INNOVATIONS
INDUSTRY NEWS ROUND-UP
FUTURE STEEL FORUM 2020
EUROPE UPDATE
16 pages of the latest new products and recent contracts
A round-up of the latest global steel industry news
The latest on the greatest – leading steelmakers to speak in Prague
Uncertain times lie ahead for the European steel industry
Since 1866
www.steeltimesint.com Digital Edition - February 2020 - No.14
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CONTENTS DIGITAL EDITION – FEBRUARY 2020
INNOVATIONS
INDUSTRY NEWS ROUND-UP
FUTURE STEEL FORUM 2020
EUROPE UPDATE
15 pages of the latest new products and recent contracts
A round-up of the latest global steel industry news
The latest on the greatest – leading steelmakers to speak in Prague
Uncertain times lie ahead for the European steel industry
Since 1866
www.steeltimesint.com Digital Edition - February 2020 - No.14
Picture courtesy of: Friedrich Kocks GmbH & Co KG. KOCKS believes in German engineering and manufacturing standards. The core components of KOCKS 3-roll blocks are manufactured at their own workshop in Bremen with more than 50 years of production experience boosted by modern digitised industry 4.0 production standards.
2 Leader by Matthew Moggridge.
37 Environment Ultrasound for energy
4 News round-up The latest global steel news.
42 Rolling A solution for axial bearing positioning
7 Future Steel Forum It’s going to be the best yet.
48 Material solutions High performance material solutions
8 Europe update Some growth expected
54 Plant maintenance Improving bearing reliability
12 Market Intelligence Uncertainty clouds nickel market outlook
58 History The Moira blast furnace
HEAT TREATMENT – WE LOOK AT HDQT TECHNOLOGY
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 Sales Director Ken Clark kenclark@quartzltd.com Tel: +44 (0) 1737 855117
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16 Innovations The latest new products
Managing Director Tony Crinion tonycrinion@quartzltd.com Tel: +44 (0) 1737 855164 Chief Executive Officer Steve Diprose 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. Printed in England by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK ©Quartz Business Media Ltd 2020
ISSN0143-7798
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LEADER
Top steelmakers choose the Future Steel Forum
Matthew Moggridge Editor matthewmoggridge@quartzltd.com
Digital Edition - February 2020
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The Future Steel Forum 2020 is going to be a conference to remember. The fourth Future Steel Forum takes place at the Grandior Hotel, Prague, in the Czech Republic, and it’s going to be a real humdinger for one simple reason: the steel industry has embraced the event and delegates can expect to hear from leading steelmakers, R&D organisations, steel industry associations, academics and production technology specialists. I am pleased to announce that Dave Stickler, CEO of Osceola, Arkansas-based Big River Steel (BRS) in the USA is the opening Keynote for day one. Dave and I last met in Monterrey, Mexico, late last year at the World Steel General Assembly, where he calmly informed me of his intention to speak. I was elated because Dave’s company represents the world of high-tech steelmaking; his mill, located in one of America’s southern states, epitomises what can be done when a steel manufacturer sets its heart on developing the world’s first ‘learning mill’. Dave will be joined on stage by Prof. Dr. Ing Katja Windt, member of the management board of SMS group, and Stephen Pratt,
founder and CEO of artificial intelligence specialist noodle.ai, who will explain the technology behind the success of the mill. Our opening Keynote for day two is His Excellency Saeed Ghumran Al Remeithi, CEO of Emirates Steel, a leading steelmaker and an influential player in the global marketplace. As CEO, Mr Al Remeithi has expanded the company’s product range, enhanced its production efficiency and mitigated its environmental impact. The company now exports to more than 40 countries. Delegates will hear from leading players from the world stage of steelmaking: South Korean steel manufacturer POSCO will be speaking, so will Tata Steel India, ArcelorMittal, Metinvest Digital from the Ukraine, TMK from Russia, Kobe Steel from Japan, Liberty Steel Group, Badische Stahl-Engineering and Buderus Stahl from Germany. There will be plenty of opportunities for networking with colleagues and a vibrant exhibition too. You really can’t miss this fantastic Industry 4.0 conference. To register, visit: https://www.futuresteelforum.com
www.steeltimesint.com
25/02/2020 11:34:22
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NEWS ROUND-UP
• An unexploded World War Two bomb led to the evacuation of construction workers at Tata Steel’s Port Talbot steel mill back in late January. The device was unearthed during construction work and was removed safely. Some 1,500 people are employed on-site. Source: BBC, 23 January 2020.
• Gerdau Special Steel North America is laying off around 140 employees at its facility in Jackson. Melting and rolling operations will stop at the 3100 Brooklyn Road plant, but finishing operations will continue there. A Gerdau spokesman said that melting and rolling equipment would be maintained in case a restart is ‘deemed feasible’. Proof, perhaps, that tariffs aren’t working? Source: Mlive.com, 23 January 2020.
• If the deal between Jingye and British Steel falls to pieces, British Steel will be broken up and sold in parts, according to an online news report. It’s looking as if around 500 jobs (10% of the workforce) will be lost if the deal goes ahead. Jingye is looking to buy the business from the Government’s liquidators. Currently, it is estimated that the business is losing £1 million per day. Source: The Northern Echo, 25 January 2020. • Jingye might build a new metals recycling furnace at British Steel’s Lackenby facility, bringing steelmaking back to Teeside after ‘decades of industrial decline’ according to a report by the Financial Times. At the moment, the plant’s beam mill turns basic metal into products for the construction industry. Introducing an EAF would enable the plant to produce its own primary material from scrap metal. Source: Financial Times, 25 January 2020.
• Things might be getting a little hot and bothered over at ThyssenKrupp following news that Marc Tuengler, managing director of DSW, the German investors’ association, has criticised, among other things, the massive pay-off being handed to former CEO Guido Kerkhoff (a cool 6.5 million Euros!). When you consider that the German steelmaker has issued four profits warnings AND botched two restructuring attempts, according to an online report, you might conclude that Tuengler has a point. Source: Reuters, 24 January 2020. Digital Edition - February 2020
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• Tenova has been awarded a contract from Nippon Steel to supply a Consteel EAF to be installed at the company’s Hirohata works. Tenova believes that the facility will save around 400kt/yr in terms of CO2 emissions by installing the new equipment. Source: Foundry Planet.com, 13 February 2020.
• ArcelorMittal South Africa (AMSA) is to report a 4 billion Rand ($2.8) loss for the year ended December 2019 – a challenging year for the South African steelmaker. The company plans to shed 1,000 jobs following a loss on profits of 1.7 billion Rand ($951 million). Source: ETNOWNEWS.com, 26 January 2020. • If it all goes Pete Tong between Jingye and British Steel, then worry not because there’s a Turkish industrial giant lurking in the wings. Cengiz is ready to bid for the out-of-luck British steelmaker and is watching developments closely. Cengiz owner Mehmet Cengiz is a close ally of President Recep Tayyip Erdogan. The company claims it is well-placed to acquire overseas assets. Source: BBC, 26 January 2020.
• Falling demand and the slowing growth of the world economy are the reasons behind JFE’s decision to idle parts of its steel plate plants in Japan. The aim is to dramatically reduce fixed costs. Workers at plants in Kawasaki and Chiba will be relocated to other positions, claims the company. Source: Nippon.com, 13 February 2020. www.steeltimesint.com
25/02/2020 08:12:24
NEWS ROUND-UP
• The USA is getting a little hot under the collar over structural steel imports from Canada, Mexico and China. The US Commerce Department claims that fabricated structural steel from these countries has been sold at less than fair value at rates of up to 6.7% (Canada); 30.6% (Mexico); and 154% (China). It is also reported that steel from China and Mexico had received unfair subsidies at rates of up to 206% (China) and 69% (Mexico). Source: Hellenic Shipping News, 27 January 2020.
• The privately owned Indian steelmaker JSW is to delay by six months the completion of its 5Mt/yr expansion of its Dolvi plant on India’s west coast. The likely completion date is now September 2020. Work started on-site in 2017 but weather issues (prolonged monsoons) and manpower problems have been cited as the main reasons for the delay. Source: Argus Media, 28 January 2020.
• A US$300 million expansion project is on the cards for US steel giant Nucor Corporation. The company is planning to expand its Berkeley County steel operations as part of a multi-billion dollar spending spree over the next two years. Source: Post and Courier, 17 February 2020.
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• In the USA, the state of Indiana accounts for about a quarter of the nation’s steel output, despite a 7% decline in production. In 2019, the state produced 24.7Mt as opposed to 26.7Mt in 2018. US steel mills in general shipped 96.1Mt last year, up 0.9% from the previous year. Source: Inside Indiana Business, 18 February 2020.
• Sluggish growth in domestic steel demand has forced Tata Steel in India to slow the planned expansion of its Kalinanagar steel plant in Eastern India. In 2018, the original plan had been to grow the capacity from 3Mt/yr to 8Mt/yr and complete operations by 2022. A new deadline has not been given. Source: Argus Media, 14 February 2020.
• 100kt of steel produced by Tata Steel Europe in the Netherlands is exempt from paying a 25% tariff announced by US president Donald Trump in June 2018. Dutch foreign trade minister Sigrid Kagg said it was good news for the Netherlands and for Dutch employees. Source: Reuters, 28 January 2020.
• Finnish elevator giant Kone has moved away from discussions to acquire ThyssenKrupp’s elevator technology. Apparently, TK had already ruled out Kone as a bidder in favour of two private equity buyout consortia. Source: Reuters, 17 February 2020.
Italian plant builder Tenova has been contracted by Russian steelmaker NLMK Ural to supply the company with an intelligent electric arc furnace (iEAF). The unit will be installed at the Revda plant in Russia and bolted on to the existing EAF. Source: India Education Diary, 17 February 2020. www.steeltimesint.com
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• In India, a country that depends largely on oil and coal for its energy, the nation’s biggest gas utility is talking to steel mills with a view to convincing them to switch to less polluting fuel – and revive their own sales growth! As demand from its existing client base wanes, GAIL is on the hunt for new business. Source: LiveMint, 18 February 2020.
• There’s more to plant safety than preventing employees from falling into a blazing furnace. At a Tata Steel mill in Jamshedpur, Jharkhand, India contract worker Laxmi Soren was attacked by father-of-three Badal Hansda who had been engaged in a threeyear long affair with Soren. When she discovered his marital status she started to avoid him so he decided to attack her in the plant and close to blast furnace D. Hansda hit her on the legs with a rod and twice around the head until she fell unconscious at the scene. Source: The Avenue Mail, 18 February 2020.
Digital Edition - February 2020
25/02/2020 08:12:40
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FUTURE STEEL FORUM 2020
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Top speakers at the 2020 Forum The Future Steel Forum has come of age. For 2020 the steel industry has taken the event under its wing and fielded some exceptional speakers for the event’s fourth conference, which this year takes place at the Grandior Hotel in Prague, 2-3 June. It’s shaping up to be an unmissable event THE Future Steel Forum, a global steel conference focused on the application of Industry 4.0 technologies, has attracted top draw speakers for its event in Prague this summer. Senior level representatives from worldleading steel manufacturers will gather at the Grandior Hotel, 2-3 June, for the fourth outing of this highly successful event, which brings together the high-tech steel fraternity to discuss subjects as diverse as artificial intelligence, logistics, sustainability and plant safety. The two-day event kicks off with a Keynote Address from Dave Stickler, CEO of Big River Steel of Osceola, Arkansas, USA. Big River Steel epitomises the strong and successful partnership that can exist between a steelmaker and hi-tech digital manufacturing technology. Dave is joined on stage by Katya Windt, a member of the management board of SMS group, and Stephen Pratt, founder and CEO of San Francisco-based noodle.ai, an artificial intelligence provider that together with SMS group and Big River’s in-house team, developed the world’s first ‘learning mill’.
