations the following conclusions can be drawn: � Addition of pre-hydrated burnt-lime to the sinter-feed significantly improves the sinter-bed permeability through improvement in various process parameters of sintering such as, air filtration velocity, balling index and degree of granulation. � The addition of pre-hydrated lime

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solution into the sinter-feed at a rate of 4m3/h, at a concentration of 20g of lime per litre of water was found to be optimal for the sinter plant under study. � The productivity and yield of the sinter machine are significantly increased with the addition of burnt-lime in pre-hydrated form. � Addition of pre-hydrated lime solution into the sinter-feed at an optimum rate in the primary mixing drum eliminates the earlier practice of adding process water separately to the drum to maintain moisture in the sinter-feed. � The addition of pre-hydrated lime solution into the sinter-feed significantly reduces the consumption of burnt-lime used in sinter production, due to its increased effectiveness in the raw-mix. � The addition of burnt-lime in liquid form to the raw-mix reduces wastage of burnt-lime while handling in contrast to charging lime fines. � Acknowledgement The authors express their deep gratitude to the management of the Research and Development Centre for Iron and Steel

(RDCIS) of Steel Authority of India Limited (SAIL) for permitting this innovative research work and sincerely acknowledge the valuable contributions made by Sri A Das, Dr S Chaudhuri, Dr S K Pan, Sri. V R Deshmukh, Sri T P Das, Sri Atanu Hazrah, Sri Ashit Prasad, Sri Saurab Kumar Jha, Sri R Choudhary and Sri S K Srivastav . Bibliography 1. V M Kurkin, M S Tabakov, ‘Effects of Lime on sintering’, Metallurgy, No 8, August 200, pp 49 to 52 2. H K Shin, S J Yoon, H J Yang, ‘Improvement of sintering operation by addition of pH controlled solution’, Proceedings of The Sixth International Iron and Steel Congress, Nagoya, ISIJ, 1990 pp 81-87 3. P I Gurin, N S Khlaponin and A M Osipenko, ‘Effectiveness of using lime in sintering charges’, Stal, No 9, 1981, pp 9-12 4. S T Selvam et al, ‘Design, development and installation of a system for addition of -10mm lime fines to improve productivity’ AISTech 2006 proceedings – Vol I, pp 215 – 221

Digital Edition - January/February 2019

ROBOTICS

Less handling, thanks to robotics Tebulo Industrial Robotics has developed a new reel-hole fixation robot for the steel industry. By Henriëtte van Norel * FOR cold-coiled steel with material thicknesses ranging from 0.13mm to 0.5 mm, the inner flap regularly drops down when it comes off the mandrel in a steel shop. Even during handling there is a considerable risk that the entire coil will collapse due to the insufficient internal stiffness of the coil. In the former situation, a flap that drops down must be welded or glued manually by the operator, in a relatively unsafe manner. In the latter situation, a coil weighing 30 tonnes has to be removed, because it can no longer be placed back on a mandrel. Backed by a successful feasibility study, this constituted a sufficient reason for Tebulo Industrial Robotics to engineer a new reel-hole fixation robot for the steel industry Contrary to the traditional solution, the robotised solution coils the material directly onto the mandrel, so that the production process may continue without

unnecessary interruptions. Consequently, the 8mm to 10mm thick steel sleeves – which were traditionally pushed over the mandrel before the material could be coiled up – are no longer necessary. This makes a substantial difference in man hours and handling costs. The sleeves no longer need to be transported from one location to another. Moreover, sleeves are no longer dropped and/or deformed. There is also no longer a need to reserve storage space in a warehouse or at the mandrel. Principles “In developing the head for the reel hole fixation robot, we were intensely focused on reducing storage, handling and material costs. It was also essential that the payback time was less than 1.5 years," says Hans Spaans, CTO of Tebulo Industrial Robotics (TIR). Based on the above requirements, TIR took a standard ABB robot and converted it

into a new tool, with welding functionality completely tailored to this purpose. The welding tool is designed for sheets with a thickness ranging from 0.13mm to 0.5mm. The average welding depth varies from 2-3mm (approximately 10 wraps). The number of spot welds and the welding depth together provide reinforcement of the reel hole. As in the procedure with the sleeves described above, with the newly developed robotised solution the last 10 to 15 metres of material cannot be used and should, therefore, be disposed of as scrap. Welding method “In this case, traditional spot welding was not an option, since there was no possibility to reach the back of the material. That’s why we opted for twin spot welding,”says Spaans. The twin spot welder integrated in the new robot head, consists of a welding tool with four welding tips (two on one

* Tebulo Industrial Robotics Digital Edition - January/February 2019

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ROBOTICS

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ROBOTICS

side and two on the other) in conjunction with an 'intelligently' working pressure mechanism. The chosen welding method requires a great amount of power, so in the robot head four 40mm thick copper, hollow water-cooled cables run from the transformer to the welding tips. A control unit located in the background powers the transformer. As soon as the desired welding programme is entered on this unit, a low voltage and a high current runs from the transformer to the individual welding tips, generating a medium high frequency welding current for the electrical welding process. Welding occurs with a pulsation frequency between 1000 and 4000 Hz. At the part undergoing plastic deformation, temperatures may increase to 1200-1400 ° C, whereas the cooling water temperature in the 20 litre capacity unit reaches 60° C. The water in this closed loop circuit cools the welding transformer, the head cables as well as the two welding tips. So it is essential that the recycled water is constantly cooled in the heat exchanger during the welding process." Flap detection Another important design requirement was the robot head’s compact design. The robot head must always be able to enter the reel hole, without getting stuck anywhere, even when a particular flap is hanging loose. Spaans: “A coil of steel always has a 420mm reel hole diameter. So in the design phase it was decided to maintain a minimum free passage of 340mm for the robot head. In the available space, the head must be able to scan and weld a 360° area without any complications. The scan data are communicated to a PLC. Having made a successful scan, the entire robot head retracts and the robot takes up its starting position. Next, the PLC calculates where the robot head should start applying the first welds. We opted for a 180° rotation range because of the large number of continuously rotating (power) cables, water and pneumatic hoses. The robot head is, therefore, equipped with a double set of welding tips at 180° relative to each other, achieving in all cases a 360° range. Welding process The PLC then determines the exact location to start welding as well as the welding pattern, communicating the data with the line control. Next, the robot head starts

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Digital Edition - January/February 2019

