Steel Times International July August 2021 by Quartz Business Media

WELDING

INNOVATIONS

ARTIFICIAL INTELLIGENCE

PERSPECTIVES Q&A

Enhancing declining welding skills in the United Kingdom

The latest contracts and new products news

SAIL’s Indranil Banerjee examines the role of AI in steelmaking

We talk to Lee Zorn, Shell general manager, B2B direct sectors at Shell

Since 1866

www.steeltimesint.com July/August 2021 - Vol.45 No5

STEEL TIMES INTERNATIONAL – July/August 2021 – Vol.45 No5

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CONTENTS – JULY/AUGUST 2021

WELDING

INNOVATIONS

ARTIFICIAL INTELLIGENCE

PERSPECTIVES Q&A

Enhancing declining welding skills in the United Kingdom

The latest contracts and new products news

SAIL’s Indranil Banerjee examines the role of AI in steelmaking

We talk to Lee Zorn, Shell general manager, B2B direct sectors at Shell

Since 1866

2 Leader

www.steeltimesint.com July/August 2021 - Vol.45 No5

STEEL TIMES INTERNATIONAL – July/August 2021 – Vol.45 No5

Front cover: Recently commissioned SprayCooled™ EAF Roof at Industeel Belgium

4 News round-up The latest global news.

36 IMOA Swiss army knives still cut it.

11 USA update President Biden’s Transportation Bill.

39 AI in steelmaking SAIL on artificial intelligence.

15 Latin America update Mexico’s long steel market.

44 Oxygen in steelmaking Intelligent steelmaking.

19 India update Steel mills expand capacity.

49 Welding Declining standards in the UK.

23 China update China – carbon neutral by 2060?

54 Perspectives Q&A: Shell Lubricants Continuously innovating.

26 Innovations Contracts and products news.

56 History The Recitza ironworks in the 19 century.

SPRAY-COOLED

WILL CHINA BE CARBON NEUTRAL BY 2060?

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 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 £195.00 Other countries: £270.00 2 years subscription: UK £350.00 Other countries: £485.00 ) Single copy (inc postage): £45.00 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 2021

36 ISSN0143-7798

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Contents.indd 1

12/07/2021 06:17:02

LEADER

First, Hyundai Steel and now POSCO.

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

July/August 2021

leader.indd 1

Is it possible to make too big a deal of fatal industrial accidents? I don’t think so. In all honesty, I was flabbergasted when I read last month that South Korea’s national media had labelled Hyundai Steel’s Dangjin steel mill as ‘the plant of death’, and that’s why I berated the company’s management in last month’s digital issue of the magazine. Any steel mill that can be branded in such a way needs to take a serious look at itself. It’s all very well Hyundai Steel promoting the idea of upcycling coffee waste (see page 4) and arguing that 150kt of discarded coffee is buried or incinerated annually in South Korea. Well, perhaps they should wake up and smell the coffee instead. People have died. One of the dead was found near a furnace, another fell while engaged in welding work, and you may recall – if you read my Leader article last month – that ‘real workplace safety’ (at the Dangjin mill) is a long way away, according to the Korea Times. I sincerely hope that Hyundai’s management is looking seriously at recent events and pondering that awful label now attached to one of its steel mills. Mud sticks and it will be a long time before

South Korea’s second largest steelmaker can shake off its now very poor public image. If you want to live dangerously, it seems, forget base jumping from a Seoul skyscraper, go get yourself a job in a steel mill. Please don’t think I’m making light of this issue, I’m not. This month I read that problems lurk for South Korea’s largest steelmaker, POSCO. The Financial Times reported that a 35-year-old man was killed at the company’s Pohang steelworks while replacing a conveyor roller and that, a month later, a 56-year-old died in a similar incident, which kind of infers that lessons are not being learned. Three workers were killed last November in POSCO’s Gwangyang facility and over the past three years, 14 workers have died. South Korea’s labour ministry found 225 safety breaches at the Pohang works. The global steel industry as a whole continues to do its level best to maximise worker safety. Most steelmakers have their own initiatives in place and their achievements are recognised by the World Steel Association every year at its General Assembly. So, what is going wrong in South Korean steel mills?