Day Two of the conference will open with a Keynote Address from His Excellency Eng. Saeed Ghumran Al Remeithi, CEO of Emirates Steel, a leading steelmaker operating from the United Arab Emirates and a major and influential player in the global marketplace. Since Mr. Remeithi assumed the role of CEO in 2012, Emirates Steel has expanded in both manufacturing capability and production output, producing steel products in Abu Dhabi that are exported around the world. The 2020 Future Steel Forum is shaping up to be an unmissable event. In addition to Big River Steel and Emirates Steel there will be presentations from South Korean steelmaker POSCO, Tata Steel India, ArcelorMittal, Liberty Steel Group, Metinvest Digital, Japan’s Kobe Steel, Russia’s TMK and two German steelmakers, Buderus Edelstahl and Badische Stahl Engineering. There will also be cutting edge presentations from the German Steel Federation and the Austrian Mining and Steel Association alongside leading research and development associations, renowned academics and steel production technology specialists.
Way back in 2015, when the team on Steel Times International embarked upon the challenging task of creating an Industry 4.0 conference for the steel industry, it had no idea of how things would turn out or how successful the event would become. Back in the day it was a case of emailing people, meeting with experts at home and overseas and trying to find specialists in the field who would be willing to speak and exhibit at the event. Would there even be an event, we often wondered, but eventually things started to happen, the Forum received the go-ahead from those at the top and you could say that the rest is history. The inaugural Future Steel Forum took place in 2017 in Warsaw, Poland, at the Sheraton Hotel, a venue so great we went back for year two and then moved to Budapest for last year’s conference, hosted by the Sofitel Chain Bridge close to the banks of the Danube.
TO REGISTER AND FOR FULL DETAILS OF THE FUTURE STEEL FORUM’S 2020 PROGRAMME, GO TO
www.futuresteelforum.com www.steeltimesint.com
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EUROPE UPDATE
Some growth expected
A continued slump in the European Union’s manufacturing sector due to weakened exports and investments, e a fall in apparent steel consumption of 3.1% in the third quarter of 2019. Apparent steel consumption concern and by third country exporters. This figure is a slight moderation when compared to second quarter figures of -
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EUROPE UPDATE
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vestments, escalating trade wars, growing import distortions and a further deterioration in business has led to tion concerns the supply of all steel products delivered to the EU28 market by domestic producers in the EU r ďŹ gures of -6.7%, according to the European Steel Association (EUROFER).
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EUROPE UPDATE
EUROFER claims that no significant rebound is forecast before the second half of 2020 and the current downturn is not likely to bottom out in the short-term. Various factors are involved including Brexit and escalating trade wars between the USA and its main trading partners, notably China. The situation may lead to a further deterioration in business sentiment, says EUROFER, and might seriously hamper investment growth. “2019 was another challenging year for the steel sector, with declines in steel consumption and import levels which – while down compared to 2018 – were still very high compared to historical levels,” said EUROFER’s director-general, Axel Eggert. He added that some growth is expected to return to steel markets in 2020, but if events take an unexpected turn ‘even these modest estimations could be upended’. According to EUROFER, the current downturn in steel demand led to a fall of 4% year-on-year in EU domestic deliveries in the third quarter of 2019, following a decrease of 3% in the first quarter. After the exceptional drop of 19% year-on-year experienced in the second quarter, third country imports decreased by just 1% (to 8.8Mt) in the third quarter, accounting for
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23.8% of EU steel demand. Monthly data continued to show high volatility. The challenges facing the EU sector became more severe during the third quarter of 2019, having negative repercussions on market conditions. After falls in quarters one and two and an acceleration of the negative trend in real steel consumption, early indicators suggest a further year-on-year reduction in the final quarter of 2019; and this means a total decrease in real steel consumption of 1.1% over the whole year. EUROFER expects real consumption levels to recover in the second half of 2020 and stabilise around low levels in historical terms. “The expected fall in apparent steel consumption in 2019 of 3.3% year-onyear and persisting import pressure is, in essence, expected to mostly have penalised EU steel producers in their business performance,” said EUROFER. Market conditions are expected to improve slightly from the third quarter of 2020 and apparent consumption will recover with a growth rate of 1.2% as a result of modest re-stocking rather than a rebound in demand from steel using
sectors. There are, however, risks related to import distortions and global overcapacity, which will continue to undermine the stability of the EU steel market and widen the gap between capacity and production. EUROFER claims that business conditions have deteriorated since the end of 2017 and that the downward trend was steeper in the second quarter of 2019, particularly in the automotive sector. The construction industry, on the other hand, has reported record growth in output and has out-performed other steel using sectors resulting in a slowing of output growth since the first quarter of 2018. The industrial downturn has had global repercussions, reflecting growing trade frictions and uncertainty, which have hampered business investment. While a substantial rebound is unlikely short-term, some recovery in EU steel-using sectors is expected in 2020. The recent US-China trade agreement, signed on 15 January, has eased tensions, but had little effect on the serious downturn in EU manufacturing. Furthermore, a no-deal Brexit – which is still a possibility – plus continued trade protectionist policies and geo-political tensions in the Middle East, will curb business confidence, EUROFER believes. Output in the EU’s steel using sectors will grow by 0.6% in 2020 and 1.4% in 2021. �
www.steeltimesint.com
25/02/2020 08:16:03
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MARKET INTELLIGENCE
Uncertainty clouds nickel market outlook All eyes will be on the Indonesian nickel market this year. The knives may be out for the country’s nascent stainless industry, but the staggering potential for expansion in nickel pig iron (NPI) may reduce the impact of the nickel ore export ban to a minor inconvenience, argues Wood Mackenzie*
ALTHOUGH the global battery sector share of nickel demand is much smaller than other metals, getting the quantity of nickel that electric vehicles (EVs) will need by the mid-2020s will remain a challenge. According to Andrew Mitchell, Wood Mackenzie’s head of nickel, there are five key themes to the biggest trends to watch this year and they are: • Nickel sulphate (NiSO4 ) premiums will switch to discounts • High Pressure Acid Leach (HPAL) – plants come and go while delays mount in Indonesia • Chinese nickel pig iron (NPI) stutters as Indonesian NPI expands rapidly • Indonesian stainless output stalls… and may even fall • European stainless rebounds as imports from Asia are warned off Mitchell said: “Despite continued investment in new battery plants, weaker demand for NiSO4 tied to last year’s cut in Chinese electric vehicle subsidies will translate to more discounts in 2020. “We previously noted that premiums for NiSO4 might come under pressure due to stronger supply. While that did materialise, the unexpected and immediate mid-year downgrading in Beijing’s EV subsidy programme had a greater impact. EV sales were reduced by half. China’s EV sales target of 1.5 million units was derailed and this cut demand for batteries and, therefore, precursor materials, including NiSO4. The impact will extend well into 2020. “We anticipate further discounts on NiSO4 in 2020. It is even possible that some sulphate refiners will switch a portion of chemicals output back to metal production. The recent rush to make chemicals available
will become more evident this year, as some western sources also fulfil their promises to satisfy specialist product demand from the EV sector. “However, we believe the 27% surge in EV-related demand for nickel chemicals was exaggerated last year and that growth will be restricted to only 3-4% in 2020.” Wood Mackenzie’s view comes despite the impressive pace of investment in new battery manufacturing facilities. “China remains the preferential location for new factories, but European and US players are now cementing development plans for the near future. While this investment is for the future, it enhances the perception that demand for batteries is strong, which is counter to the current reality caused by China’s adjustment in subsidies,” added Mitchell. Closure of the HPAL plant at VNC, New Caledonia, will contrast with the re-start at Ravensthorpe, Australia. However, challenges at three new HPAL complexes in Indonesia will progressively derail their commissioning schedules, says Wood Mackenzie. “For now, we maintain our outlook for 22kt nickel production at Vale’s VNC HPAL operation in New Caledonia in 2020. However, output may decrease from February-March once the company completes its review of the facility, which has been losing, on average, US$9 million a month. “At the same time, First Quantum Minerals aims to switch Ravensthorpe back on, having placed it on care and maintenance in 2017. We forecast production of 9kt nickel in mixed hydroxide precipitate (MHP) in 2020, increasing to 20kt in 2021.
Wood Mackenzie, www.woodmac.com Digital Edition - February 2020
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MARKET INTELLIGENCE
tlook
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“Thus, between them, these two operations could increase the availability to battery chemicals streams of nickel in MHP by 20-25 kt in 2020.” “Greater challenges may await the three new HPAL plants in Indonesia that are scheduled to enter production in 2021,” said Mitchell. The restart of the Indonesian nickel ore export ban will mean that, once ore stocks are depleted, Chinese NPI production will decrease sharply. “However, this decline could be more than counter-balanced by expansion in Indonesian NPI,” said Mitchell. “Even though the Indonesian nickel ore export ban began on 1 January, we expect about 6Mt of Indonesian ore to arrive in China in the first part of this year. “Concurrently, imports from the Philippines will be sustained at around 30Mt. Combined with ore stocks already available in the country, we believe achievable nickel-in-NPI production in China is 526kt, with monthly production levels expected to be sustained at 50kt through the first half of 2020 before declining to 30kt as ore supply becomes tighter. “The potential future production of NPI in Indonesia is staggering. We currently anticipate output of 500-520kt nickel in NPI in 2020 compared with 360kt in 2019 as 18 RKEF lines became operational across three industrial parks. “However, with Tsingshan’s intent to add a further 10 lines by 2021, and VDNi’s longer-term plan to build 35 more lines, then possible capability by the end of 2020 could be 660-800 kt/yr, depending on the NPI grade. Thus, whatever happens to NPI productivity in China may ultimately prove inconsequential.” There are now two stainless steel melt shops in Indonesia: Tsingshan Indonesia and Delong Obsidian. Tsingshan was widely expected to reach nominal capacity of 3Mt/yr in 2019, but the anti-dumping duty against Indonesian imports closed the door to China, leaving it with more product than it could place in Southeast Asian markets and limiting production at 2.2 Mt/yr. Wood Mackenzie does not expect the ramp up to 3Mt/yr to be viable in 2020. “Delong Obsidian was completed late in 2019 and we assume that it will enter production in the first half of this year, melting around 300kt over the year. While Digital Edition - February 2020
25/02/2020 08:17:24
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MARKET INTELLIGENCE
commissioning will give rise to an initial production of at least a few thousand tonnes, whether it remains operational for longer is open to debate – putting that 300kt of new production at risk. “On the presumption that Obsidian produces stainless flat products (FPs) – slab and hot rolled coil (HRC) – Delong will struggle to arrange off-take for any of its output. China is effectively closed because of the penalties against imports from Indonesia, while Tsingshan has already secured most other Southeast Asian destinations. Obsidian may struggle to make headway in a market where Tsingshan is now struggling to make further advances. “Alternatively, Obsidian may cast billet rather than slab and produce stainless long products (LPs). One benefit of this option is that Obsidian would not compete directly with Tsingshan and Delong has already added LP rolling capacity in China. Unfortunately, LPs are also not exempt from China’s duties on Indonesian imports. However, there is a suggestion that if LP semis sent to China for rolling are then re-exported – and are not for sale in the Chinese market – they would not be subject to duties. “Focusing on LPs may be the most viable option for Obsidian if it is to sustain commercial activities beyond a short commissioning period. On the downside, the size of the LPs market is smaller and
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potentially unable to support its reported 1Mt annual capacity,” added Mitchell. Europe will confirm anti-dumping duties on hot rolled stainless imported from China, Taiwan and Indonesia in 2020, thereby removing much of the threat posed by exregion imports.
“Imports, chiefly from Southeast Asia and China, have taken a steadily increasing share of the European stainless steel market in recent years. Definitive safeguards put in place in 2019 eased that situation, but imports still accounted for around 30% of the regional market in 2019. This, in combination with weakening demand, led to European stainless melt output decreasing by 8% in 2019.