ROBOTICS

out by firmly pressing the flap outwards, against the inside of the coil, creating a nice round hole. Especially for this purpose, the robot head comes equipped with a pneumatically driven cylinder with a 160 mm stroke length, which pushes out two pressure blocks. The four welding tips then move alternately. Based on the transition resistance caused by several layers of material, welding requires a pressure of approximately 450kg; two pneumatically driven cylinders achieve this, each with a 30mm stroke length. During the application of the first welds, the coil is still half situated on the reel, ensuring the flap cannot drop inside. Upon completion of the welding, the coil is completely removed off the reel, so that the production process may continue. Moreover, the robot can also access the coil of steel from the other side to fully strengthen the inside, 20 to 30 seconds after it has finally been completely removed from the reel. In this way, with the help of the aforementioned welding tool, the coil's own material is utilised to create a sleeve inside of the reel hole. Spaans explains: “Particularly, the detection of the beginning of the flap, and the calculation of where the first spot weld must be placed is a precision job. If the first weld is placed incorrectly, then the inner wrap pulls apart during hoisting, which must be avoided at all cost. Operation Depending on the processed material thickness, the selection of the correct welding parameters is initiated. During welding, it is then measured whether the current flows through or not. If the current does not flow properly, for example because the copper points are not properly pressed, this is immediately detected by a sensor, which sends a feedback signal to the PLC. The correct pressure, clean pressing material, good components and a properly functioning electronic feedback system are all essential for a good weld. Capacity The production line, with the currently successfully running robotised welding installation, has a capacity of approximately 400 coils per week. The steel coil stays on the reel for an average of 20 to 30 seconds during the first stage of the welding process. As soon as the coil has come off the reel, it is no longer time critical. This leaves the robot with about 15 minutes to perform the remaining activities. In other Digital Edition - January/February 2019

words: Flap detection as well as producing the first welds in particular should be carried out as quickly as possible. Spaans explains: "The biggest challenge in the development of the above-mentioned robot head was to find an optimal balance between transformer, power supply, cable diameter and reel hole size. For example, 450kg of pressure had to be applied in an extremely small diameter reel hole, while the robot head had to be as compact and light as possible. After all, the robot also had to be able to handle the head over a larger distance. From a safety point of view, we opted for pneumatics instead of hydraulics for the welding tool’s drive technology, since the risk of potential oil leakage was undesirable,”Spaans explained.

Finally The reel hole fixation robot described above can also be used for aluminium coils. Says Spaans: “Since there are so many different types of aluminium, the correct parameter set must first be determined for each type". Finally, it is worth mentioning that the robot needs a floor space of approximately 3x3 metres, within which it can operate the so-called ‘safe move'. As soon as the robot arm detects interference with the imposed restrictions, it is fully automatically limited by the built-in safety contcoiler, which closely monitors all of its movements. Safety first,“ says Spaans. �

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ROLLING

Solutions for vertical roll stands Timken claims that its TDOH bearing construction offers many advantages. It says that the heavy section cup acts as a roller and integrates two functions into a single component and eliminates the assembly of separate cups in to the roll/wheel and the potential for cup OD fretting. There are many other advantages, says Sorin Tudor* 1. Production of I Beams

1.2. Rolling mill equipment

1.1. Product range

The production of I beams involves a number of processes that include heating of the bloom, rolling to proper contour and dimensions, cutting while hot to lengths that can be handled, cooling to atmospheric temperature, straightening, cutting to ordered lengths, inspecting, and shipping.

Long products include bars and wire rods, sectional steel shapes and special steel sections. Long products possess a constant cross-sectional area throughout their length, but are of variable thickness over the cross section. ‘Structural shapes’ is the general term applied to rolled flanged shapes in which at least one dimension of their cross section is 76 mm (3 inches) or greater. Structural shapes can be designed as wide-flange shapes, standard I beams, channels, angles, tees and zees. Other shapes include H piles, sheet piling, tie plates, cross ties and those designed for special purposes. These products are used in the construction of bridges, buildings, ships and railroad rolling stock, and for numerous other constructional purposes. I beams (also known as H beams) are considered structural shapes and have an I- or H-shaped cross section. The horizontal elements of the “I” are known as “flanges,” while the vertical element is termed the “web.” European standard I beam shapes include the IPE (European I beam), IPN (European standard beam), HD (wide flange column), HE (European wide flange beam), HL (European extra wide flange beam) and HP (wide flange bearing pile). These shapes are shown in Fig. 1. Please consult appropriate I beams standards for effective dimensions. US standard I beams include W shapes (American wide flange beams), WT shapes and HP shapes (American wide flange bearing piles). These are shown in Fig. 2.

The rolling operation is usually distributed among several stands: • Breakdown stands, where the initial I beam shape is achieved. • Two or three groups of REF (roughing, edging and finishing) stands, with each REF group containing more than one set of roll stands. The REF group of stands is arranged in a train, as shown schematically in Fig. 3. The roughing stand, as shown in Fig. 4, consists of two driven horizontal rolls that influence the web cross section and two vertical rolls that act on the flange of the I beam. All four rolls are positioned in a single vertical plane and are adjustable. The vertical rolls on this stand are contoured, creating the characteristic “dog-bone” shape of the I beam in section. The rougher is responsible for the majority of the deformation of the stock, so the largest reductions in cross-sectional area occur here. The edging stand consists of two high horizontal rolls. Very little reduction in area of the stock occurs at this stand, which instead is responsible for controlling the shape of the I beam — in particular, the flange. The finishing stand, also shown in Fig. 4, consists of two driven horizontal rolls

that influence the web cross section and two vertical rolls that act on the flange of the I beam. All four rolls are positioned in a single vertical plane and are adjustable (the configuration is similar to the roughing stand). Rolls on this stand are cylindrical and are responsible for controlling the final dimensions of the I beam. The finishing stand is used only on the final pass through the REF stands.

2. Vertical rolls 2.1. Application overview Modern I beam mill applications require greater bearing service life and reliability than ever before. Product requirements have been instrumental in the development of new high-speed mills. In particular, vertical roll applications have been most critical. Bearing selection for the vertical roller position is based on the available space between the horizontal rolls. The bearing is mounted inside the roll and operates on a dead pin or post with outer race rotation (Fig.5). The primary load is radial; the axial load is relatively small. The vertical roll is friction-driven by its contact with the I beam. Shock loads are generated when the I beam enters between the rolls. As a consequence, the roll must have a hard exterior to reduce wear and a resilient core to absorb shock loads without cracking. 2.2. Mounting These applications use the tapered roller type of bearing, with outer diameters ranging from 200 mm to 600 mm (approximately 8–24’’). Bearing styles include the TDO (tapered double outer),

* Principal application engineer, Timken Europe Customer Engineering Digital Edition - January/February 2019

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Fig 1. European I beam shapes

Fig 2. US I beam shapes

2TS-IM (two tapered single indirect mounting), TQO (tapered quadruple outer) and TQI (tapered quadruple inner). The bearingsâ&#x20AC;&#x2122; main components are shown in Fig. 6. The vertical roll is an outer ring rotating application, which requires the cup to be mounted with a tight fit to avoid relative rotation versus the roll. Since they are stationary, the cones are mounted with a loose fit on the shaft.

Fig 3. REF (roughing, edging and finishing) group

2.3. Sealing A labyrinth seal is located above the roll face on the top side in order to prevent water and scale from directly entering the bearing. A similar arrangement may be used on the bottom side. An additional lip seal can also be provided, depending on the design of the frame.

Fig 4. Roughing and finishing stand

2.4. Lubrication Grease or air-oil lubrication is applied to the centre of the bearing through holes in the cone spacer. Because of the very harsh operating environment, the bearing is usually connected to a continuous lubrication system.

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Fig 5. Vertical roll

Fig 6. Tapered roller bearing components (TDO type shown here)

b) Effect of poor lubrication

Fig 7. Damage of a bearing mounted in a vertical roll

a) Effect of overloading

Fig 8. TQO bearing design

2.5. Application concerns Strict attention must be paid to the bearing fatigue life calculation, lubrication assessment and roller-race contact stress verification of a bearing mounted into a vertical roll application. Bearing damage develops quickly in cases of overloading or lubrication starvation due to the difficulties in lubricating the top row. Fig.7 shows Digital Edition - January/February 2019

examples of roll bearing damage caused by these factors.