www.steeltimesint.com

12/07/2021 06:22:39

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4 NEWS ROUND-UP

• Huge respect is certainly due to Tata Steel in India. The company has announced that if an employee dies of COVID-19, it will pay the employee’s family the deceased’s last-drawn salary until such time as the employee would have turned 60. Furthermore, the children of an employee who dies of COVID while on the job will have their education paid for by Tata until they graduate. Source: NDTV.com, 23 May 2021 • Shou-Tao Chen, formerly assistant vice president of the production division of China Steel Corporation (CSC), has been promoted to vice president of the production division, effective 18 June 2021. Source: MarketScreener, 22 May 2021

• Despite news reports to the contrary, Indian steelmaker JSW Steel has denied that it is interested in bidding to buy Liberty Steel assets in the UK and elsewhere. The company claims that its focus remains firmly on India and that news reports stating otherwise were ‘misleading and mischievous’. Source: Business-Standard, 23 May 2021

• Two ArcelorMittal locomotives have been involved in an accident near Ganta City, Nimba County, Liberia. The incident occurred early in the morning on 21 May 2021. No casualties were reported and the incident was the first of its kind since ArcelorMittal Liberia started rail operations in the country. Source: AllAfrica.com, 23 May 2021

• A 35 year-old man was killed while replacing a conveyor roller at POSCO’s Pohang steelworks in South Korea. A month later, at the same plant, a 56-year-old was killed in a similar incident, according to a report in the Financial Times. Three workers were killed at the company’s Gwangyang works in November, and over the past three years, 14 workers have died. After inspecting the Pohang works, South Korea’s labour ministry found 225 safety breaches. Source: Financial Times, 24 May 2021

• Hyundai Steel is continuing its Coffee Waste Resource Recovery Project started in the city of Incheon in 2018 in conjunction with the Korea Productivity Centre and the Korea Green Foundation. For the third consecutive year, the South Korean steelmaker is promoting the idea of upcycling coffee waste, arguing that around 150kt of discarded coffee is buried or incinerated in South Korea annually. Source: Korea Herald, 24 May 2021

• ArcelorMittal is planning a demonstration plant in Hamburg, Germany, that will produce 100kt of pig iron using ‘blue hydrogen’. The plant will commence operations some time between 2023 and 2025, it is claimed. The report, by Mining Magazine, claims that the world’s biggest steelmaker is also developing a hybrid blast furnace process using DRI gas injection technology in the blast furnace in addition to gas injection in the BF tuyeres, using plasma technology to create a reducing gas. Source: Mining Magazine, 24 May 2021

• The high price of scrap iron is behind soaring rebar prices in South Korea, a problem exacerbated by supply cuts from Chinese producers and the suspension of operations at Hyundai Steel, claims a report in the Korea Times. Hyundai accounts for 15% of domestic rebar material supply, but the company’s hot coil plant has been closed temporarily because of an industrial accident. Source: Korea Times, 23 June 2021 www.steeltimesint.com

Industry news.indd 1

09/07/2021 09:20:47

NEWS ROUND-UP

• ArcelorMittal is stepping up its iron ore operations in Liberia following a halt in Phase 2 expansion plans in 2014 due to an outbreak of Ebola. The brownfield project will need around $800 million to be completed, but, says the world’s biggest steelmaker, 85% of procurement is done and 60% of civil construction is complete. The first concentrate is expected at the end of 2023. Source: Mining Weekly, 24 May 2021 • Liberty Steel will sell its Stocksbridge aerospace and special alloys business to help pay off its debts to creditor Credit Suisse. A report by City AM claims that the facility was not viewed as core to Liberty’s vision and that its sale will allow the troubled steelmaker to focus on transforming its Rotherham plant. Source: CityAM.com, 24 May 2021

• The UK government is reviewing tariffs against the USA in response to conﬂict surrounding Donald Trump’s controversial Section 232 tariffs on steel and aluminium. International Trade Secretary Liz Truss says that the UK now has the power to shape tariffs so they reﬂect UK interests, but is treading carefully in order to tone down the dispute and continue to work closely with the USA on other matters, such as tackling unfair trade practices by non-market economies (the problem that led to Section 232 tariffs!). Source: GOV.UK, 24 March 2021 www.steeltimesint.com

Industry news.indd 2

• Vajihollah Jafari, head of Iranian Mines and Mining Industries Development and Renovation Organization (IMIDRO) has announced 29 mining projects are ready to be inaugurated throughout the country. Thirteen of the projects are steelrelated, six are linked to the copper industry and 10 are in other fields, such as minerals production and machinery. Source: Tehran Times, 25 May 2021