“We forecast Europe’s stainless melt production rate to recover in 2020, with growth of 7.5%, or 500kt, to 7.4 Mt. The ratification of anti-dumping duties on imported stainless HRC from China, Taiwan and Indonesia would aid this rebound. The investigation by the European Commission is due to finish in Q2 2020. If confirmed – which we expect will be the case – duties could be backdated to January 2020. Based on annualised trade data for January to October 2019, the new duties could reduce imports by 400kt. “With the European door closing, China’s stainless exports could fall by a further 250kt, having already declined by an average 700kt/yr since mid-2018. This will place more pressure on the country’s current oversupply in stainless, which is precipitating cuts this quarter. “Similarly, Taiwan will have to find new off-takes for 60-70kt or reduce domestic production by a similar amount. This comes at a time when mills in the region have already cut back their melting rates because they have imported substantial quantities of Indonesian slab instead. “In contrast, Indonesia was ramping up stainless shipments to Europe, possibly enabling Tsingshan Morowali to reach full capacity. The new duties would prevent this happening, leaving a big question mark over whether Tsingshan will be able to increase output at all,” said Mitchell. �
www.steeltimesint.com
25/02/2020 08:17:28
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INNOVATIONS
ISRA Vision AG, a company that started life 35 years ago under the leadership of CEO Enis Ersü has reached a longterm and future-oriented succession agreement with Atlas Copco. The partnership provides a framework for ISRA Vision to continue to realise its visions for the future, to exploit market potential and continue the continuity of its business and pursue its growth strategy. Ersü, who is 67 years old this year, is convinced that Atlas Copco will enable ISRA to continue to pursue its growth path in the field of Surface Vision and
Atlas Copco – the perfect partner, says Ersü Chinese steelmaker selects Friedrich Kocks Chinese steelmaker Guangdong Shaoguan Iron & Steel Company, part of the Baosteel Group, has awarded Friedrich Kocks of Germany the contract to supply its third reducing and sizing block (RSB) – in this particular case the RSB 370++/4 in 5.0 design. This contract represents the third RSB for the Baosteel Group, but the second for Shaoguan.
The plan is to install the RSB into an existing 490kt/yr bar mill line as part of a plan to further expand and strengthen the company’s share in the SBQ sector for high quality engineering steels for the automotive industry. According to Kocks, the RSB 370++/4 in 5.0 design will produce straight bars in a range between 17 to 80mm with a very close tolerance level
on to the cooling bed. Each diameter within the complete finished size range can be rolled step less. This can be realised either by rolling a wide dimensional finished size range in very fine increments from the same entry cross-section only by roll gap adjustment within a billet gap (‘free-size rolling’) or by changing the set-up in the RSB within a maximum stand changing
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3D Machine Vision as well as ‘fill its innovation pipeline and continuously strengthen and expand its team. Currently, ISRA Vision employs 900 people at 25 sites around the world. Atlas Copco employees 37,000 people and has customers in more than 180 countries as well as a EUR 9 billion annual turnover. Ersü believes that Atlas Copco shares ISRA Vision’s future and innovation-oriented view as well as its strategy of diversification across various markets. In fact, Atlas has identified machine vision as a key technology and is planning to
develop a new Machine Vision division with ISRA Vision as its nucleus. “Our two segments, Surface Vision and Industrial Automation, as well as our global presence, offers enormous potential for growth and synergies with Atlas Copco’s business activities,” Ersü said.
ISRA Vision will continue to work from Darmstadt as an independent pillar within the Atlas Copco organisation and Ersü will oversee the integration process to ensure a smooth transition. ISRA’s plans for a new building in Darmstadt will continue and staff will move in some time in 2021.
For further information, log on to www.isravision.com
cks time of four minutes. The RSB 5.0 will be located as a finishing unit after the roughing and intermediate mill, consisting of 20 stands in H/V arrangement. A roll shop for offline stand and guide preparation as well as supervision for erection and commissioning will also be handled by Kocks. The start-up for the new RSB is scheduled for 2021.
kocks.de
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INNOVATIONS
Panduit’s push-button safety solution Established in the USA in 1955, Panduit, a creator of leading-edge physical, electrical, and network infrastructure solutions, has introduced VeriSafe, an absence of voltage tester (AVT) that is designed to minimise the risk of electrical hazards by verifying the absence of voltage before electrical equipment is accessed. According to the company, VeriSafe automates the standard multi-step testing process in around 10 seconds, with highly visible indicator lights. The job is done in a fraction of the time normally required to test for zero voltage using portable test instruments. Panduit believes that electrical safety has increased in importance for work environments where uptime is crucial and balancing safety and productivity has remained a key challenge. With the VeriSafe system, electrical safety
is achieved in both 3- and 1-phase applications with 50 or 60 Hz and up to 600 V. The company claims that the test system can be easily mounted and
integrated into EMC-compliant equipment housing. The system is compliant with European and American safety standards.
For further information, log on to www.panduit.com
Celsa wants SMS group for plant revamp Spanish steelmaker CELSA Barcelona has contracted SMS group to revamp its section mill at the plant in Castellbisbal in Catalonia. CELSA Group operates various steel production facilities. At Castellbisbal, the company has been active since 1967. Today, the facilities comprise an EAF meltshop, a bar rolling mill, a wire rod mill and a medium-section mill. Annual production totals 2.4Mt. CELSA Barcelona has been producing I and H beams on a medium-section mill supplied by SMS group for the past 20 years. The mill was originally designed for an annual production of 500kt/yr. SMS group first expanded the initial range of products rollable on the mill during a revamp in 2007. Continuous plant
optimisation in co-operation with SMS group has raised the mill’s annual capacity to 1Mt/yr since then. The recent contract covers the replacement of an existing cooling bed with a new, higher-capacity one and an upgrade of the facility’s compact roller straightener (CRS) making it capable of straightening heavier products. These measures will require adjustments to and upgrades of the existing electrical and automation systems, all of which will be performed by SMS group. The new cooling bed comes with an aerosol cooling system designed to boost cooling efficiency and, therefore, the mill’s productivity. Another special feature of the new cooling bed will be a turning device, which is designed to turn I and H beams through 90 degrees into or out of the upright position. This device will further increase the throughput rate of these
products. According to SMS group, the planned revamp will enable CELSA Barcelona to add HEA and HEB up to 600 to its portfolio and further enhance its production efficiency. Prior to placing this modernisation order, CELSA Barcelona contracted SMS group with a study to determine the amount of investment needed to add the new product sizes, and gave SMS Concast the order to add a further strand to the plant’s continuous casting machine to enable the casting of heavier beam blanks for the larger cross-sections to be rolled in future. That project was completed at the end of 2019. The work on the straightening machine will take place during the 2020 summer break. The new cooling bed will be installed and commissioned during the summer shutdown of 2021.
For further information, log on to www.sms-group.com
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New attachment boosts productivity, says Brokk Brokk, a leading global manufacturer of remote-controlled demolition machines, is now offering the BCP Planer Attachment for controlled material removal on walls, floors and ceilings for cleaning, renovation and restoration applications. According to Brokk, the three models in the BCP series are specially designed to work with Brokk remote-control demolition machines and offer up to seven times the speed of hand-held options while providing greater precision and safety for grinding, brushing or removing concrete, glue, carpet, tile and other materials. Hood and
vacuum connections are available, enabling operation in contaminated environments such as asbestos and nuclear applications. Lars Lindgren, president of Brokk Inc, said that BCP Planer means that cus-
For further information, log on to www.brokk.com
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tomers can tackle more jobs in more industries with confidence. He added that the attachment streamlines removal applications by eliminating the need for bulky scaffolding and additional manpower. Lindgren said that the BCP Planer attachment offered a degree of precision that handheld options can’t
match. “Our industry continues to prioritise safer, more efficient options, and Brokk remains at the forefront with innovations that allow contractors to work smarter – and safer – not harder,” he said. The BCP Planer offers contractors a new option for fast removal of deteriorated or contaminated concrete, adhesives or other materials in a number of applications and provides high-quality, even removal across a wide area, unlike handheld options which often provide uneven results. A selection of cutting drums for different operations further increases versatility with drum replacement taking less than five minutes, enabling contractors to switch quickly from removing concrete to removing plaster, glue and Asbestos. The BCP Planer is fully remote controlled from the Brokk control box and comes in three sizes designed for specific Brokk models.
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INNOVATIONS
Ametek gets closer to its customers
Yamina Lansari
Satoshi Suzuki
For further information, log on to www.ameteksurfacevision.com
Paul Stuyt
Franรงois Levac
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AMETEK Surface Vision, a leading provider of automated online surface inspection solutions, has reorganised its sales, support and application expertise in order to be closer to customers in 2020. Dedicated business regions in the Americas, Europe, and Asia will become the primary regional gateways for Surface Vision to support users of the SmartView® and SmartAdvisor® surface inspection and monitoring solutions. According to Ametek, ‘by offering easy access to local sales and project teams, service requirements, technical support and application engineering, Surface Vision will respond quickly and decisively to all its customers.’ The company claims that Surface Vision can fully support customers through the entire lifecycle of their assets by drawing on the expertise of its regional teams and extending the pool of technical and applications knowledge embedded in its global business. François Levac and Satoshi Suzuki have been promoted to the roles of Americas business director and Asia business director, respectively. They will be responsible for developing all customer-facing functions regionally. Their familiarity with customers — combined with their technical and application knowledge — will help them develop sales and support functions best suited to local customer requirements. Paul Stuyt and Yamina Lansari have been appointed global manager of projects and service, and global manager of technical services, respectively. Paul will develop new processes to improve the co-ordination and delivery of special projects and service requirements; Yamina will manage technical support teams, improving their accessibility and responsiveness. Ametek Surface Vision’s divisional vice president of sales and project management, Jason Zyglis, commented that customers in every region will see significant improvements in how they access and are supported by the company. “Our mission is to be the customer’s primary choice as the trusted supplier of surface inspection technologies, building long-lasting relationships that bring direct and measurable benefits to their processes and productivity.”
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Chinese steelmaker takes on Primetals Technologies China Steel Machinery Company (CSMC), a subsidiary of theTaiwanese steel producer China Steel Corporation (CSC) has placed an order with Primetals Technologies to supply staves for CSC´s blast furnace 2 at the company´s Kaohsiung plant. The new staves are part of the third rebuild of blast furnace 2. The aim is to extend the lifetime of the furnace by a further 18 years. In future, five out of six blast furnaces operated by CSC and their subsidiary Dragon Steel will operate with equipment from Primetals Technologies. Final delivery is expected for end June 2020. Blast furnace 2 has a hearth diameter of 12 metres and an inner volume of approximately 3,300 cubic metres. Average production is 6,900 metric tons/day. The third rebuild of blast furnace 2 includes a complete shell and cooling system replacement. The cooling system will be a combination of copper and castiron staves from hearth to upper stack. Primetals Technologies was contracted to
supply nine rows of cast-iron staves. The installation of the new staves is scheduled to take place during a planned shutdown period some time this year. Blow-in of the rebuilt furnace is expected for early 2021. CSC is a leading steel producer in Taiwan with an annual production of around 10Mmt/yr. Around two thirds of production is for the domestic Taiwanese market, the rest is exported. CSC produces a range of products including plates, bars, wire rods, hot and cold rolled coils, electrogalvanised coils, electrical steel coils, hot-dip galvanised coils, and Ti/Ni-base alloy. The CSC plant in Kaohsiung includes two BOF shops with a total of seven twostrand slab casters and three four-strand bloom casters. The slab casters mainly produce carbon and low-alloy steels. In addition to supplying BF equipment, Primetals Technologies recently upgraded a continuous slab caster at CSC´s Kaohsiung plant.