3. The Evolution of the application 3.1. TQO bearing selection Historically, these applications have used the TQO bearing, a four-row tapered roller

bearing designed as shown in Fig. 8. Its composition consists of two double cones assembled with tapered rollers and cages, one cone spacer, two single cups, two cup spacers and one double cup. The TQO bearing is designed around the â&#x20AC;&#x2DC;direct mountingâ&#x20AC;&#x2122;concept, which is schematically presented in Fig.9 for a tworow bearing. Cups are clamped in place to withstand the axial load (Fai) induced by the www.steeltimesint.com

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Fig 10. Vertical roll layout with TQO bearing

Fig 11. TDO bearing design

Fig 9. Direct mounting concept

Fig 12. Indirect mounting design

Fig 13. Vertical roll layout with TDO bearing

radial load (Fr) within the bearing, and to maintain the built-in lateral setting that the cup spacer provides. The direct mounting design permits the double cones to remain unclamped. Fig. 10 shows a vertical roll layout using a TQO bearing. The vertical space available between the top and bottom horizontal rolls in vertical rolls is limited, as we saw in

Fig. 4. The space limitation results in restricted space for the bearingâ&#x20AC;&#x2122;s width and end cover thickness. Consequently, problems related to the end clamping of the cups have developed. Under a radial load, which induces an axial load, the outboard cups separate as a result of end cover deformation caused by the reduced section. This results in the overloading of the two centre raceways, which reduces

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the load-carrying ability of the bearing. The stability of the unit is also reduced due to the narrow effective spread of the two centre raceways. The seal, accommodated by the covers, is limited by the same space considerations and further reduces bearing service life. Excessive end play may develop in the bearing unit during the assembly procedure if cones are not rotated properly to seat Digital Edition - January/February 2019

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Fig 14’ 2TS-IM bearing design

the rollers. This, in conjunction with cup separation, seriously reduces bearing service life. 3.2. TDO bearing solution

Fig 15. Vertical roll design with 2TS-IM bearing

Fig 16. TDOH bearing design

To correct these problems, engineers next tried using two-row tapered TDO roller bearings. The TDO design is shown in Fig. 11. Its composition consists of two single cones assembled with tapered rollers and cages, one double cup and one cone spacer. The TDO bearing is designed around the ‘indirect mounting’ concept, shown schematically in Fig. 12. Cones are clamped axially in order to set the bearing and to withstand the axial load (Fai) induced by the radial load (Fr). This configuration makes it unnecessary to clamp the cups, except at the axial roll location. A vertical roll layout using a TDO bearing is presented in Fig. 13. The bearing cup is mounted with a tight fit in the roll/tire bore. The induced axial load is taken by the heavier shoulder of the pin and the locknut. The stability of the unit is increased because of the larger effective spread of the two centre raceways. While the capacity of the two-row bearing may be smaller than that of a fourrow, it results in more real load-carrying ability as the centre two-rows of a TQO. Two-row bearings offer other advantages as well, such as better load distribution (two rows versus four rows), fewer parts to assemble, and more space for sealing and easier disassembly. Covers should accommodate the labyrinth closure arrangement. 3.3. 2TS-IM bearing solution

Fig 17. Vertical roll design with TDOH bearing

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To facilitate centering the bearing on the roll, engineers initiated the practice of adding a central shoulder on the roll bore. The TDO bearing type was then replaced with a 2TS-IM type bearing. The 2TS-IM design is presented in Fig. 14. Its composition consists of two single cones assembled with tapered rollers and cages, two single cups and one cone spacer. Fig. 15 shows a vertical roll layout using the 2TS-IM bearing. The bearing cups are mounted with a tight fit in the roll/tire bore. Clamping the cups is unnecessary because the indirect mounting design does not induce an axial load that is trying to www.steeltimesint.com

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separate the cups. The bearing is centered on the roll by means of the central shoulder, so the requirement for a heavy outside cover is also eliminated. Vertical space to accommodate a heavier bearing has been gained in this way. This is the most common design currently in use. The bearing’s axial clearance is controlled and adjusted on-site, where the spacer bearing is machined to a specific width during the bearing mounting procedure, in order to achieve higher system rigidity. The roll should be heated to allow a very tight fit mounting of the bearing cups. The appropriate fitting practice is defined in The Timken Company Engineering Manual. The bearing internal and external diameters, roll bore diameter and shaft fitting diameter must be measured and compared to the drawings’ tolerances before bearing mounting.

Fig 18. Vertical rolls — sectional and isometric views

Fig 19. TDOCD H242649-H242610CD bearing offer drawing

4. TDOH Bearings in vertical rolls The Timken Company’s proposed solution for vertical roll applications comes as a natural extension of the development evolution described above. But instead of the bearing types traditionally used in these applications, it takes advantage of the TDOH (tapered double outer heavy) bearing, which integrates the roll into the bearing’s cup. The TDOH bearing design is presented in Fig. 16. Its composition consists of two single cones assembled with tapered rollers and cages, one heavy section double cup and one cone spacer. Additional closures can be included. Fig 20. Compute r-modeled application

A vertical roll layout using a TDOH bearing is shown in Fig. 17. TDOH bearing construction advantages include: 1. The heavy section cup acts as a roller, integrating two functions into a single component. 2. Eliminates assembly of separate cups in to the roll/wheel and potential for cup OD fretting 3. The bearing pitch diameter can be increased, providing a better rating and robustness.

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Fig 21. Load zone and max. roller-race contact pressure for the most loaded roller

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Fig 22. Vertical roll damage

Fig 24. 3D view of the TDOH NP880812-NP862889

Fig 23. TDOCD NP880812-NP862889 bearing offer drawing

Fig 25. Vertical roll layout using new TDOH NP880812-NP862889 bearing

Fig 27. Load zone and max. roller-race contact pressure Fig 26. Computer-modeled application

4. The bearing assembly end play is preset to a specific value customised for the application, calculated by Timken application engineering and kept under tight control by Timken manufacturing. 5. The bearing is shipped as a preassembled, packaged unit, thereby reducing assembly time and costs (no need to mount the bearing into the roll). 6. Tailored solutions to meet specific needs – for example, delivery of the rest of the vertical roll components (pin, flanges, seals, etc) – are also available. Digital Edition - January/February 2019

for the most loaded roller

5. Case Study — existing solution and problem description In this case study, the application was performed on a long product rolling line, on the vertical rolls of a universal mill stand. The original equipment manufacturer (OEM) and mill end user selected the bearing without Timken support. The sectional and isometric views of the vertical roll are shown in Fig. 18. Vertical roll design attributes Mill type: vertical roll; roll nominal diameter: 550 mm; roll length: 280 mm

Operating conditions Maximum radial load: 1800 kN; maximum line speed: 270 m/min (= 156 rpm max. roll speed) Lubrication: Air-oil system Sealing: Existing seal system consists of a labyrinth and a radial seal. Customer complained of poor sealing after they found oil contaminated with rolling mill cooling solution. Timken bearing (customer selection): TDOCD H242649-H242610CD (Fig. 19) www.steeltimesint.com

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Envelope: 206.375 x 336.660 x 211.138 x 169.862 mm Timken rating: C90(2) = 612 kN, C1(2) = 2360 kN Bench end play = 0.610 mm, standard roller profile Computer model The computer-modeled application is shown in Fig. 20. Assumptions: • The computer model is equivalent to the roll boundary conditions previously described. • L10 life calculations are performed for operating conditions of 75% of maximum load and 75% of maximum speed. • Radial load: 0.75 x 1800 kN = 1350 kN per bearing; roll speed: 0.75 x 156 rpm = 117 rpm. • The adjusted bearing fatigue life L10a is 700 hours per row. The maximum contact pressure roller inner ring is 3951 MPa (roller end) and the maximum central contact pressure roller inner ring is 2547 MPa (Fig. 21). • Bearing selection was performed by the customer without Timken support. Problem description The customer complained that the vertical rolls become prematurely damaged, generally by a roll jam or tire crack (Fig. 22). The customer requested Timken service engineering support. There were no other reported issues with the existing bearing performance.