• ArcelorMittal Dofasco has been fined $268,750 for what one online media report described as a “billowing black cloud from a blast furnace”. The plume from AMD’s Hamilton facility has been described as ‘a massive release of pollution’ and was witnessed by Environment Hamilton staff, one of whom spotted it while cycling to work. An AMD employee reported two separate emissions. The opacity from the cloud peaked at 70-100%. Source: CBC.ca, 25 May 2021

• Indian steelmaker JSW Steel plans to boost capacity at its Vijayanagar facility by 5Mt/ yr to 17Mt/yr by the end of March 2024. The company will spend just over US$2 million on the expansion. A similar project was completed in April at JSW’s Dolvi mill where capacity was boosted to 10Mt/yr. Source: Argus Media, 27 May 2021

• Austrian steelmaker Voestalpine has posted a healthy full-year net profit of 32 million Euros ($38.97 million). Last year the company made a loss of 261.5 million Euros. The company cited strong demand from the automotive sector as a chief reason behind its good news. Source: Reuters, 9 June 2021

• Efficiency savings implemented by Russian steelmaker MMK have resulted in annual savings in the region of RUB 6.7 million ($92,000). Source: MarketScreener, 9 June 2021 July/August 2021

09/07/2021 09:21:25

• JSW Steel (USA) and JSW USA Steel Ohio, part of the Indian steelmaking parent JSW Group, is taking three US steelmakers to court in Texas for allegedly boycotting and refusing to supply JSW Steel USA with domestic semi-finished steel slab at the beginning of 2018 to the present day. The plaintiffs allege that defendants Nucor Corporation, US Steel and Cleveland-Cliffs cost them hundred of millions of dollars in lost profits and increased expenses. In a nutshell, the US steelmakers allegedly refused to sell slabs produced in the US to JSW, forcing the company to import and incur costly tariffs in the process. Source: Telegraph India, 10 June 2021

NEWS ROUND-UP

• Russian steelmaker Severstal has told S&P Platts that where hydrogen steelmaking is concerned, the steel industry needs to produce it in large quantities, at low cost and without a carbon footprint, according to the company’s director of business development and corporate venture projects, Andrey Laptev. In Europe, hydrogen will be produced using electricity produced with wind and solar power, but this won’t be possible in Russia. Instead, it is likely that hydrogen will be produced from natural gas once its decarbonisation has been solved. Source: S&P Global Platts, 18 June 2021

• Tata Tiscon is claimed to be the first GreenPro certified rebar brand in India, according to an online media report. Tata Steel, therefore, is the first Indian steelmaker to receive GreenPro certification for rebar, which is used extensively in the construction industry. According to Peeyush Gupta, VP of steel marketing and sales at Tata, the GreenPro Ecolabel represents a significant milestone in the company’s efforts to create sustainable products for building homes and infrastructure. Source: IndiaInfoline.com, 18 June 2021 For more steel industry news and features, visit www.steeltimesint.com

• US Steel is going to add a 200kt (short ton) non-grain oriented electrical steel line to its Osceola, Arkansas-based Big River Steel facility with the sole aim of servicing the electric vehicle industry. The line will go live in Q3 2023. Ultimately, NGO steel products could make up around 7% of BRS’ product mix, according to Argus Media. Source: Argus Media, 10 June 2021

• HBIS Group Serbia Iron & Steel, part of Hebei Iron & Steel Group, plans to restart its blast furnace number one in Smederevo on 16 August. It was shutdown on 5 July last year due to the pandemic and the resulting market conditions. The company has relied upon its blast furnace number two over the past year. Source: Steel Orbis, 16 June 2021

July/August 2021

Industry news.indd 3

• Magnitogorsk Iron and Steel Works (MMK) has been ranked among Russia's top 10 corporations in terms of open innovation performance. The company obtained the best result among Russian metallurgical companies, it is claimed. The independent rating was published by the Barometer Project (part of A Partners Capital Investment. Source: MMK, 18 June 2021

• The Great Place to Work Institute in India has named Tata Steel as one of ‘India’s Best Employers Among Nation-Builders’, a new category recognising 15 companies which have exhibited commitment towards kick-starting and rebuilding the Indian economy after COVID. To be in this category, candidates must be infrastructure creators and among the highest taxpayers. To be a finalist, entrants were required to show that they promoted/impacted at least three of the UN’s global sustainable development goals. Source: The Avenue Mail, 18 June 2021 www.steeltimesint.com