For further information, log on to www.primetals.com Digital Edition - February 2020
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EVRAZ orders QSP-DUE technology from Danieli
For further information, log on to www.danieli.com Russian steelmaker EVRAZ has ordered a QSP-DUE (Danieli Universal Endless) plant for the production of high value-added products at its Novokuznetsk plant in the Kemerovo region of Russia. The order follows the start-up of the first ever DUE plant, which was installed at Shougang Jingtang United I&S, in China last year. According to Danieli QSP-DUE technology features ‘an innovative and patented layout configuration, which allows in a single thinslab casting and rolling production line all the winning features that, up to now, have been developed using either coil-to-coil, semi-endless or endless rolling modes in separate rolling mills, while eliminating the limiting factors of each one of them.’ The Italian plant builder claims that QSP-DUE technology allows the plant operator to reach all the production niches of the flat-products market by applying the process that is best suited to each steel grade and product. The QSP-DUE plant for EVRAZ will be designed for a total capacity of 2.5Mt/yr
of hot rolled coils for strip from 0.80mm to 16mm thick and 950mm to 1,700 mm wide. The vertical-curved thin-slab caster features a 5.5m main radius, designed to operate with a slab thickness range from 100mm to 123mm, thanks to the application of dynamic soft reduction, and with a maximum casting speed of 6m/min, depending on the steel grade. A tunnel furnace, supplied by Danieli Centro Combustion, will provide a fundamental buffer function that increases flexibility between casting and rolling and provides the possibility of performing workroll changing as a background task, without affecting the operation of the caster and melt shop QSP-DUE technology separates mill stands into high reduction units and finishing units in order to enable dual step rolling. According to Danieli, the mill stands are designed to guarantee the ‘superb geometrical properties of the final product’ and are equipped with state-of-the-art technology for the utmost strip crown and profile control, bearing in mind that
these control functions also have to be operational under load conditions as required by the endless rolling process. The line is completed with a laminar cooling system, including power and normal units, and a coiling area consisting of a highspeed shear to cut the coil to length when working in endless mode, pinch rolls and down coilers. In addition to technological equipment, Danieli will also provide detailed equipment engineering, design solutions for equipment placement, construction of the main QSPDUE building, and auxiliary infrastructure facilities. Danieli says it will also supply a 310-tonne twin-station ladle furnace and a 310-tonne twin-tank vacuum degasser and associated auxiliary equipment, including fume and water treatment for the whole facility. Danieli Automation will provide complete process control from liquid steel to coils, including on-line instrumentation, medium and low voltage drives and control of auxiliary plants.
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Spanish steelmaker chooses ABB
ABB has installed ABB AbilityTM Asset Vista conditioning monitoring for metals at the CELSA III MBM mill in Barcelona, Spain, to help improve equipment reliability, prevent unplanned downtime, optimise maintenance and increase overall efficiency and productivity. The ABB ability-based application monitors the health of a variety of production assets, including automation, instrumentation, electrical, mechanical and/or process equipment. The company claims that it offers CELSA a complete overview of its production assets’ health, avoiding unnecessary maintenance, reducing exposure to hazardous areas and speeding repairs. “ABB’s digital solution will provide a comprehensive and continuous overview of asset performance, facilitating CELSA’s transition to a predictive maintenance model,” said Rafael Margarit,
ABB digital lead, metals, Europe. “Our deep domain knowledge, technical expertise and ability to combine operational technology (OT) with informational technology (IT) are just some of the reasons metals customers are looking to collaborate with ABB as part of their digital transformation.” ABB Ability Asset Vista conditioning monitoring for metals will initially collect real-time data on the condition of common equipment across CELSA’s bar mill including hydraulic units, lubrication devices, motors, drives and sensors. In the future, it can be scaled up to assess and evaluate the health of more complex, specialised assets and components to cater to changing business demands. The solution offers operations, automation and maintenance engineers an in-depth overview of the performance of plant equipment and systems.
Reports generated by the software are periodically sent to the customer, enabling CELSA to plan and schedule maintenance activities based on the actual condition of equipment and systems at the mill, helping to boost operational efficiency, increase uptime and reduce costs. “By moving to a predictive maintenance model, we aim to improve equipment reliability and reduce unplanned shutdowns in order to boost our overall efficiency,” said CELSA’s plant manager, Ramon Garriga. Garriga said that ABB’s condition monitoring solution was the ideal choice for CELSA because the software can be easily integrated with any DCS system and is flexible and scalable. “We look forward to leveraging ABB’s digital expertise, automation experience and end-to-end customer support to meet our digital transformation goals.”
For further information, log on to www.abb.com Digital Edition - February 2020
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00 26 INNOVATIONS
Edwards Vacuum introduces ELRi pump range Edwards Vacuum has developed the ELRi series of liquid ring pumps. Megha Ajmal, product manager for rough vacuum products, commented: “This product offers a range of features and benefits that will distinguish itself from other competitor pumps in the market. From the ability to optimise processes to save energy, ELRi complements the range of solutions we offer for the industrial and rough vacuum markets�. The technical features of the ELRi series are of central importance. The stainless steel impeller, endplates, liquid reservoir and heat exchanger, for example, make this pump highly resilient against corrosion and harsh process gases. The internal injection channels reduce the risk of leakage while the horizontal motor flange arrangement saves time on maintenance. Use of mechanical seals ensures reliable operation by preventing leaks as well as extending service intervals. There is also a compact noise-cancelling canopy protecting and extending the lifetime of the electronic components. The ELRi is equipped with two VSD. While the main one matches the speed of the pump to the vacuum level by adjusting its speed, the second regulates
water flow through the centrifugal pump according to the operating conditions in order to avoid risks of cavitation. A patented algorithm maintains harmony between the two VSDs ensuring optimal performance, Edwards claims. Furthermore, it is protected against automatic seizure, so users do not have to worry about pump failure after long periods of inactivity. The system’s integrated air logic controller enables the monitoring of important features and parameters of the pump, but also offers the option of set- point control, which allows users to have a vacuum pump that matches process demand and, therefore, saves
energy. While the ECOntrol box allows users to connect and control multiple ELRi pumps, the Icon Box enables smart monitoring and remote control ensures optimal servicing to get maximum uptime. Water consumption is reduced as the separator is only filled up when required. The ELRi series comes with a pumping capacity range of 750 tonnes to 1050m3/hr and covers a wide range of applications in the central vacuum, pharmaceutical, plastics, conveying and food applications. Manual and automatic modes of flushing allow operation in the dirtiest applications with minimal downtime.
For further information, log on to www.edwardsvacuum.com Digital Edition - February 2020
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Tenova, a Techint Group company, is a worldwide partner for innovative, reliable and sustainable solutions in the metals and mining industries. We work alongside our client-partners in metals and mining industries to design and develop innovative technologies and services that improve their business today and tomorrow as well. We are a team of more than three thousand forward-thinkers that share the long-standing principles of our Tenova S.p.A. Via Gerenzano, 58 21053 Castellanza, VA - Italy tenova@tenova.com www.tenova.com
industrial group and understand our partners’ needs. We are professionals who take a proactive approach to problem solving in every business area in which we operate, and are forever seeking new, cost- and energy-efficient ways to resolve the challenges our clients are facing.
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New stuff from Hubtex at LogiMat 2020 Hubtex will present numerous vehicles for handling long goods as well as heavy and bulky loads at the LogiMAT exhibition in Stuttgart (Messe Stuttgart, 10-12 March). In addition to the expanded PhoeniX modular system, Hubtex is presenting its new RoxX heavy-duty compact forklift, signalling a return to the compact forklift market. The company is now focused systematically on the electric drive. According to Hubtex, the RoxX offers a significantly more compact alternative to the classic heavy-duty front loader and enables efficient handling of loads between 8 and 30 tonnes even in confined spaces. LogiMAT will also showcase products from the FluX series, offering not only the 7, 4 and 3 tonne variants, but also a more compact vehicle for goods up to 2 t. Hubtex claims it has the perfect vehicle for every transport task and that by offering a wide range of multi-directional trucks, the specialist in conveyor technology and logistics enables all loads to be transported safely – even long, bulky and heavy loads. The RoxX range, claims Hubtex, offers a robust and manoeuvrable alternative to front loaders. RoxX
equipment has been developed in collaboration with Dimos and the aim was to reintroduce compact forklifts to the Hubtex portfolio – but this time a version running solely on electric power. The new RoxX is claimed to enable efficient handling of loads between eight and 30 tonnes, even in the smallest of spaces. This is because RoxX equipment is claimed to be ‘significantly more compact than classic front-lifts’as well as 20% shorter and up to 25% narrower. Different steering systems are also available, according to Hubtex. The patented single-wheel steering reduces the turning circle by 50%. A lifting mast is available in three versions and is claimed to move loads safely and reliably. The driver always has an optimal view of the goods being transported, says the company, adding that the purely electric drive means greater energy-efficiency, low-maintenance and quiet operation of what is essentially a heavy-duty compact truck. The FluX 20 electric multi-directional counterbalance forklift truck belongs to the FluX series with its flagship product, the FluX 70, designed to handle loads up to seven tonnes. It operates in a load range of up to two tonnes and boasts a shorter frame length of 1740mm. A patented HX steering system is integrated ‘as standard’ and offers impressive manoevrabiity according to Hubtex. “The driver is able to change quickly from longitudinal to transverse travel without stopping,” claims the company and also boasts a powerful 48-volt drive allowing the vehicle to reach top speeds of up to 12km/hr.
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For further information, log on to www.hubtex.com
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Ametek secures ISO certifications
For further information, log on Temperature measurement and combustion monitoring specialist Ametek Land has secured two certifications to ISO 14001:2015 Environmental Management Systems and ISO 45001:2018 Occupational Health and Safety Management Systems standards. The company started working towards the new certifications 12 months ago, as both complement its current ISO 9001:2015 Quality Manager Systems standard and would put the business in a stronger position when tendering for international contracts. Alan Tarry, the company’s division vice president (operations) commented: “We’re delighted to have secured these two new certifications, which
demonstrate the hard work and dedication of our teams in our UK business. Achieving these standards gives a clear indication that we are committed to both operating sustainably through the use of resources and recycling, as well as with the strongest focus on health and safety. “It is very positive to see strong participation across all functions with regards to both safety and environmental management and the increased awareness levels and engagement of our employees.” AMETEK Land worked alongside health, safety, environmental and quality consultancy HSEQSmart, which provided support throughout the
accreditation process, to ensure the company was ready for the first and second stage audits that took place in August and December last year. AMETEK Land achieved the certifications within a 12-month period. The certification confirms that AMETEK Land — its leadership team and its employees — is committed to the overall safety of both in-house and external processes, products and instrumentation. The company is committed to the well-being and training of its employees and customers, while striving to manage the overall environmental impact of the business. Paul Coates, the company’s environment, health and safety manager
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log on to www.ametek-land.com commented: “Environment, health, and safety issues are everyone’s concern within the business, and this is now made evident through these certifications.” AMETEK Land set up a Health & Safety Environmental Continuous Improvement Group within its business, consisting of 12 people across all departments. Any issues or concerns are shared with the group, which uses best practices to reach an effective solution that is disseminated throughout the business. The company claims it is committed to helping its customers meet their environmental commitments. One of its latest innovations, is the FGA, a www.steeltimesint.com
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multi-gas analyser that provides an accurate, reliable measurement of carbon monoxide, nitric oxide, and oxygen in flue gases. The FGA calculates values for combustion efficiency, NOx, and carbon dioxide, allowing for better process control, reduced fuel costs and optimum emissions within compliance levels. ISO 14001:2015 is a certified management system for organisations that want to enhance their environmental performance. AMETEK Land has introduced a target of a 5% reduction of electricity and gas usage over the next 12 months and targets for reducing general waste, particularly plastic, with the company recently converting
to recyclable cardboard across all its packaging. ISO 45001:2018 is a certified management system for organisations that want to improve occupational health and safety, eliminate hazards and minimise risks; its key components include business and operational policies, the context of the organisation, leadership commitment, operational monitoring, and improvement, plus overall performance evaluation. AMETEK Land invested in HSE training for all of its 100 + employees, including directors, operations personnel, administrative staff and external service engineers. – involving around 105 employees in total. Digital Edition - February 2020
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Into the future Konecranes highlights the latest technological refinements made to its range of lift trucks. The new, specially-designed top-pick spreader has given impressive abilities to the full range of Konecranes reach stackers for standard container handling. All three rows have one metric ton of additional capacity each, with a fully-laden maximum of 46 tons in the first row. The heavy-duty SMV 4646 TCX5 allows 46 tons on all three rows. According to Konecranes, every one of these reach stackers adds strength and flexibility to meeting the needs of specific operating conditions. Higher capacity leads to higher productivity, says the company, as bigger loads can be moved in less time. Low-ceiling warehouses Some customers need lift trucks for lowceiling warehouses. To address this directly, Konecranes has added a triplex mast and free-lift option to empty container handler model SMV 6/7 ECC 100DS. With this new feature, customers can use the same lift truck to move containers both inside and outside a storage building. The truck has a total lifting height of 7,650mm,
allowing stacks up to seven containers high out in the yard, and free-lift means container handling is manageable indoors, keeping the total mast height under set limits. The Smart Lift feature uses lasers to automatically select lifting height based on container size and stack position. For lighter loads According to Konecranes, the Liftace range of forklifts are renowned for its productivity, easy-to-use features and small turning radius for tight maneuverability. The latest addition to the range includes two new models with a load centre of 600mm: the F10-600 C for 10 tons and the F12-600C for 12 tons. Designed for extra visibility, easy maintenance and low fuel consumption, the Liftace product family is claimed to offer a durable lifting solution for operating areas with low-weight requirements and limited space. Flow drive leads Ecolifting Lift trucks with Ecolifting features are still relatively new to the market, says Konecranes. According to the company, they are making an impression as customers move towards more eco-efficient equipment. Power Drive, the first Ecolifting feature, reduces CO2, fuel consumption and costs
Konecranes reach stackers
by up to 15%. Flow Drive, the second, does the same thing up to 25%. Hybrid Drive, the third, gives reductions of up to 40%. Currently, the most popular feature is Flow Drive, with its hydromechanical variable transmission and unique engine compartment design. Five reach stackers with Flow Drive were shipped to Australia this year, with more orders in the book to locations in the Netherlands and Thailand. “From the very start, Konecranes Lift Trucks has always invested in research and development, and we continue to do so today,” says Patrik Lundbäck, director and head of sales and distribution at Konecranes Lift Trucks. “Technology never stops advancing. New products and upgrades improve the safety, productivity and cost- effectiveness of our equipment. Our aim with this new technology is to give every one of our customers exactly what they need for their own particular set of circumstances – in other words, for their own worlds.”