6. Case Study — Timken vertical rolls upgrade solution Application analysis: Outer ring backing with a snap ring was observed, which is not acceptable, and the bearing cup backing diameter was incorrect on both sides (see red marks on Fig. 18). These conditions can lead to bearing misalignment and roller end overload. In order to eliminate the backing issue, a new TDOH bearing design following the Timken solution (roll integrated into bearing cup, as described in part 4) was incorporated. www.steeltimesint.com

Sealing: The existing radial seal was replaced with an improved seal. An additional radial seal was integrated into the new bearing. New TDOH bearing design The offer drawing of the new TDOH NP880812-NP862889 integrated bearing is presented in Fig. 23. Timken ratings: C90(2) = 662 kN, C1(2) = 2560 kN Note: A further solution improvement is possible in which the bearing pitch diameter is increased to maximise the bearing rating. Fig. 24 is a 3D view of the TDOH NP880812-NP862889 integrated bearing. A vertical roll layout with the TDOH NP880812-NP862889 bearing can be seen in Fig. 25. Computer model The computer-modeled application is shown in Fig. 26.

Results of mill vertical rolls upgrade The adjusted bearing fatigue life L10a improved to 1900 hours per row, an increase of 63%. The maximum contact stress decreased from 3951 MPa to 2613 MPa and the maximum central stress from 2547 to 2501 MPa (Fig. 27).

7. Summary and conclusions 1. The production of I beams involves a number of processes including heating of the bloom, rolling to proper contour and dimensions, cutting while hot to lengths that can be handled, cooling to atmospheric temperature, straightening, cutting to ordered lengths, inspecting, and shipping. 2. The rolling operation is usually distributed among several stands. The initial I beam is shaped using breakdown stands. The final shape is achieved with REF (roughing, edging and finishing) stands. Each REF stand is made up of horizontal and vertical rolls. 3. Historically, several bearing types have been used in vertical rolls, beginning with the TQO and progressing to the TDO and 2TS-IM types. The 2TS-IM currently is the most commonly used design.

4. The Timken innovative proposal for vertical roll applications comes as a logical follow-up to the application’s historical evolution; it utilises the TDOH (tapered double outer heavy bearing), which integrates the roll and the bearing’s cup. 5. The TDOH bearing provides important advantages. The bearing pitch diameter can be increased, providing a better rating and higher robustness. Assembly of separate cups in to the roll/ wheel and potential for cup OD fretting is eliminated. Settings, preset to specific values, are kept under tight control by Timken manufacturing. Also, the bearing is shipped as a preassembled, packaged unit, thereby reducing assembly time and costs. 6. In order to increase resistance against contaminants, the TDOH can accommodate additional seals that bearings of standard construction cannot. 7. The TDOH bearing solution can be tailored to meet specific needs; for example, the rest of the vertical roll components (pin, flanges, seals, etc.) can be delivered as well. �

Acknowledgments The author would like to thank The Timken Company for permission to publish this paper. References 1. The Making, Shaping and Treating of Steel, 10th Edition/Latest Technology, AISE Foundation, USA 2. Harris, T. and Kotzalas, M. (2007), “Rolling Bearing Analysis – Advanced Concepts of Bearing Technology” 3. Metal Making Handbook, The Timken Company 4. Section and Billet Mills, SMS Group GmbH (eDocument) 5. ISO 281 (2007), Rolling Bearings – Dynamic Load Ratings and Rating Life 6. Timken Engineering Manual – Metals Industry Edition (2013), The Timken Company, Order No. 10688 7. Timken Engineering Manual (2011), The Timken Company, Order No. 10424 8. Timken Metals Product Catalog (2014), The Timken Company, Order No. 10675

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INNOVATIONS

High-performance compact cold mill for M Italian steelmaker Marcegaglia Ravenna SpA has contracted the German SMS group for the complete supply of a two-stand reversing cold mill. The new mill, of SMS group’s CCM design, will be implemented at Marcegaglia’s Ravenna facility where cold rolled carbon steel sheets and strips for a wide range of industrial applications are produced. As a high-performance mill, it is designed to process a comprehensive material mix, including high-carbon and duplex steels, chrome-manganese alloyed steels, and silicon steels. The annual capacity is about 550kt. Depending on the product mix, it rolls strips with widths of between 750mm and 1,570mm and entry thicknesses ranging between 0.60mm and 5.00mm The minimal achievable final thickness is 0.23mm. According to SMS group, the CCM will be equipped with one pay-off and two reversing reels. Both rolling stands will be realised in four-high design. It will be possible, claims SMS group, to operate the mill with work roll sets of

two different diameters. “Excellent strip quality, high productivity and efficient rolling operations are provided by proven SMS group rolling technologies, such as the CVCplus (Continuously Variable Crown) roll shifting technology, which, in combination with work roll bending, ensures a wide flatness setting range,” SMS group explained. “One dry strip system per stand will be provided to remove surplus emulsion from the strip surface. The plant will be equipped with the X-Shape flatness measuring and control system, which, together with multi-zone cooling, ensures optimal flatness results of the finished strip,” the company said. The CCM will be operated with the SMS X-Pact automation system, which provides a consistent and complete solution for the high-performance control concepts and strategies implemented by SMS group. In addition to the features aimed at optimising plant efficiency, the TRC (Total Roll Gap Control) assistance system developed by SMS group will be ap-

plied for automatic and stabilised strip threading into the pre-set optimised roll gap. SMS claims that the assistance system makes for stable rolling from

Advanced GalvControl7 coat weight optimisa Indev-ACT, a world-leading supplier of web gauging systems, has introduced GalvControl7 real-time coat weight optimisation control for galvanising, galvanneal, galvalume and hot dip lines. GalvControl7 is claimed to be an advanced, robust, feature-rich control product designed to improve coating quality while minimising overcoating. According to Indev-ACT, the new product provides tight quality control for minimal yield loss with new features, real time displays and supervisory optimisation controls. Its change-based