09/07/2021 09:22:00

NEWS ROUND-UP

• The development of head-hardened rails at Steel Authority of India Ltd’s Bhilal Steel Plant in Chhattisgarh, India, has been placed on the back burner due to a lack of foreign experts who were working on trials, but left India when COVID cases began to surge in April. Work will resume when it is safe for the experts to return, said SAIL Source: LiveMint.com, 20 June 2021

• Tata Group in India is taking on the country’s big e-commerce players Flipkart and Amazon. It has acquired 1MG Technologies, an Indian start-up founded in 2015, and has acquired BigBasket, a 10-year-old grocery delivery business. 1MG is an online pharmaceutical sales site with around 40 million monthly users, it is claimed. Source: Nikkei Asia, 21 June 2021

• TV Narandren, managing director of Tata Steel in India, claims that vaccination is the most important factor in terms of rebooting the Indian economy. In an interview with The Indian Express correspondent Sandeep Singh, Narandren said that if the nation’s vaccination programme isn’t speeded up there was a very real risk of derailing the economy. In the short-to-medium term the key focus should be on vaccination, he stressed. Source: The Indian Express, 21 June 2021

• Metinvest CEO Yuriy Ryzhenkov told reporters in Kyiv that the company spent over $200 million in 2020 on pollution reduction projects, and over $1 billion overall. He claimed that European emissions standards would be met within two to three years and that 2020’s net profit was $526 million. Mr Ryzhenkov was speaking at the 15th birthday celebrations of the business. Source: Kyiv Post, 23 June 2021.

• Nucor Corporation has been recognized as a General Motors Supplier of the Year for the third year running during a virtual ceremony on 22 June. The North American steel giant remains the only electric arc furnace steelmaker to receive this award. Source: Nucor Corporation, 22 June 2021 www.steeltimesint.com

Industry news.indd 4

• A shortage of iron ore in the Indian state of Odisha is causing serious problems for steelmakers in the region without captive mines. In the financial year 2019-20 the state produced 141Mt of iron ore, but a year later just 111Mt, down 30Mt, according to an online report. Exports increased from 17.4Mt in 2019-20 to 29Mt the following year, causing a scarcity of 42Mt and steep price increases. Odisha’s Chief Minister, Naveen Patnaik, wants any auctioned mines not yet operational to fall under the control of the Odisha Mining Corporation, which he believes would solve the problem as OMCcontrolled mines only produced 13Mt in 2020-21 compared with 65Mt from mines owned by the major steel mills. The OMC needs to produce 26Mt/yr in order to control prices and make up for the shortfall. Source: Orissa Post.com, 22 June

• ABB India has completed work on the digital transformation of JSW Steel’s Dolvi meltshop in Maharashtra, India. Owner JSW Steel is in the process of doubling the plant’s capacity from 5Mt to10Mt/yr at a cost of around $US3.75 million. Source: Economic Times, 24 June 2021

• Shared growth is the name of the game at South Korean steelmaker POSCO. The company’s chairman, Choi Jeong-woo told his company’s 90 partners and suppliers that POSCO was only possible because of the sacrifices and contributions of the steel giant’s partners. Listening to his speech were Moon Sung-hyun, chairperson of South Korea’s Economic, Social and Labour Council, Lee Cheol-woo, governor of North Gyeongsang Province, Lee Kang-deok, mayor of Pohang, and lawmakers from regional constituencies. Source: The Korea Herald, 25 June 2021 July/August 2021

09/07/2021 09:22:38

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NEWS ROUND-UP

• It is being reported that capacity utilisation rates in India are rising above 80% as lockdowns are lifted and there is a rise in COVID recovery rates. Steel demand is expected to improve as more people receive vaccinations. Source: Argus Media, 25 June 2021

• POSCO and HBIS, China’s second biggest steelmaker, are joining forces to produce automotive steel in China. The 50-50 joint venture will mean each company investing $300 million to build a galvanized steel sheet factory. Source: Nikkei Asia, 26 June 2021