Konecranes empty container handle
Konecranes Liftace forklift
For further information, log on to www.konecranes.com Innovations.indd 16
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Improving quality monitoring AMETEK Surface Vision, a world leader in surface inspection technologies, recently delivered a state-of-the-art defect detection system to a Canadian steelmaker
A
A. Installation of SmartView surface inspection system at Samuel Nelson Steel, Stoney Creek, Ontario, Canada; visualisation of defect enabled by SmartView side light technology; B. 2x lamination visualisations, highlighting
Samuel Nelson Steel of Stoney Creek, Ontario, Canada, is the proud owner of what Ametek Surface Vision is calling a ‘state-of-the-art’ defect detection system. The steelmaker wanted a solution for monitoring defects on its push-pull pickling line, which is used to process hot band carbon steel. The company processes steel coils provided by third-party steel suppliers, so it was important to be able to identify incoming defects and their location within each coil. The overall aim was to gain the ability to produce simple, one-page reports for customers summarising the surface quality for each coil pickled. Moving from visual to automated inspection Previously, Samuel Nelson Steel monitored quality through visual inspection, depending on its operators to inspect the strip and identify defects. Not only was this time consuming, but it also meant that only gross defects and issues visible to the human eye were detected, mostly on the top surface since the bottom is challenging to properly inspect. In addition, operators were not able to devote 100% of their time to coil inspection, so defects were missed. According to Ametek, while customers were generally happy with the quality of the steel pickled by Samuel Nelson Steel, a common response in satisfaction surveys was that they would value an automated inspection system. Ralph Benincasa, general manager at Samuel Nelson Steel, commented: “Within the marketplace, there are competitors that have similar systems, so that forced us to look at our situation.
defect areas of overlapping material of various shapes and sizes, irregularly distributed over the surface of the rolled material and often only partially bonded to the underlying surface.
B
“We spoke to several steel processors with existing automated inspection systems, as well as some of our customers who were also investigating surface inspection. We worked with them to understand what they were looking for, noting all the pros and cons. The company ended up selecting AMETEK Surface Vision’s SmartView® system because it was happy with the clarity of the images, the classification accuracy of the defects, and the fact that the side light location was less likely to be hit by strip. “Overall, we liked the capabilities AMETEK Surface Vision provided compared to some of the competitor systems,” Benincasa said. One of the key capabilities that Samuel Nelson Steel required was the side light technology used in the SmartView solution. This creates a 3D effect that enhances the defect and helps show depth. Benincasa said: “The additional insight provided by the system is really helping us accurately identify defects”. The system has met Samuel Nelson Steel’s expectations, delivering several benefits to the steel production process. Operators are now able to spend more time processing as opposed to
B
B
having to visually inspect the steel surface, thus improving productivity. In addition, it has helped reduce customer rejections and non-conformances. The company has received positive feedback from customers on the accuracy and detail they have been able to provide regarding coil quality. “For example, we are able to provide additional detail on non-conforming coil tags – we can see exactly where in the coil, in terms of length and how far in from the edge, the defect exists,” Benincasa said. AMETEK Surface Vision provided training for key Samuel Nelson Steel personnel. “We now have a few people that know the system very well,” Benincasa said. “The system is always learning so it’s up to us to make sure that we continue updating and working with the classifier to provide the latest images that we’re seeing and identifying. “Everybody that uses an automated surface inspection system says you have to devote the personnel and necessary time to get the maximum benefit from the technology. We have been fortunate that we have been doing that.”
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Anchors have several functions. They hold the refractory to the wall to keep it from falling in. They also prevent wall buckling due to the internal thermal stresses created by high temperatures. And, to a lesser degree, anchors can also help support the load of the refractory weight. To create a monolithic refractory lining that is properly supported and maximises service life, here are three important metallic anchor tips you need to know. 1. Anchor types and service temperatures For refractory linings in which metallic anchor systems are used, refractory engineers and designers almost always use Class III austenitic stainless-steel anchors of various qualities. The typical grades of stainless steel used are AISI 304, 309, and 310. These contain chromium and nickel to provide the best corrosion resistance and ductility at high temperatures. For some applications in which temperatures are more extreme, and the use of ceramic tile anchors is not practical for various reasons, AISI 330 and even Inconel 601 is sometimes used. These anchors have higher nickel content for superior oxidation resistance and tensile strength at temperatures of 2000°F or higher. Inconel 601 gives the added advantage of good resistance to both carburisation and sulfidation in extreme applications. 2. Industry Best Anchor Practices Anchor sizing for a refractory lining depends on the refractory thickness and the number of components. Some designers use the practice of sizing the anchor height to be 75%-85% through the main dense castable or gunned lining. Other rules of thumb used in the industry dictate that the anchor tip should be no more than two inches from the hot face of the refractory for thicker lining designs greater than six to seven inches. For refractory applications, it is useful to know the temperature gradient through the refractory lining, from the hot face to the cold face, to choose the proper anchor size so that one doesn’t Digital Edition - February 2020
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How to prevent lining failures Up to 40% of refractory lining failures can be attributed to a problem with the design of the anchor system or improper installation. This is a significant number. When designing a refractory lining for an industrial application, anchor design becomes one of the most important factors in creating a robust lining that is supported properly. In particular, the tips of the anchors experience the highest temperatures because they are closest to the hot face and thus become an important consideration. By Dan Szynal*
* Vice president of engineering and technical service, the Plibrico Company
exceed the temperature limit of the alloy being used. To help calculate the correct temperatures at different points in the refractory lining, many industry professionals will use a heat loss calculator/estimator. Using a heat loss calculator/estimator, one can choose the proper anchor height by determining the anchor tip temperature it will experience. There are numerous heat loss applications that can estimate the cold face of a furnace lining given the input conditions of a thermal unit. As part of its value-added service as a refractory solutions provider, Plibrico Company, LLC, has a web-based heat loss application that gives a good estimation of the
thermal gradient of the refractory lining from hot face to cold face to maximise the anchor thermal performance. For example, look at Fig.2. You can see a 9in side wall of refractory lining using 6in of a typical 60% alumina low-cement castable and 3in of 2300°F lightweight insulating castable for an application operating at 2000°F with an ambient temperature of 80°F. For this application, we would select 309 SS or 310SS metallic anchors because the intermediate temperature at about 80% of the main lining thickness is at about 1900°F. Although 304 SS anchors would be more cost effective and are most commonly used in the www.steeltimesint.com
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INNOVATIONS
Anchor Type
Service Limit (째F)
Mild Steel
800
304 SS
1700
309 SS
1850
310 SS
2000
330 SS
2100
Inconel 601
2200
Fig.1 Recommended anchor tip temperature limits for various common alloys
Typical stud + Vee anchor arrangement
Cold face (210째F)
Hot face (2000째F)
Critical anchor tip temperature (<1850째F for 309 S.S.)
Fig.2 Typical refractory anchor lining configuration
industry, the anchor tips would oxidise at this temperature and would essentially burn out. A word on anchor tips Standard practice for years now has been to allow for expansion of the anchor tines by covering the anchor tips with plastic caps, dipping them in a wax, or putting tape on them. Metallic anchors expand at about three times the rate of alumino-silicate refractories. The expansion material affixed to the anchor tips burns out at low tempera-
ture and allows the anchor a space to expand without causing cracks in the refractory. Best practices in metallic anchor design must also include anchor spacing. Refractory engineers must consider the specific installation area, which is largely influenced by the specific equipment and geometry size. For example, anchor spacing patterns will be different in a flat wall or roof, as compared to a section that has a transition of geometry or a less critical area of a vessel. Anchor spacing should be based on
the features of each specific project, such as the mechanical properties of the anchor, and the refractory lining as a function of the temperature. Refractory engineers will use these properties in mathematical models to help create the optimal anchor spacing pattern and plan. Often, failures commonly attributed to the refractory component can, in fact, be caused by deficiencies in the anchoring system. A robust anchoring system is key to maintaining monolithic refractory lining integrity, even when it is cracked, to prevent a total structural collapse. To prevent vessel lining failures, increase service life, and maximise refractory performance, incorporate these metallic anchor tips. With these tips, it is possible to design and optimise an anchoring system that will work well with the demanding needs of refractory linings today.
For further information, log on to www.plibrico.com www.steeltimesint.com
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The Future Steel Forum 2020 has landed! LEADING GLOBAL STEELMAKERS ARE SPEAKING: • Big River Steel • Emirates Steel • POSCO • Tata Steel India • Liberty Steel Group • ArcelorMittal Global R&D • Metinvest Digital • Kobe Steel • Badische Stahl-Engineering • Buderus Stahl Plus leading steel trade associations, academics and plant builders To register, visit https://www.futuresteelforum.com
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ENVIRONMENT
Ultrasound for energy conservation For plants using steam or compressed air in their processes, the energy waste due to leaks can be significant. Oliver Pogmore* explains how ultrasonic detection techniques can help to reduce this waste, improve reliability and save money. COMPRESSED air and steam are embedded in steel manufacturing processes, from cast cooling and blast furnace blowers to heaters and turbines. Leakages are common and can be caused by a range of problems typical to any plant, such as pipework corrosion or vibration. But the result is the same. The compressor runs less efficiently, more pressure is placed
on the motor running it, so more energy is needed to maintain continuous production. Because these leaks are generally small in nature, they can be difficult to detect and easy to overlook. But over the course of a year they can cost companies tens, if not hundreds, of thousands of pounds. To ignore them is to ignore the potential
for quick-win operational efficiencies, improved safety, extended equipment lifespan and long term cost savings. In a typical plant that has not been wellmaintained, the air leak rate may equate to between 20% and 30% of total compressed air production capacity. The financial impact of these leaks can accrue significantly over time.
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One US company recorded
more than $56,000 savings in the course of just a few months after identifying and remedying compressed gas leaks, with the cost of those repairs amounting to little over $7,000.