Digital Edition - January/February 2019

design structure includes high-speed, self-learning adaptive controls that consistently monitor multiple process parameters at over five times a second. This approach, says the company, builds an accurate process model for its predictive knife control algorithms that optimise coat weight, coat quality and yield for the galvanising processes. It is a model-based system that does not require ongoing retuning. The GalvControl7 advanced control suite includes dynamic speed-retuning, automatic gain adjustment, feed-forward pressure control and self-learning

capability for adaptive knife control. Air-knife distances or heights are set in real time for optimum galvanise coat weight performance without a series of presets as with conventional control products. GalvControl7 features algorithms that significantly improve its response to process changes. For example, feed-forward pressure control used during product and speed changes continuously update the process model for optimum performance. Also, profile prediction at the weld significantly improves both coating uniformity and material consumption, minimising the

INNOVATIONS

Marcegaglia

the strip head end, increasing material yield as a result of reduced strip bulging at the head and tail ends. The high automation level of the

CCM is claimed to be an important step towards digitalisation and adaptability to future requirements. The new mill is expected to com-

mence operations in April 2020.

ensure that the coating quality targets are observed, says Indev-ACT. Also included is a comprehensive HMI with continuous coat weight information, a predictability display for effective process management and coil reporting with detailed single and triple spot quality analysis by coil. Indev-ACT claims that GalvControl7 has provided significant coating yield savings of between 3-5%, often resulting in paybacks of weeks or months. There are many other benefits including 30% improvement for high-speed coating transitions; 70% reduction in qual-

ity variation between coils and a 50% reduction in overcoat versus target. “For mills that need to meet today’s stringent automotive and aerospace requirements, GalvControl7 has proven to be the most complete, user friendly and precise system that is currently available,” the company said.

For further information, log on to www.sms-group.com

ation settling time for the new coils. The control algorithms include gain adaption that has an ‘aggressive feature’ to bring the coating to target quickly during product transitions, process disturbances or when running heavier coils. GalvControl7 includes optimisation controls such as advanced target management (ATM), that supervise the average coat weight to a minimum coating application without violating the coating specifications. GalvControl’s enhanced triple/single spot coil analysis further assists ATM control to

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For further information, log on to www.indev-act.com

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INNOVATIONS

Get smart! LR Smartobserver is an â&#x20AC;&#x2DC;out-of-theboxâ&#x20AC;&#x2122; application software product from ifm electronic. Smartobserver software enables users to condition data acquisition primarily to see what is actually happening on their manufacturing plant right down to individual sensor level. At the heart of the software is the LR agent CP which is the key to collecting data and is essentially configurable, bio-directional communicating interface software. It collects and handles the information from the machines in the manufacturing process and transmits it to other systems (databases, ERP systems, MES). Smartobserver provides operators with details of the bigger picture with an analysis of what is actually occurring in their process, driven by direct data collected from the sensors in their plant. Relying on historical data for estimations becomes unnecessary and irrelevant. The result is improved machine and installation condition monitoring, better energy consumption analysis and optimum quality control of the processed products. Smartobserver offers continuous condition monitoring of machines and systems, trend analysis, representation of limits and evaluation of all process parameters, data collection of all available parameters, visualisation and evaluation with trend display for pressure, flow, temperature, current and rotational speed. Also if required, changing operating condition of machines, data provision for more sophisticated systems such as ERP, SAP, HANA, MII, ME and alarm escalation chains. Customer benefits, claims ifm electronic, include more energy-efficient production, improved quality assurance and preventative maintenance, reduced manufacturing costs, increased uptime and remote maintenance and notification. For further information, log on to www.ifm.com Digital Edition - January/February 2019

Brokk launches latest demolition machine

INNOVATIONS

Brokk, a leading global manufacturer of remote-controlled demolition machines and attachments based in the USA, has introduced the Brokk 200, a new weight class of machine that packs the power of a 3-ton Brokk machine into a 2-ton package. The Brokk 200 is one of four new next generation remote-controlled demolition machines the company showcased at the World of Concrete 2019 convention in Las Vegas. The machine is equipped with Brokk’s signature SmartConcept technology for increased efficiency. It is claimed that, SmartConcept includes the extra power of SmartPower, the added reliability of SmartDesign and the enhanced ergonomics and productivity of SmartRemote. “When we set out to design the Brokk 200, we saw an opportunity to support customers further by introducing a new weight class,” said Martin Krupicka, president and CEO of Brokk Group. “The Brokk 200 allows contractors to work in tight spaces without a loss in power.” The 27.5-kW machine operates tools with requirements typical of one weight class above. When paired with the new Brokk BHB 305 breaker, the unit’s hitting power is increased by 40%. The new class of machine delivers 450 foot-pounds (610 joules) with each blow of the 650-pound (295-kilogram) hydraulic breaker. In addition to its heightened power, the Brokk 200 is claimed to offer 15% longer vertical and horizontal reach in a compact footprint similar to the Brokk 170. The extra chassis length and machine weight ensure proper balance, even when wielding heavy attachments, such as breakers, drum cutters, grapples and concrete crushers. The Brokk 200 is ideal for heavy duty, difficult-to-access projects and applications and represents the new standard in compact remote-controlled power.

For further information, log on to www.brokk.com www.steeltimesint.com

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INNOVATIONS

XPR rotational torch sleeves from Hypertherm Industrial cutting systems and software supplier Hypertherm, has introduced three new torch sleeves for XPR plasma cutting torches and lead sets. The sleeves allow the torch and lead sets to remain axially fixed while the torch holding device rotates 360 degrees in either a clockwise or counter-clockwise direction. This greatly enhances torch lead life in high-flex applications, says the company. The new sleeves are available in short, medium, and extended lengths and are claimed to be ideal for bevel or 3D/robotic cutting applications when using either an XPR170 or XPR300 X-Definition Plasma system. The sleeves include several engineering advances. An outside diameter of 76 mm (3in), allows for increased wall thickness and eliminates compression caused by clamping. Pre-sealed, high precision bearings reduce axial play by 90% and radial play by 81%. This, says Hypertherm, keeps out dirt and other particulates that are associated with plasma cutting and greatly extends the life of the sleeve and lead system. When used with Hypertherm’s specialised robotic/bevel lead sets, the rotational sleeve will, it is claimed, afford customers an especially robust industrial solution in applications requiring frequent rotational flexing when cutting with an XPR170 and XPR300, the only two X-Definition capable systems in the world. “A combination of engineering advances and refined high definition plasma processes help X-Definition

class plasma deliver unmatched plasma cut quality on mild steel, stainless steel, and aluminium,” said Hypertherm. “Laboratory testing shows ISO-9013 Range 2 cut quality on thin mild steel and extended ISO Range 3 cuts on thicker metals.” Both X-Definition systems contain patent-pending processes such as vented water injection (VWI), plasma dampening, and cool nozzle technologies for squarer cut edges, markedly less angularity, and excellent surface finish on non-ferrous metals like stainless steel. At the same time, the systems cut faster and use power more efficiently than earlier Hypertherm systems, the company claims. Phil Parker, product manager for Hypertherm’s heavy industrial plasma products, commented: “Hypertherm is constantly working to advance the capability of our products by devoting extensive resources to research and development. By listening and incorporating feedback from our partners and customers, we are able to deliver products like our X-Definition Plasma and these new torch sleeves that help customers increase the efficiency of their cutting operation.” Hypertherm advises customers who think they may benefit from the new sleeves to talk to their authorised Hypertherm OEM when ordering their system. For further information, log on to www.hypertherm.com/plasmaprecisely