• Discussions have begun to initiate the separation of Tata Steel UK and Tata Steel Europe, according to online media reports. It is claimed that the separation will enable each business to pursue alternative strategies. Talks with the British and Dutch governments are ongoing, but unions in the UK are unhappy about the possible replacement of blast furnaces with EAFs as job cuts would be involved. Source: Argus Media, 25 June 2021

• Svenja Schulze, Germany’s Federal Environment Minister, has invited ThyssenKrupp to submit a funding request for a direct reduction plant within the scope of Federal Ministry for the Environment, Nature Conservation and Nuclear Safety’s (BMU’s) Funding Program Decarbonization. An initial outline of the project had been met with a positive response from the BMU and Kompetenzzentrum Klimaschutz in energieintensiven Industrien (KEI). Source: ThyssenKrupp, 28 June 2021

• Indian steelmaker JSW Steel has received an environmental accolade in the shape of a GreenPro ecolabel for its Neosteel brand of TMT rebars. According to one online media report, JSW has long been a front runner in terms of demonstrating its commitment to sustainability. Source: Business-Standard, 2 July 2021

• The world’s biggest steelmaker, ArcelorMittal, is still the frontrunner for Liberty Steel’s French assets, according to media reports. It has, however, been reported that Saarstahl has struck a provisional deal for the purchase of Liberty’s Ascoval steel facility and Hayange rail plant. Source: NDTV.com, 2 July 2021

For more steel industry news and features, visit www.steeltimesint.com

www.steeltimesint.com

Industry news.indd 5

• Following on from years of acquisitions, China Baowu Steel Group (CBSG) recently took over from ArcelorMittal as the world’s largest steel company. ArcelorMittal, the previous holder of the title, according to one online media report, has dropped into second place. CBSG produced 115.29Mt of steel last year and ArcelorMittal produced 78.46Mt, down from 97.31Mt because of COVID-19-related issues. ArcelorMittal held the crown from 2006 to 2019. Source: BusinessKorea.co.kr, 5 July 2021

Sumitomo Metal Mining of Japan is planning to spend 47 billion yen ($424 million) on boosting its production capacity of cathode materials, which are used in the manufacture of rechargeable batteries for EVs (electric vehicles). A new plant is being built in Besshi, Ehime prefecture in Western Japan, according to an online media report. Source: Reuters, 6 July 2021 July/August 2021

09/07/2021 09:23:11

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USA UPDATE

President Biden’s Transportation Bill

The first week of June saw an intense ﬂurry of activities between Democrats and Republicans over President Joe Biden’s $547 billion transportation bill, with the president insisting that it was necessary to energize the economy. The US steel industry welcomed the bill, anticipating increased demand for steel generated by the reconstruction and modernization of the infrastructure. By Manik Mehta*

PRESIDENT Joe Biden’s transportation bill was unveiled by Democrats in the House Transportation and Infrastructure Committee; the biggest chunk of the allocations, about $343 billion, is being earmarked for road and bridge construction as well as highway safety, an increase of over 50% over the last transportation bill passed by Congress in 2015. It also provides an allocation of $100 billion for transit and $95 billion for rail, including a trebling of

funds for Amtrak, the country’s railway provider. As of writing this piece, negotiations between the two parties were still ongoing, with President Biden having met Senate Republicans led by Sen. Shelley Moore Capito (R-W.Va.), over a broader infrastructure deal. The five-year bill will emphasize environmental protection goals as an important factor while implementing the projects.

Aside from efforts to achieve bipartisan support for the bill, Biden’s infrastructure plan faces other challenges, foremost among them being shortages in many areas, including materials and labour. The contractors and companies that will be assigned to construct roads, build bridges, lay steel pipes for water and assemble the trains face challenging times ahead. Indeed, even before the bill’s implementation, the shortages already