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ENVIRONMENT
As one example, based on 100psi, at a cost of £7/million per m³ for one year (8,760 hours), a leak as small as 0.16cm can cost £846 annually. By doubling this to 0.32cm, the cost jumps to £2,721 annually. That’s just for one leak – imagine if a plant had 10 leaks, or 50 leaks? This really is not an uncommon situation. In addition to being a source of wasted energy, air leaks cause a drop in system pressure, which can make air tools function less efficiently, adversely affecting production. By forcing the equipment to run longer, leaks shorten the life of almost all system equipment, including the compressor package itself. Increased running time can also lead to additional maintenance requirements and more frequent unscheduled downtime. Steam leaks Steam leaks are typically found at valve stems, pressure regulators, connection flanges and pipe joints. If ignored, they can contribute to a drop in system pressure, resulting in heat loss and lower operating efficiency. At a pressure of seven bar (100psi), a cavity measuring just 3mm can cause the loss of 25,000 kg of steam per annum. Multiplying this by a typical steam production cost of £5.30 per kilogram would incur a loss of £132 a year. Considering that leaks are often not limited to one point of emission gives some measure of the potential for significant annual costs across a plant. Ultrasonic detection techniques Detecting leaks by normal visual or audible methods can be ineffective, especially when they are small and set in the context of a noisy plant environment. Ultrasound circumvents both these barriers to pinpoint emissions and prevent small leaks from turning into big financial losses. During a leak, liquid or air moves from a high pressure to a low pressure and as it passes through the leak site, a turbulent flow is generated. This turbulence has strong ultrasonic components and typically the larger the leak, the greater the ultrasound level. Ultrasound is a high frequency, short wave signal and the intensity of the ultrasound produced by a leak drops off rapidly as the sound moves away from its source. The sound will, therefore, be loudest at the leak site. Both steam and Digital Edition - February 2020
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air leaks can be located, via both the atmosphere and solid surfaces, using a simple hand-held portable ultrasonic detector. This electronically translates ultrasound frequencies down into the audible range, where they are heard through headphones and observed as intensity and/or decibel (dB) levels on a display panel. The more advanced digital instruments contain onboard sound recording to capture sound samples for spectral analysis, providing both visual and audible reporting. They are connected to data management software, so the logged data can be downloaded to a computer for analysis. The benefits of ultrasound Energy efficiency should be a key focus for any company keeping a close eye on both the bottom line and its commitment to the International Standards Organisation (ISO) 50001 standard for energy management systems. Unidentified leaks can be their silent enemy, nudging up energy use imperceptibly by reducing the efficacy of equipment, while at the same time diminishing its reliability and adding to the risk of unscheduled downtime and generating avoidable maintenance costs. Ultrasound roots these bad actors out. Because the high frequency ultrasonic components of leakage sounds are extremely short wave in nature, and a short wave signal tends to be fairly directional and localised, it is easy to separate them from background plant noises and detect their precise location. This directional element also means that subtle changes in mechanical equipment can be detected early, before a machine gets to the point of failure. Pre-emptive action can be taken at the first sign of a leak, meaning energy loss is kept to a minimum and the risk of unscheduled downtime is reduced. A comprehensive overview of operations is central to any effective condition-based maintenance programme. The visual and audible reporting offered by digital ultrasound allows for enhanced diagnostics and intelligent decision-making. Users are able to review test results, compare current data with baseline data and trend changes. The reports produced can be shared widely and speedily, promoting a more cohesive approach to a condition-based maintenance programme. The range of diagnostic and analytical
software tools offered by digital technology can also keep users informed of the savings generated through compressed gas surveys and steam surveys, so they can evidence their savings in energy and carbon gases – particularly pertinent to UK steel companies in light of the EU’s suspension on carbon trading allowances until the Brexit withdrawal agreement is finalised. One US company recorded more than $56,000 savings in the course of just a few months after identifying and remedying compressed gas leaks, with the cost of those repairs amounting to little over $7,000. Advances in ultrasound technology over the past decade mean it can be used as both a ‘stand-alone’ inspection method and as an effective CBM screening tool for bearings monitoring and other electrical and mechanical applications. What all have in common is ease of use, faster and more efficient reporting and greater insight into the condition of assets and what action is required to optimise their performance and reduce unnecessary expenditure. Perhaps the simplest analogy for the financial advantages this presents is that of fitting loft insulation in the home. The energy efficiency benefits may not be instantly obvious – but just a few months down the line the savings will be strongly in evidence. �
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ENVIRONMENT
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ROLLING
A solution for axial bearing positioning The Timken Company has developed a new version of its TDIK bearing (tapered double inner keyway) that utilises an integrated spring system. The bearing’s spring system is claimed to develop the appropriate axial force sufficient to seat the unloaded row. The company claims the design is suitable for new mills, to simplify their overall design, or for retrofitting existing mills. By Sorin Tudor*
THE primary purpose of the rolling mill is to reduce material thickness. A typical rolling mill could include only one stand, but generally includes several. These stands are usually arranged in a line to produce a sequential reduction in the thickness of the rolled products being manufactured. Fig.1 shows a cross-sectional arrangement of a four-high mill stand, where four-row tapered roller bearings are mounted on the roll necks of the back-up rolls (BUR) and work rolls (WR). Thrust tapered roller bearings also are used in a screw-down system to adjust the thickness of the rolled product. The left side of the mill stand in Fig.1 is connected to the drive unit. The WR end is machined for a coupling connection. The bearing housing floats freely in the window on this side. The right side of Fig.1 represents the mill operator’s side, on which the bearing housing is fixed in the frame. The path of the loads generated by the rolling process is pictured in the figure. The bearings are being subjected to very high radial loads and varying degrees of axial load. When the BUR or WR employs a fourrow cylindrical roller bearing (4CRB), a separate heavy-duty thrust bearing must be incorporated at the fixed side of the mill to support the external thrust loads inherent in the rolling mill process (Fig.2). This thrust bearing is often a spring-mounted two-row tapered roller bearing, type TDIK (tapered double inner keyway) assembly. On the floating side, the same thrust bearing can be used for continuity of design, but a lighter-duty locator bearing such as a deepgroove ball bearing also is suitable.
2. Axial bearing a) Standard TDIK assembly: Spring system incorporated into housing (traditional mill design). Fig. 2 shows a roll neck construction in which a 4-row CRB is mounted as a radial bearing and a TDIK is used to assure the thrust position. External springs are required to preload the TDIK’s cups axially in order to seat the unloaded row. Springs located in the housing keep the bearing outer rings clamped, regardless of the thrust direction. Because the bearing is loose-fit mounted, the inner rings are keyed onto the roll neck to prevent rotation and bore fretting. The outer rings are mounted with a large clearance of approximately 2–3 mm over the outer diameter to ensure that the bearing does not carry any radial load. The gap between the spring-loaded cup face and the housing is 0.15 mm to 0.30 mm on each side. b) Timken solution: TDIK with integrated spring system (simplified mill design) In most cases, when four-row tapered roller bearings are used, no additional axial positions are required (see Fig. 1). But in cases where the axial load is too high (such as when axial shifting or roll crossing systems are incorporated in the mill), an additional thrust bearing is needed to take this additional axial load. The thrust bearing prevents the radial bearing from absorbing the axial load. Fig. 3 shows a roll neck construction with four-row tapered roller bearings and the additional thrust TDIK bearing. The Timken Company has developed a version of the TDIK thrust bearing that
utilises an integrated spring system. The spring system’s purpose is similar to that presented in Fig. 2 (springs mounted in the housing). The bearing’s integrated spring system is designed to develop the correct amount of axial force to seat the unloaded row. This new bearing is appropriate both for assisting new mills in simplifying their overall design and for retrofitting existing mills. The integrated spring system design has two primary advantages compared to an externally preloaded TDIK mounting (traditional) design: 1. The surrounding mounting arrangement is simplified since springs are no longer required in either the housing shoulder or follower, which minimises the possibility of either losing or damaging the external springs needed for the standard TDIK assembly. 2. The spring requirements and assembly are handled by the bearing manufacturer (easier for mill builder to assemble). The design of a TDIK with an integrated spring system (exploded view) is pictured in Fig. 4. This construction includes one double cone assembly with rollers and cages (1) and two single cups (2). The double cone is typically keyed (3) to the roll neck on the outboard face. The keyways are located on both faces of the double cone so the bearing assembly can be reversed to extend its life if the roll thrust is predominantly in one direction during mill operation. While the keyways are normally located on the faces, bore keyways also can be provided. This design has no cup spacer. The spring system is composed of springs (4), piston rings (5) and retaining rings (6).
* Specialist application engineer – HI Primary Metals, EU customer engineering Digital Edition - February 2020
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ROLLING
g
Load path arrows
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Screw-down bearing
BUR
WR machined end for coupling connection
WR
Four-row tapered roller bearings
Operator side Drive side
Figure 1: Cross-sectional arrangement of a 4-high mill stand
4CRB
Spring system
2-3mm
TDIK
0.15-0.30mm Figure 2: Roll neck construction with 4CRB (radial) and TDIK thrust bearing
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ROLLING
3. CASE STUDY Standard TDIK assembly: Spring system incorporated into housing (traditional mill design). Spring calculation and selection procedure 3.1. PURPOSE The calculation and selection procedure for designs in which a spring system is incorporated into the housing (traditional mill design) is presented here, based on the following case study, which details the procedure in support of mill builders, who often ask about spring selection when designing new mills because of the close relationship between springs and bearings. This example illustrates the traditional mill design, but The Timken Company performs similar calculations in the case of TDIKs with integrated spring systems.
3.3. CALCULATION PROCEDURE a) Calculation of the desired spring force to seat the unloaded row 1. The accumulated mass (M, unit of measure Kg) of the cup that needs to be seated and the corresponding rollers and cage are calculated first: M = cup mass + roller mass + cage mass = 22 + 16 + 2 = 40 Kg The accumulated mass M (cup mass + roller mass + cage mass) should be assumed as a third part of the bearing mass (catalogue data) if the specific masses of the cup, roller and cage are unknown. 2. The weight force (W, unit of measure N) corresponding to the accumulated mass of the cup and corresponding rollers and cage is calculated next: W = M*9.81 = 40*9.81 = 392.4 [N] 3. The desired spring force (RSF, unit of measure N) is recommended to be 10 times higher than the weight force W previously calculated (a guideline based on practical experience in the field) and is calculated thus: RSF = W*10 = 10*392.4 = 3924 [N]
3.2. INPUT DATA In this case study, the BUR roll neck of a new 6HI aluminum mill is fitted with fourrow cylindrical roller bearings (600RX2643) mounted in the radial position, and a TDIK bearing (HM959740DW-HM959710) mounted in the axial position. A schematic drawing of the TDIK bearing is presented in Fig. 5. The bearing’s axial capacity is Ca90 = 522000 N.
b) Force developed by a selected spring (tensioned) Fu = K*Xn = 250 x 4.7 = 1175 [N]
A drawing of the BUR roll neck is presented in Fig. 6.
d) Total spring force The total spring force is calculated by multiplying the selected spring’s force by the number of springs: F = Fu*n = 1175*4 = 4700 [N]
A close-up view of the spring mounted in operation (Detail A) is presented in Fig. 7. The pre-selected spring has a stiffness of K = 250 N/mm. The loose spring length is L0 = 30 mm and the solid high spring length is LSH = 24 mm.
where K = spring stiffness = 250 N/mm and Xn = spring compression nominal distance. c) Determination of number of springs needed, n n = RSF/Fu = 3924/1175 = 3.3 Therefore, the designer would choose n = 4 springs.
e) Spring force vs. bearing axial Ca90 capacity ratio verification r = F/Ca90 = 4700/522000 = 0.9% (accepted since 0.9% < 2%) The spring force should be kept below 2% of Ca90 in order to avoid putting too much additional load on the seated row and decreasing the bearing’s L10 life.