INNOVATIONS

Accurate temperature measurement from Ametek

AMETEK Land, an industrial infrared non-contact temperature measurement specialist, has developed a new pyrometer for measuring the temperature of galvannealed and galvanised steel strip. The SPOT GS steel application pyrometer is claimed to provide continuous and accurate temperature measurement of coated steel strip during the galvanneal reaction. This enables steel producers to accurately measure the temperature in a galvanneal furnace, allowing it to run at optimum throughput rates in order to ensure consistent, high-quality, premium-coated steel demanded by the automotive industry. “The SPOT GS is a revolutionary new pyrometer, designed for even greater accuracy and convenience in galvannealed and galvanised steel strip applications. With specialised pre-set algorithms, the SPOT GS can provide both accurate digital temperature readings for galvannealed or galvanised surfaces and liquid surfaces seen on the exit from the zinc pot,” commented Chris Leonard, director of development and product management for AMETEK Land. www.steeltimesint.com

“We are confident that we have developed a temperature measurement solution that will optimise efficiency and achieve cost savings for steel producers, who can benefit from its accurate digital temperature readings, ease of use and robust design,” he said. SPOT GS enables automated furnace management to provide close control of the reaction and position of the reaction zone, delivering tighter control of product quality. By maintaining control of the reaction zone, the steel application pyrometer accommodates rapid changes of line speed and furnace power with variations to substrate or coating weight, says Ametek Land. This allows for furnace optimisation, reducing heating costs, maximising throughput and avoiding excessive over-reaction and powdering or flaking of the coating during subsequent forming operations, it is claimed. The SPOT GS application pyrometer can be integrated with furnace controls, PLCs and control software. By integrating directly, furnaces can run reliably and consistently and produce the highest quality products, with

minimal scrap, according to Ametek. The SPOT GS has additional inputs and outputs including emissivity out and LED switching, which are available as analogue/digital control I/O as well as over Ethernet. Combining Ethernet, Modbus TCP, video, analogue and alarm outputs within one device, SPOT makes all these conveniently available to the operator. Pyrometer readings and configuration settings are available on the rear display and remotely via a web browser or through dedicated SPOT software. SPOT GS is available with free-todownload SPOTViewer software, which allows configuration and display and logging of data. In addition, AMETEK Land offers a range of mountings and accessories compatible with all SPOT pyrometers, which allows for greater flexibility and ease of use. The SPOT GS was specifically developed in close collaboration with industry-leading steel producers and plant control system engineers. Further details, log on to www.ametek-land.com Digital Edition - January/February 2019

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INNOVATIONS

Hyster focus on operator environment Hyster Europe is focusing on enhancing the operator environment in accordance with the application, including in the wood, metal, construction, ports and paper industries. According to Chris van de Werdt, “When handling expensive, awkward and heavy loads, the driver environment matters more than ever,” he said, adding that every lift truck brand claims its products are ergonomic, but under what conditions? “Intelligent Hyster lift truck design focuses on the driver environment in all applications, but this proves particularly important for efficiency and driver

comfort in extreme and demanding operating conditions,” Chris added. Where metal handling is concerned, high shock load applications can negatively affect driver comfort, claims Hyster. The company is now offering the Hyster H16XM-9 heavy-duty lift truck, which is commonly used in the metal handling industry because of its robust frame, mast and carriage. A wide drive axle offers stability when handling loads at full capacity. Hyster claims that its rugged lift truck design helps reduce vibrations in the cab, and when combined with the full suspension seat, the drivers can benefit

from a comfortable ride for the duration of their entire shift. In fact, whole body vibration can be as low as .35 m/ s2, claims the company. “It’s often the small details that make a difference to drivers,” said Chris. “For example, Hyster high capacity lift trucks are designed to make driver ingress and egress easier with lower effort.” In foundry operations he said that tinted windows can be used to help protect the driver’s eyes from flashing and hot metals, while HD air conditioning in the cab keeps the operator environment at a comfortable temperature and free from dust.”

For further information, log on to www.hyster.eu Digital Edition - January/February 2019

INNOVATIONS

CM Labs Simulations’ new technology

CM Labs Simulations, developer of Vortex training simulators, will be releasing a host of new training technologies at Bauma 2019 (8-14 April, Munich). Each element is designed to work independently, or as part of a total team learning solution. CM Labs is launching its new Augmented Reality application, which makes it possible for instructors to bring a virtual mobile crane into the classroom, where trainees can interact with it, conduct ‘walkarounds’, and learn about machine inspection.

Once familiar with the equipment, trainees can get behind the controls of an equipment simulator and work through the built-in training curriculum, or focus on the development of specific operator skills. Two training simulators will be on display at CM Labs’ booth: the immersive Vortex Advantage and the desktop Vortex Edge Plus. Both can run CM Labs’ full catalogue of lifting and earthmoving training packs, including mobile crane, flat-top tower crane, luffing tower crane, crawler crane, ex-

cavator, wheel loader, backhoe, dozer, motor grader, and more. These simulators are designed to run independently, or as part of a unique tandem lift operation that will be on display for the first time at Bauma 2019, allowing two trainees to work simultaneously and co-operatively to complete a crawler crane lifting exercise. In addition, CM Labs will be displaying its signalperson training station, which allows a third team member to provide hand signals to the operators, while a fourth can supervise the operation, or inject challenges using the instructor operating station. “The impact of today’s training simulators goes far beyond equipment and controls familiarisation,” says Drew Carruthers, CM Labs’ director of training solutions. “With full team training, each member of the team is fully engaged in developing skills and best practice techniques, while also acquiring the collaboration skills that are vital to safety and efficiency on the work site.” CM Labs will display the full team training experience at booth C2.127 in the Canadian Pavilion. For further information, log on to www.cm-labs.com

Superior high-temperature tags and labels for track and trace applications. Polyonics® offers thermal transfer printable polyimide and aluminum bar code tag and label materials so you can accurately control inventories from when the materials leave the furnace through to delivery to your customers.

Keeping you on track www.steeltimesint.com

polyonics.com/HotMetal 603.352.1415 | info@polyonics.com

Personal Chemistry

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Off-highway truck company celebrates Philippi-Hagenbuch Inc, a US-based speciality manufacturer of off-highway truck enhancements, is celebrating its 50th anniversary this year and is kicking off celebrations by looking back at all the innovative new products it has introduced to the marketplace. Josh Swank, vice president of sales and marketing for the company (which is also known as PHIL) said that the company was responsible for the world’s first commercially available tailgate specifically for off-highway haul trucks. “From our humble beginnings in the basement of our founder’s home to the present where we’ve invented countless technologies for the off-highway truck industry, we’re proud to be known for our engineering and innovation,” said Swank. Over the past 50 years, PHIL has pioneered over one hundred domestic and international patents and innovations relating to off-highway truck bodies, on-board weighing systems and black-box technology, as well as improvements in the safety of haul trucks through seat belt detection, water tank access, distribution and material confinement. Patented innovations surrounding ejector body and trailer technology, truck body volumetric capacity technology, bottom dump trailer technology, industrial strength hook-trucks and scissor lifts have assisted niche operations in maximising their haulage efficiency while minimising downtime, the company claims. PHIL helped their original client, a Wisconsin rock quarry, achieve the rated load of their haul trucks with the addition of tailgates and sideboards. Just three years after delivering their first product, PHIL established its first international distributor in Brisbane, Australia. From there, PHIL grew into the mining and power plant industries with truck bodies and trailers. In the early 1980s, as New York City was expanding their Fresh Kills Landfill, PHIL innovated with high-volume refuse bodies that helped the city maximise Digital Edition - January/February 2019