* USA correspondent www.steeltimesint.com

USA – read OK MM.indd 1

July/August 2021

09/07/2021 09:25:47

USA UPDATE

existed – ranging from steel and cement to skilled workers who are badly needed following the sudden economic reopening after last year’s lockdown. Even as steel producers and construction firms welcomed Biden’s plan to upgrade the infrastructure, steel companies have yet to initiate steps to increase their supplies to meet the expected surge in demand. And then there is the element of affordability, given that imported steel attracts tariffs. US steelmakers are overbooked with orders, with US consuming industries forced to rely on foreign steel, notwithstanding the 25% tariffs imposed in 2018 by former President Donald Trump. The consuming industries’ call for removing import tariffs prompted Tom Conway, president of the United Steelworkers, North America’s biggest industrial union, to express concern over the adverse impact of rising imports on the US job market and how, instead, they benefit workers in the supplying countries. However, organizations such as the National Association of Home Builders (NAHB) fear that Biden’s overall infrastructure bill ‘will place a huge demand for steel and concrete that will impede our ability to build out multi-family and other types of housing,’ as NAHB CEO Jerry Howard, put it; he called for an increase in output, although it was difficult to envisage how this could be achieved given shortages of materials and workers needed for the purpose. Nevertheless, the prospect of massive spending on infrastructure has, generally, been welcomed by the steel industry. Kevin Dempsey, president and CEO of the American Iron and Steel Institute (AISI), said the bill makes the much-needed investments in the nation’s surface transportation infrastructure and was a ‘significant step to rebuilding America’s

highways, roads and bridges”. “We also appreciate that under the bill ‘Buy America’ rules will continue to require that steel purchased with federal funds for DOT (Dept. of Transportation) infrastructure projects be melted and poured in the

United States. An efficient and robust transportation network is essential to the competitiveness of the domestic steel industry, its customers and suppliers, and American manufacturing as a whole,’ Dempsey said, calling for substantial long-

term infrastructure legislation in the coming weeks. He made these comments before any breakthrough was achieved in the negotiations between the Democrats and Republicans over the bill. Meanwhile, according to preliminary Census Bureau data, the US imported a total of 2.63Mt (net tons) of steel in April 2021, including 1.65Mt (net tons) of finished steel (a rise of 14.1% and a drop of 7.6% respectively against March figures). Cumulative imports in the first four months of 2021 touched 9.26Mt and 6.11Mt (net tons), posting a 0.6% and 5.1% increase over the year-earlier period. Data suggests that South Korea was the top foreign supplier, with 263kt (net tons) – up 10% over March; followed by Japan (88kt NT, up 3%); Turkey (63kt NT, up 49%); Germany (47kt NT, down 42%); and Vietnam (46kt NT, up 4%). For the first four months of 2021, the largest offshore suppliers were South Korea (864kt NT, up 22% over the 2020 corresponding period), Japan (306kt NT, up 13%), Turkey (264kt NT, up 27%); Germany (218kt NT, down 7%); and Taiwan (189kt NT, up 2%). The question of continuing the tariffs – former President Donald Trump had imposed a 25% steel tariff in 2018 to appeal to his political base – is being debated between the steel producers and steel-consuming industries. However, with soaring demand for products using steel, such as automobiles, steel prices have risen three times over last year’s level. The US steel industry would like tariffs to continue because their removal could cause ‘market disruptions’, pointing out that supporting the domestic industry has led to greater investment and job creation. Even if prices and supplies are presently high, the threat

July/August 2021

USA – read OK MM.indd 2

09/07/2021 09:26:06

USA UPDATE

of overproduction from China and elsewhere remains. Steel manufacturers such as Nucor, US Steel Corp., Steel Dynamics, Inc., ArcelorMittal, and so on, have benefitted from the strong position of the residential construction market and a recovery in the automotive sector. Downstream customers say they are at a disadvantage, with manufacturers such as General Motors, for example, complaining about prices and shortages for semiconductors and steel. But, so far, manufacturers have passed on costs to their endconsumers. Separately, those tariff-targeted countries can choose to retaliate. The EU has threatened to do just that, but has held off taking action for some time. The retention of Section 232 tariffs has also created a dilemma for the Biden administration. Biden wants to ease tensions with European allies and has faced pressure from the US Chamber of Commerce and domestic industries that rely on metals to lift the tariffs. However, he risks angering steelworkers and other labour unions if he takes that step, particularly as the US steel industry has boomed with the tariffs in place. That would give Republicans an opportunity to hit Democrats before the mid-term elections in crucial swing states like Pennsylvania and Ohio where the steel industry is strong. The US steel industry and the United Steelworkers have urged Biden to retain the steel tariffs, warning that their withdrawal would ‘undermine the industry’s viability’, as heads of the American Iron and Steel Institute, the Steel Manufacturers Association, the United Steelworkers and other groups, argued. They warned that global steel overcapacity had only increased during the pandemic, and past economic crises had led to devastating import surges as other nations dumped their excess steel into the US market. A group of over 300 US manufacturing companies jointly wrote a letter to President Biden requesting an immediate end to the Section 232 steel and aluminum tariffs. “Manufacturers in the US currently face historic shortages of readily available and globally priced steel and aluminium products at a time when the country is relying on our sector to help drive the economy and overcome the unprecedented challenges caused by the COVID-19 pandemic,” the group said in the letter. “Without termination of the tariffs, this situation will worsen if Washington moves forward with an infrastructure bill to invest in America, as these projects will create more strain on domestic steel and aluminium supplies, causing delays in construction and risking manufacturing jobs.” � www.steeltimesint.com