Table below:
Design input data:
Design calculations:
Housing hole depth, LA: 36 mm
Spring nominal length, Ln = LA-LR-X2-LH=36-7-1.7-2 = 25.3 mm
Retaining ring length, LR: 7 mm
Spring compression nominal distance, Xn = L0-Ln = 30-25.3 = 4.7 mm
Spring compression tension distance, X2: 1.7 mm Piston ring head length, LH: 2 mm Axial gap between cup face and housing, LG: 0.3 mm
Verification to avoid fully compressed spring: Ln > LSH
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25.3 > 24 mm (verified)
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ROLLING
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TDIK with integrated spring system Integrated spring system
5
Figure 3: Roll neck with four-row tapered roller bearings and TDIK with integrated springs
springs (4), piston rings (5) and retaining rings (6) 1
3 4
5
6
2
Figure 4: Design of TDIK with integrated springs
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ROLLING
4. SUMMARY AND CONCLUSIONS The Timken Company has developed a new version of the TDIK that utilises an integrated spring system. The bearing’s spring system develops the appropriate axial force sufficient to seat the unloaded row. This design is suitable for new mills, to simplify their overall design, or for retrofitting existing mills. The new bearing design has two primary advantages over an externally preloaded TDIK mounting: 1. The surrounding mounting arrangement is simplified since springs are no longer required in either the housing shoulder or follower, which minimises the possibility of either losing or damaging the external springs needed for the standard TDIK assembly.
Figure 5: Schematic of TDIK HM959740DW-HM959710 bearing
Detail A
2. The spring requirements and assembly are handled by the bearing manufacturer (easier for mill builder to assemble). The spring system calculation and selection procedure has been presented in the case study in section 3. Spring calculation and selection are frequently requested by our customers for new mills− even in traditional roll neck designs where the spring system is incorporated into the housing − because the spring features influence bearing performance. The purpose of this article is to assist mill builders in the selection of the correct springs. � Figure 6: Schematic of BUR on new 6HI aluminum mill
5. ACKNOWLEDGMENTS The author would like to thank The Timken Company for permission to publish this study. 6. REFERENCES Vladimir B. Ginsburg and Robert Ballas, Flat Rolling Fundamentals (2000). Marcel Dekker, Inc., New York Timken Engineering Manual, Metals Industry Edition (2013). The Timken Company (Order No. 10688) Timken Metals Product Catalog (2014). The Timken Company (Order No. 10675).
Figure 7: Detail A, spring in operation
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PIONEERS AT HEART
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MATERIAL SOLUTIONS
High performance material solutions
At present, the automotive supply sector is the major market for bright steel products. However, due to the industrial upheaval currently taking place, the future development of bright steel is unclear, both in terms of quantities and production quality. With the technology described here, manufacturers as well as end users can benefit from a high degree of flexibility regarding batch sizes and the variety of materials that can be processed. By Alexander Borowikow1 (founder and CEO) Kristin Helas1, (head of technology development) Margarita D Bambach1, (head of materials development) Guido Olschewski2 (head of quality and development) and Linda Oberli2 (development engineer in product development)
1 GMT Ltd. (Association for Metallurgical Software- and Technology Development), Germany; 2 Steeltec AG, Switzerland Digital Edition - February 2020
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MATERIAL SOLUTIONS
The challenges of the steel industry ALTHOUGH steel is one of the most widely used materials today, the steel industry continues to face new challenges. New technologies emerge and demand on the used materials constantly increases. The automotive industry in particular faces dramatic changes related to the development of modern drive and material concepts. Moreover, steel producers also have to react to the very flexible demands of their customers, which is difficult to handle for large production facilities. In this context, small, flexible plants with a wide selection of materials can react faster to market dynamics. High Deformation Quenching and Tempering (HDQTÂŽ) technology represents an opportunity to produce a new quality level of common and new steel alloys as well as of high strength materials within a highly flexible, demand-oriented production process. Compared to conventionally treated steel products, the ultra-finegrained microstructure together with an outstanding combination of high strength and high toughness as well as tight geometric tolerances are the key advantages of the HDQT products. A broad field of applications The technology and plant development described below enables new property categories for a broad spectrum of bars of different steel alloy grades: structural steels, PHFP (precipitation-hardening ferritic-pearlitic) steels, martensitic grades, austenitic steels and complex special alloys. The HDQT plant, highly variable in terms of its dimensions and quality spectrum, yields a wide range of steel bar products for different application fields, such as mechanical bright steel processing and cold or hot bulk forming. In addition,
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HDQT technology offers a possibility for a product-specific tailoring of both the microstructure and the mechanical properties of conventional steel grades in order to best fit a certain application, such as chains, lashes, shackles, fasteners and couplings, transmission gears, U-bolts, stabilisers, springs, cardan shafts, safety locks, products in liftings, fork lifters, escalators, helicopters, safety and defense technology, medical, oil & gas, offshore and the aerospace sector. The concept of HDQT technology HDQT technology combines two basic components: an intensive forming step and a precise temperature control. A wide range of technological variants is made possible by the flexible process layout (see Fig. 1). Temperature control is performed in a flexible manner thus enabling a variety of heating and heat treatment cycles (see Fig. 2). Immediately after forming, the rod enters the adjacent outlet temperature guidance system where the required forming temperature is set over the rod cross-section by holding, reducing or increasing the temperature. Subsequently, intensive forming is performed for the targeted adjustment of the microstructure using the selected degree of deformation, temperature and other process parameters. Immediately after forming, the rod enters the adjacent outlet temperature guidance. At this point a thermal post-treatment or a controlled cooling of the bar takes place with the help of cooling or heating segments which can be arranged in a variable manner. In the subsequent tempering section, the microstructure of the bar can be tempered in an inductive heating system and cooled at air, similar to conventional tempering technology.
Fig. 1. A schematic overview of the HDQTÂŽ technology
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MATERIAL SOLUTIONS
The intensive forming step The heart of HDQT technology is a specially adapted intensive forming unit where the cross-section of the rod is reduced locally over the bar length within one pass in numerous incremental forming stages. This enables very high degrees of deformation of up to 70% and corresponding degrees of elongation λ of the rod up to 2.5 % within a single pass. The high-energy input into small areas of the workpiece leads to extreme grain refinement, which has been proven by light microscopic examinations (Fig. 3). Furthermore, a characteristic twisting of the grains occurs at the near surface region of the rod. The deformed core is entangled by the twisted case as in a network. This gradual microstructure leads to a significantly better resistance to different load conditions. At the same time, a high surface quality and tolerance accuracy over the diameter as well as ovalities of the bar of less than 0.5 % (targeting h9-tolerance after deformation) can be guaranteed. Depending on the technological concept, forming can be carried out in the ferritic, austenitic or super-cooled austenitic region. In order to realise low forming temperatures in the range 930 °F to 1300 °F and the resulting high forming strengths of the materials, the stand possesses a rigid construction designed for high deformation forces and moment loads. With a production capacity of 1 to 2.5 Mt/hr, the smallest stand size is used for forming rod material in the final dimension range from 0.71in to 1.57in. Larger units can achieve final diameters between 2.36in and 3.15in with up to 5Mt/hr with the corresponding capacity at the induction unit. Enhancing commercially available steels The described technology leads to a significant improvement of the properties of multiple existing steel grades. The latter has been proved by mechanical testing after processing on an industrial scale. The facility used for this purpose developed by the GMT company has been implemented at Steeltec AG, whose materials are sold under the trademark XTP® [2]. Here, utilising HDQT technology, the range of properties has already been significantly enhanced for more than 20 steels. Fig. 4 shows the achievable property ranges for known steel classes after HDQT processing compared to the mechanical properties of the same Digital Edition - February 2020
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Fig. 2. The flexibility in temperature management in combination with intensive forming (schematic)
Fig. 3. Extreme grain refinement through processing with the HDQT® and the XTP® technology [1] (* see Tab. 1)
steel grades after conventional forming. By extensive knowledge of the respective process conditions, a broad spectrum of mechanical properties can be adjusted to one and the same steel grade thus tailoring its material behaviour to a specific delivery condition. The potential of HDQT products Continuous efforts are being made to activate existing property reserves of steels and to convert them into specific products, e.g. quenched and tempered steels for automotive engineering with increased
toughness and fatigue strength values of at least 10 %. Based on the spectrum of their properties and the wide range of possible applications, the potential of the steels and special materials produced with the HDQT® technology is depicted in Fig. 5. By further processing of HDQT products – for example, by cold or semi-hot forging – the material potential may be further expanded. Thus, the strength/ toughness combination of PHFP steels is retained during subsequent semi-hot forming at temperatures below 1300 °F and notched bar impact work of up to www.steeltimesint.com
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MATERIAL SOLUTIONS
150 J at tensile strengths of around 115 ksi can be achieved. The extraordinary forming capacity of bainitic steels can also be exploited in the case of subsequent cold forming, e.g. for the manufacture of U-bolts. Furthermore, the HDQT process allows the setting of a specific pre-structure, for example, a ferritic-perlitic ultrafine grain for quenched and tempered steels, and the utilisation of the material's potential during subsequent thermal treatment, such as hot bending and quenching for springs and chains. HDQT processing of high strength materials HDQT technology is not only be used for the processing of steels, it can be applied successfully to non-ferrous high strength materials such as Nickel-base superalloys and Titanium alloys. Due to the small reduction ratios required here, a new HDQT processing scheme, including a reverse intensive forming step, has been developed. The bars can be reheated after each forming step and higher reduction ratios are thus made possible. First tests have been carried out successfully and promising results have already been achieved. Fig.6 shows the difference in the microstructure after forging a HDQT pre-formed and a conventionally hotrolled stock material of Ti-6Al-4V alloy for aerospace applications. There is a microstructure gradient observed through the cross-section of the conventionally hotrolled sample. This microstructure gradient is related to the non-homogeneous strain distribution as shown by Finite Element analysis. In contrast, HDQT-processed samples show a much more homogeneous microstructure throughout the specimen’s cross-section and it is refined significantly at both the core and at the surface area. More information on the HDQT forming of a Ti-6Al-4V to produce high performance components alloy may be found in [5]. Summary HDQT technology responds to the increasing demands on materials’ performance by revealing the hidden material potential while maintaining the highest quality standards. This technology is extremely flexible in terms of lot sizes and materials. Both conventional steels and speciality alloys with the highest demands can be processed successfully by simultaneously improving their mechanical www.steeltimesint.com
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Fig. 4. Expanding the mechanical properties of different steel grades via HDQT® treatment [3], modified from [4] (* see Tab. 1)
Steel grade DIN
Composition in wt%
C
Mn
Si
Cr
Mo
7MnB8
0.06-0.09
1.85-1.95
0.15-0.25
max. 0.20
max. 0.05
13MnSiCr7
max.0.18
max.2.20
max.0.80
Other
Sum max. 1.00
V, Ti, Al, B V
33MnCrB5-2 (cf. AISI 50B44) HSX130
0.30-0.36 1.20-1.50 max.0.40 0.30-0.60
B
ca.0.18 ca.1.60 ca.1.20 ca.1.20 ca.0.30
Table 1. Extract from the chemical analysis for selected steel grades [2]
Fig. 5.Enhanced mechanical properties after HDQT® processing and possible applications (* see Tab. 1)
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MATERIAL SOLUTIONS
Fig. 6. Titanium samples after upsetting: (a) true plastic strain distribution (FE-calculation) and light optical images of (b) conventionally hot-rolled and (c) HDQT® processed material [5]
behaviour. The room and low temperature toughness as well as strength may be increased.
In future, we will continue to develop HDQT technology in order to further enhance the mechanical properties of both
existing and new steel grades as well as other high strength alloys, and to broaden their application fields. �
Literature [1] Internal pictures of the Steeltec AG (2018). [2] Further information about the XTP® technology: www.xtp-technology.com/en. [3] Internal data of the Steeltec AG (2019). [4] Bleck, W., Bambach, M., Wirths, V.: Microalloyed Engineering Steels with Improved Performance. HSLA Steels 2015, Microalloying 2015 & Offshore Engineering Steels 2015. Springer, Cham. S. 97-107 (2016). [5] In Print: Bambach, M.D., Seifert, D., Sizova, I.: Intensive forming of Grade 5 Titanium bars with increased performance for aerospace applications. 23rd International Conference on Material Forming (ESAFORM 2020).