their trucks’ capabilities and haul their refuse as efficiently as possible. Water tanks – and the inherent innovations PHIL developed around them – were added to the product line in the late 1990s, and 2000 ushered ejector body and trailer technology into PHIL’s repertoire. “Over the last 50 years, the dedication and forward-thinking of our associates has led us to become a global leader in haul truck usage and innovation,” Swank said. “Everyone at PHIL contributes to our family environment with a willingness to do what’s right for the client.” The company was founded by LB “Phil” Philippi and LeRoy Hagenbuch, P.E. The father

and son-in-law team of sales and engineering resulted in a combination that worked well for the off-highway industry. Unfortunately, LB passed away in 1977. Remaining family owned and operated, Philippi-Hagenbuch is now led by LB’s granddaughter (LeRoy’s daughter) Danette Swank. LeRoy continues to thrive as PHIL’s chief engineer. He oversees the engineering

INNOVATIONS

department and R&D and is excited to celebrate his 50th year of doing what he loves best â&#x20AC;&#x201C; learning and inventing. Throughout the year, PHIL will be conducting various celebrations related

to its 50th anniversary,In including appearances at the AGG1 and Haulage & Loading trade shows, client and dealer visits and special mailings to past and present clients and dealers.

For further information, log on to www.philsystems.com

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Danieli starts up Yildizlar cold mill complex Inside the Yildizlar cold mill

Italian plant builder Danieli has started up the new cold mill complex of Turkish steelmaker Yildizlar in Izmit (Kocaeli). After the start-up of the pickling, galvanising, batch annealing lines and temper mill, Danieli and Yildizlar’s technical teams started up the cold tandem mill.

According to Danieli, “right from the beginning the quality and productivity results were twice the contractual values, with the PAC signed after two weeks. Four weeks after start-up the productivity was three times the expected rate”.

The five-stand tandem mill is made up of six-high stands featuring Danieli OSRT shaped-roll technology controlled by a Danieli Automation process control system. Danieli Automation’s D-REC automatic eccentricity compensation algorithm is claimed to ensure ‘precise and simple control of strip thickness’. As a result, strip thickness tolerance is ± 0.6%, head/tail off-gauge length lower than four metres, and strip flatness less than 5IU. Coils in final strip thickness of 0.20 mm and widths up to 1,550 mm in a product mix including DP600, DP1000, IF and HSLA, are produced.

OMK gets to work on 500kt/yr steel works Danieli will provide plant and equipment engineering, equipment manufacturing, supervision for erection and commissioning, and customer training for OMK’s new Vyksa Steel Works in Russia. The new facility will produce 500kt/ yr of OCTG seamless pipes (casing and tubing), linepipe and industrial pipes from 2” 7/8 to 10” 3/4. The facility will manufacture OCTG seamless pipes (casing and tubing), line pipe and industrial pipes, according to Italian plant builder, Danieli. All lines will be equipped with advanced Danieli Automation process control and tracking systems. According to Danieli, the plant mainly consists of a hot rolling line based on

Focus on Danieli For further information, log on to www.danieli.com

What the plant will look like in 2020...

the company’s Fine Quality Train (FQT) technology and a finishing centre featuring heat treatment, quality assurance and finishing lines. The majority of pipes produced by the new OMK plant will be used for gas and oil extraction, claims Danieli. “We are pursuing our long-term strategy of developing an integrat-

ed product offering. When the project is complete, our company will be able to break into new market segments by offering customers quality product that meets the most advanced requirements”, commented OMK’s chief investment and asset development officer Dmitri Chernyshev. The new plant is scheduled to be commissioned in 2021.

Usiminas to replace Ipatinga converte Usinas Siderúrgicas de Minas Gerais S.A. (Usiminas) has awarded Danieli Corus the contract to replace converter #4 at its Ipatinga integrated steelworks (BOF plant #2), in Brazil. This will be the seventh converter revamp project for Danieli and the first contract for such a project since the integration of Danieli Linz Technology into Danieli Corus. The converter vessel will be built by Usiminas Mecânica, a subsidiary of Usiminas, with Danieli Corus providing design, supply of

INNOVATIONS

French plate producer chooses Danieli French steel plate producer Laminoirs des Landes has selected Danieli for the supply of a new hydraulic hot shear to be installed in Tarnos, France. The selected shear will allow the company to cut hot plates (600-900 °C) into a wide range of thicknesses up to 50 mm and widths up to 3,500 mm. Thanks to the knife-angle and knife-

Laminoirs des Landes choose Danieli

gap adjustment systems, the machine allows the same optimal performances when cutting thick and thin products, claims Danieli. The company said that its hydraulic shears are ‘a smart solution to reduce

CapEx in comparison to the common electro-mechanical rocking-type shear’. The new shear will be sent to France from Danieli’s high-tech workshops in Italy and put into operation at the beginning of 2020.

Danieli has entered into a new partnership with GFG Alliance for the design and construction of a new high-tech rail and section mill at the Whyalla Steelworks in South Australia. The new 750kt/yr structural and rail heavy section mill will, claims Danieli, be an environmentally friendly facility that will increase the steelwork’s production capacity, reduce waste and enable GFG’s Liberty Primary Steel to lift its product capability and improve its competitive advantage. The mill will be equipped with Danieli’s patented RH2 process for rail hardening that enhances the mechanical properties of high-speed rails through multi-immersion steps into a quenchant. The project will be executed in two phases. Phase one will involve Danieli working in conjunction with AAR TEE Ferretti International for turnkey construction and auxiliaries, and the Liberty team to develop the engineering stage. Phase two will involve equipment design, manufacturing, supply and

commissioning to reach the goal of hot commissioning in the following 18 months. The Australian government has paid considerable attention to the project. Scott Morrison, Australia’s Prime Min-

Below: Celebrating the 56th anniversary of Ipatinger

Above: Sanjeev Gupta, widely regarded as the saviour of the UK steel industry (middle bottom) signs up to a partnership

Danieli enters into GFG Alliance partnership

ister, Bill Shorten, the Federal Leader of the Opposition, South Australian Premier Steven Marshall, and the Mayor of Whyalla City, Clare McLaughlin, all attended the signing ceremony.

with Danieli

materials and supervision. The contract was signed on the occasion of the 56th anniversary of the Ipatinga plant. The new 180-tonne converter will be equipped with an air-cooling system for the barrel part of the vessel and water-based cooling for the top cone. A Q-TEMP temperature-monitoring system and automation packages will also be installed as part of this revamp project. The first heat with the new converter is scheduled for early 2020. www.steeltimesint.com

Digital Edition - January/February 2019

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Focus on Primetals Technologies â&#x20AC;&#x201C; For further informa