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ADD THE DATES TO YOUR DIARY
2-3 JUNE 2020
PRAGUE • CZECH REPUBLIC
DO YOU HAVE
2020 VISION?
The next Future Steel Forum conference will take place at the Grandior Hotel, Prague, Czech Republic, 2-3 June 2020 Now in its fourth successful year, the Future Steel Forum, established in 2017 by Matthew Moggridge, editor of Quartz Business Media’s Steel Times International, can confirm that the 2020 conference will include presentations from leading global players including an opening keynote presentation from Dave Stickler, CEO of Big River Steel of Osceola, Arkansas, USA, the world’s first ‘learning mill’ which relies heavily upon digital manufacturing and artificial intelligence technology supplied by SMS Digital and San Francisco-based noodle.ai who will also be making presentations. The Future Steel Forum 2020 will be hosting top flight speakers from ArcelorMittal, the world’s biggest steelmaker, Tata Steel India, Liberty Steel, Kobe Steel of Japan, South Korean steel giant POSCO, Metinvest Digital of Russia, Badische Stahlwerke and Buderus Edelstahl of Germany. In addition to steelmakers, the 2020 Forum will hear from leading academics in the field, steel industry associations, production technologists, plant builders and cyber security specialists. For further details on the Future Steel Forum 2020 and to register, visit www.futuresteelforum.com From the publishers of:
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PLANT MAINTENANCE
Improving bearing reliability Properly functioning bearings are key to ensuring the efficient running of plant machinery. But without appropriate maintenance they can also be one of the main causes of equipment malfunction and unscheduled downtime. Joshua Banks* explains how a proactive approach to bearing care can improve reliability and avoid unnecessary costs
Engineer using tablet 2
* Bearing protection manager, AESSEAL Digital Edition - February 2020
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PLANT MAINTENANCE
There are a number of reasons why bearings fail, but chief among them are particle contamination, inadequate lubrication and misalignment. Collectively, these cause almost three quarters of all bearing failures, but what is even more noteworthy is that it could be reduced significantly, simply by making judicious decisions about the maintenance approaches and sealing solutions being employed.
impediment to achieving an L10 life cycle. To give an indication of the impact even the smallest amount of contamination can have, research indicates that water contamination as low as 0.002% – that’s equivalent to a single drop of water in a typical bearings chamber – can reduce bearing life in some oils by as much as 48%.
Lubrication Lubrication is often the ‘poor relation’ of a condition-based maintenance (CBM) programme, treated as an afterthought, lumped in with other maintenance activities or, worse, not planned at all. Even where routine lubrication is carried out, data may not be captured and guidelines fail to specify what, how and when it should be used. Yet the condition of oil can tell you a lot about the condition of the equipment it is lubricating, and as such routine testing and analysis should be a fundamental part of any regular CBM programme. Contamination Contamination of the lubrication oil by dust particles or moisture is one of the most common and costly causes of premature bearing failure and presents a serious
and speed under ultra-clean conditions (nc = 1) can complete 15,250 operating hours. Introduce contaminated conditions where nc = 0.02 and the bearing’s operational life plummets to just 287 hours – a dramatic decrease in mean time between failure (MTBF). Contamination of the oil accounts for more than 20% of all bearing failures. It therefore stands to reason that, if you can solve this issue, you will have removed a major barrier to bearing reliability.
Joshua Banks
Misalignment According to design requirements, machine components are typically coincident, parallel or perpendicular during operation. Any deviation from this can cause equipment malfunction or failure. Misalignment between the shafts of a driver and the equipment it is coupled to, increases the stress on the shafts, leading to excessive wear. Breakdown is almost inevitable and bearing damage is a common by-product. When the cost of repairing or replacing bearings and other components is added to that of lost production, the importance of accurate alignment becomes ever more apparent.
In another example – an oil-lubricated 45 mm radial bearing running at constant load
Technology for reliability Bearing failure is such a common
Left: Bearing fitted with protector seal
Above: Bearing failure due to water ingress
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PLANT MAINTENANCE
occurrence that some engineers see it simply as a necessary evil to be factored into ongoing maintenance. Downtime is accepted as part of this process. However, advanced technology presents the opportunity to make a seismic shift away from a costly reactive maintenance approach. The single most common cause of bearing failure – contamination of the lubrication oil – can be all but eliminated by installing labyrinth-design bearing protector seals which prevent the ingress of dust or moisture into the bearing chamber. These replace commonly applied lip seals and incorporate dynamic lift technology to facilitate the ‘breathing cycle’ required by rotating equipment, while preventing the ingress of contaminants. The centrifugal force of rotating equipment is employed to open a temporary micro gap, allowing expansion of the oil air mixture in the bearing housing and letting the equipment ‘breathe’. When the equipment stops rotating, the micro gap immediately closes, forming a perfect seal against potential contaminants. The seals’ integral shut-off O-ring is made from a highly resilient elastomer material, which exhibits near-zero wear. They can be retrofitted, require minimal maintenance and will protect a bearing until it reaches the end of its natural lifespan – estimated
to be 12 years or more. With contamination no longer a threat, upgrading to a more efficient synthetic bearing lubrication oil becomes less a risky investment and more a common sense measure to optimise efficiency. Cloud-based CBM Advanced cloud-based technology has created an opportunity to introduce genuinely proactive, operator-driven CBM practices. Safety and business-critical assets can be managed online, employing highspeed wireless connections to collect diverse data, including vibration and oil analysis, which can be collected and consolidated on one platform from multiple locations, where it can be securely accessed from anywhere via a standard web browser. A key feature of this technology is its automated diagnostics, which can predict stage 2, 3 and 4 bearing failure and detect a wide range of other common fault conditions known to reduce reliability or halt production. Some systems on the market can present up to four potential points of failure, ranked in order of likelihood, and propose an action plan to tackle impending issues before they impact on operations. Common threats to bearing performance, such as poor lubrication or misalignment, can be pre-emptively remedied.
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The continuous availability of data provides a bedrock of in-depth knowledge on which to base an ongoing maintenance plan. Lubrication can be more effectively managed through the same platform to ensure the smooth functioning of equipment. Failure detection becomes woven into the daily fabric of a maintenance programme, decision-making is better informed, and assets can be maintained to ensure optimum productivity. Cost will understandably be a consideration for companies looking to secure a swift return on investment and it should be noted that this technology has become cheaper, even as its capabilities have become more sophisticated. It is scalable to any industrial plant and any maintenance team can use it, regardless of qualification. It is calculated that, for every £1 spent on ADA technology, at least £5 is saved in terms of time, expertise and hardware and software costs. Over a three-year period, such a system could increase uptime by 33%. Parts could be reduced by 23% and labour costs reduced by 16%. These operational and financial benefits make a compelling case for considering investing in automated solutions in order to make bearing failures the exception, not the rule. �
FaultDiagnosis
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LEADING GLOBAL STEELMAKERS SPEAKING INCLUDE:
Big River Steel Emirates Steel POSCO Tata Steel India Liberty Steel Group TMK ArcelorMittal Global R&D Metinvest Digital Kobe Steel Badische Stahl-Engineering Buderus Stahl
Plus leading steel trade associations, academics and plant builders
TOPICS INCLUDE
ARTIFICIAL INTELLIGENCE
SUSTAINABILITY
LOGISTI
Have you got 2020 vision? The 2020 Future Steel Forum will take place in the
of Big River Steel of Osceola, Arkansas, USA , opens
Czech capital of Prague at the Grandior Hotel, 2-3
Day One. Dave’s company epitomises the strong
June, and it promises to be a top flight event. What
and successful partnership that can exist between
makes the 2020 event so good? Well, it’s down to
a steelmaker and hi-tech digital manufacturing and
the speakers and the exhibitors and, ultimately, the
Industry 4.0-based technologies.
delegates, and this year the steel industry has taken the event under its wing as we have some major global players signed up to speak including our opening Keynote speakers. Dave Stickler, the CEO
Dave will be joined on stage by Prof. Dr. Ing. Katja Windt, a member of the management board of SMS group, and Stephen Pratt, founder and CEO of San Francisco-based Noodle.ai, an artificial intelligence
VISIT THE WEBSITE FOR MORE INFORMATION
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DA KE YN OP Y O OT EN NE E A IN – DD G RE SS
2-3 JUNE 2020 Grandior Hotel, Prague, Czech Republic
DA KE YN OP Y T OT EN WO E A IN – DD G RE SS
SPEAKERS INCLUDE
Dave Stickler, CEO, Big River Steel
Saeed Ghumran Al Remeithi, CEO, Emirates Steel
Katja Windt, member of the management board, SMS group
Stephen Pratt, founder and CEO, Noodle.ai
EXHIBITORS INCLUDE
PLANT SAFETY
CASE STUDIES
provider that together with SMS group and Dave’s in-house team, developed the world’s first ‘learning mill’. On Day Two, the conference will open with a Keynote address by Saeed Ghumran Al Remeithi, CEO of Emirates Steel, a leading steelmaker operating from the United Arab Emirates and a major and influential player in the global marketplace. Plenty of leading steelmakers will be speaking (see panel above left) alongside leading steel industry associations, research & development organisations, leading academics and steel production technology specialists. Register online now. Official Media Partner:
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TO FIND OUT MORE AND BE PART OF THE FUTURE, CONTACT: Matthew Moggridge Programme Director matthewmoggridge@quartzltd.com +44 1737 855151 Paul Rossage Sales Manager paulrossage@quartzltd.com +44 1737 855116
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HISTORY
The Moira blast furnace Completed in 1806 by Frances Rawdon Hastings â&#x20AC;&#x201C; Earl of Moira, the Moira (or Ashby) blast furnace was built to exploit local iron ore, coal and limestone, and has the convenient feature of a canal alongside the site for ease of transport of raw materials to the furnace and the iron produced to markets in the Midlands and South of England. By Tim Smith* The short-lived Moira blast furnace, looking towards the casting arch
MUSEUM OPENING TIMES
* Consulting editor, Steel Times International Digital Edition - February 2020
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HISTORY
THE Leicestershire village of Moira lies close to the industrial centres of Birmingham about 25 miles (40km) to the south-west – and Stoke-on-Trent about 35 miles (53km) to the north-west. Despite the proximity of raw materials and markets and the advantage of transport via the Ashby Canal – built at the same time as the furnace – operations were short-lived. This was put down to a combination of technical problems and poor management. Only two campaigns are recorded, one in 1806 and the other in 1811, each thought to produce about 500 tons of metal. Insufficient mines had been opened locally to supply the needs of the furnace and the local ore was in the form of small nodules, which tended to block the furnace and interfere with the passage of the air blast. The local coal also proved to be non-caking, requiring better quality coking coal to be purchased.
The canal too, proved unreliable. Frequent temporary closures of the northern end of the 30-mile (50km) waterway were necessary due to subsidence caused by coal mining, which mitigated against efficient operations. A double-acting steam-driven beam engine provided the air blast for the coke-fired furnace. The engine house was still standing into the 1970s, but was then demolished along with other associated buildings. The casting house survived for some time operating as a foundry containing a cupola furnace. The large charging house was converted into accommodation for miners and tradesmen following the cessation of operations. This has resulted in the preservation of the remains we see today which were renovated in 1982. The building now houses a small museum about the furnace. An excavation of the site in 1984 revealed
61
a rectangular pit between the blowing house and the furnace, thought to have been a water regulator, and water-filled chambers under the furnace believed to be for cooling the air blast – contrary to modern practice – a feature then believed to improve efficiency by increasing the density of the air blown into the charge. The furnace had two tuyeres. Samples of burden and cinder taken from the stack showed a high metallic iron content. Unreduced ore indicated poor slag formation. The Ashby canal, never in fact reached Ashby, and was bought by the Midland Railway in 1846 with the expectation that it would be drained and converted into a railway line. However, this did not happen and parts were in use until 1966. A 2km section running north past the furnace was reopened in 2000 and connects with the National Canal network. �
UM
Open weekends 4 April to 27 September 2020, 11am-4pm, and Saturdays to Thursdays during school holidays.
NG
www.moirafurnace.org, e-mail office@moirafurnace.org
ES
Address: Furnaces Lane, Moira DE12 6AT Tel 01283 224667
A quay on the Ashby Canal gave direct access to the charging house
One of two blowing arches
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