Primetals Technologies wins new EVRAZ o Digital Edition - January/February 2019

INNOVATIONS

Baosteel cold reduction mill starts up A newly-built double cold reduction (DCR) mill supplied by Primetals Technologies has commenced operation at the Shanghai works of Chinese steel producer, Baoshan Iron & Steel. The DCR mill is designed to process 205kt/yr (metric tons) of cold strip and is part of the Chinese steelmaker’s Tinplate Product Structure Optimisation Project. It may be run in both reduction/temper and temper mode, and the processed strip will be used for the production of beverage cans, metal caps and electrical components. Primetals Technologies received the order in December 2016. The mill consists of a two-stand UCM and is designed to perform double-cold reduction as well as one-stand temper rolling. In the DCR process, the annealed

strip, after reduction in a tandem cold mill, is reduce rolled on the No. 1 stand and temper rolled on the No. 2 stand. This process imparts the strip with its prescribed mechanical strength. In stand No. 1, work rolls with two different diameters can be used. In onestand temper rolling, the strip is temper rolled in stand 2 to the prescribed elongation ratios to obtain the desired mechanical characteristics. The DCR mill processes strip produced by a PLTCM (pickling line and tandem cold mill). Entry strip gauges are between 0.17 mm and 0.55 mm. Exit gauges range from 0.12 mm to 0.36 mm. Strip width may vary from 700mm to 1,230 mm. At a coil diameter of 2,000 mm, maximum coil weight amounts to 24.15 tons. Steel grades include DR7 to DR10.

ation, log on to www.primetals.com

order www.steeltimesint.com

Russian steel producer EVRAZ Nizhniy Tagil Metallurgical Plant (EVRAZ NTMK) has awarded Primetals Technologies a multi-million Euro contract to supply automation and electrical equipment for its reconstructed blast furnace 6. The basic automation (level 1) and the process optimisation (level 2) will be installed as a virtualised automation system on central, redundant servers, which will drastically reduce servicing costs, especially those for future upgrades. The new process automation will enable the operational parameters of the furnace to be optimised and coke consumption to be reduced. Primetals Technologies previously supplied the electrical equipment and automation for blast furnace 7, which has been in operation since the beginning of March 2018. Blast furnace 6 was shut down at the start of last year and will be completely demolished. Secondary plant equipment, such as the stockhouse, hot-blast stove, gas cleaning and dedusting systems, will also be taken down. Once

rebuilt, the new equipment will supply hot metal for the plant in Nizhniy Tagil together with blast furnace 7. EVRAZ NTMK produces 4.9Mt/yr of hot metal and 4.2Mt (metric tonnes) of steel and is one of the largest steel works in Russia. The company’s integrated iron and steel works is located in the city of Nizhniy Tagil in the Sverdlovsk Region of the Urals. It primarily produces train wheels, rails, structural steel, pipe blanks and semi-finished products. Nizhniy Tagil is one of Russia’s oldest steelmaking and mining centres. According to Primetals, a major reason for winning the order was the company's good experience with the automation and electrical equipment Primetals Technologies had installed in blast furnace #7. In the past two years, Primetals Technologies has also received orders to install automation equipment in five blast furnaces in Brazil, Europe and India. Blast furnace 6 will be commissioned by the middle of 2020. Digital Edition - January/February 2019

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Doosan launches electric counterbal Doosan, a leading manufacturer of high-performance forklift trucks, has introduced a new range of four-wheel electric counterbalance vehicles. The B45X-7 Series is claimed to offer greater durability, enhanced productivity, increased visibility and an extensive range of safety features as standard, claims Doosan. There are four new models in the range covering capacities from 4.0 to 5.0 tonnes as well as being suitable for a wide spectrum of industries including manufacturing, engineering, transport and warehousing. According to Doosan, the versatility of electric power is now available in a durable and reliable vehicle, built for long-shifts outdoors in wet or dusty conditions – making it a viable alternative to increasingly regulated IC engine equivalents. Doosan claims that durability for outside duty is assured with IP65 and IP43 rated Curtis AC controllers and motors, offering maximum resilience to water and dust. The company’s industry leading sealed, oil-cooled disc brake system, is claimed to be virtually maintenance free and capable of lasting up to five times longer than conventional shoe brakes. The sealed units protect against outside elements such as dirt, water and grit, ensuring top-rate brak-

ing performance for enhanced safety and increased productivity. “With a tighter turning circle than its predecessor, smooth and responsive acceleration, and a conveniently placed direction switch on the hydraulic control lever for switching direction of travel quickly and easily, the all-round performance of the B45X-7 Series promises a boost to productivity inside or outside the warehouse,”said Doosan. The company claims that safety is foremost in the design of the new range. Prominent safety features include: anti-roll-back for preventing accidental movement of the vehicle when stopped on a slope, automatic speed control that adjusts the travel speed for safer cornering, and an operator sensing system that immobilises the truck and locks all hydraulic functions when an operator leaves the cab. Further safety features included as standard are: a clearer view through the mast, an easily accessible emergency stop button on the dashboard, a high visibility driver’s safety belt, large entry step and grab handle for easy access, LED lights and an overhead guard-mounted flashing beacon. Doosan claims that the cab is designed for operator comfort and to reduce fatigue. There is a fully adjustable premium Grammer suspension seat as standard, and excellent all-round

visibility for safer manoeuvring with greater awareness. An adjustable steering column, an easy and intuitive instrument panel and plenty of legroom are other notable features, claims Doosan. Improved accessibility to the controller and electric components, a tool-less side panel for simple access to the battery and easy-view software for adjusting control parameters mean easier maintenance, says the company. Brian Grady, sales and marketing director for Doosan Industrial Vehicles UK, commented: “Companies that are currently considering contracts on 3.5 – 5.0 tonne IC engine trucks should at least be looking at the possibility of switching to electric powered forklifts as a way of reducing their costs, improving safety and cutting their carbon footprint – especially in light of the Euro Stage V emission regulations that have just come into effect. “Electric trucks have come a really long way in the past few years and are now, with this series, a highly viable alternative to IC Engine trucks for most applications,” Grady added.

INNOVATIONS

lance forklifts

For further information, log on to www.doosan.com

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Monitoring th

For further information, log on to www.phoenixtm.com Digital Edition - January/February 2019

INNOVATIONS

he furnace re-heat process

www.steeltimesint.com

The PhoenixTM ‘thru-process’ temperature profiling system has been designed specifically to allow comprehensive monitoring of the entire slab/billet furnace reheat process, claims the company. Offering up to 20 thermocouple inputs using the PhoenixTM high temperature PTM1-220-HT data logger, temperatures can be measured at the surface, centre and base of the product at various positions along its length. The resulting temperature profile data can be imported directly into the furnace controller model to validate correct selection of process parameters and assumptions applied. Passing through the reheat furnace reaching temperatures of up to 1300 °C / 2372 °F, the data logger requires significant thermal protection. Such protection is provided by PhoenixTM’s specially designed TS07 thermal barrier range. Manufactured using graded insulation layers and an evaporative inner water tank, the phased evaporation of water maintains the logger temperature at a safe 100 °C/212 °F. Applying accurate profile data to mathematical models, targeted roughing mill exit temperatures can be set to obtain a desired furnace drop out temperature throughout the product thickness. “Accurate control of such variables allows a successful rolling operation with minimal scale build-up maximising mill yields, saving energy and maximising production throughput,” said PhoenixTM.

Digital Edition - January/February 2019

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