USA – read OK MM.indd 3

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LATIN AMERICA UPDATE

Mexico’s long steel market Some interesting presentations were delivered at Fastmarkets’ Mexican Steel Forum 2021, which was held in late March. Among them, Fernando Pessanha, CEO of Gerdau Corsa Mexico, analysed the supply-demand dynamics of long steel products in that country. This article is based on his presentation. By Germano Mendes de Paula* MEXICO produced 16.8Mt of crude steel in 2020, which was equivalent to roughly 1% of the global total and 17% of the NAFTA (now USMCA) output. Mexico ranked 15th as a world steel producer and 2nd as a Latin American one. Although, Mr Pessanha’s focus was on long steel, he mentioned that only 49% of flat steels consumed in Mexico are produced in the country. Longs production represents half of total finished steel products in Mexico. Fig 1 shows long rolled steel production and long steel apparent consumption over the period 2012-2020. It can be verified that this market segment has been quite balanced in the sense that net international trade was residual. Apparent demand has increased from 9.9Mt in 2013 to 11.2Mt in 2016, but it diminished to 10.2Mt in 2020. Mexican long steel production was amplified from 9.8Mt in 2012 to 10.8Mt in 2016-2017, reverting partially to 10.4Mt in 2019 and then recovering to 10.8Mt in 2020 (Fig 1). Nevertheless, for the 20122020 period as a whole, output expanded by just 1.2% annually, which can be characterised as ‘low dynamism’. Another quite interesting piece of

information provided by Mr Pessanha deals with market structure. He says there are seven key players in the Mexican long steel market segment. All of them produce rebar, followed by wire rod and commercial profiles (six players each), structural profiles and bars (five players each) and wire and drawn products (two players). Fig 2 demonstrates long steel apparent consumption by type. Wire rod, wire and drawn products enlarged from 4.2Mt in 2012 to 4.6Mt in 2020, while the respective figures for rebar were 3.1Mt and 3.4Mt. Meanwhile, the bars reduced from 1.5Mt to 1.2Mt, respectively. Structural profiles also experienced a drop from 0.8Mt to 0.7Mt, while commercial profiles had a marginal gain from 0.3Mt to 0.4Mt. Therefore, wire rod, wire and drawn products amplified their market share from 43% to 45%, whereas rebar changed from 32% to 33% and commercial profiles from 3% to 4%. For their turn, bars had their participation reduced from 15% to 12% and structural profiles, from 8% to 7%. It can be concluded that, in line with its low dynamism, only minor changes were observed regarding products’ relative importance.

Exports and imports Mexican steel exports reached 5.3Mt in 2020, of which 3.3Mt were rolled steel products and 2Mt were semis. In the same year, long steel exports reached 1.7Mt and were despatched mainly to the USA (59%), Colombia (16%), Guatemala, Peru and Canada (5% each). The remaining 11% went to other countries. However, Mexico imported 1Mt of long steel products in 2020, of which 38% came from the USA, 13% from China, 11% from Canada, 9% from Spain, 6% from Germany and 24% from other nations. Fig 3 shows that Mexican long steel exports increased from 1.6Mt in 2012 to 1.9Mt the following year, but diminished to 1.3Mt in 2016 and reverted to 1.7Mt in 2020. Regarding product mix, wire rod, wire and drawn products grew their share from 42% in 2012 to 44% in 2020, while rebar reduced from 34% to 30%, respectively. Structural profiles jumped from 8% to 17% along the same period, whereas the commercial profiles dropped from 7% to 6% and bars from 9% to 4%. Fig 4 demonstrates that Mexican long steel imports enlarged from 1.6Mt in 2012 to 1.8Mt in 2015 and then experienced

* Professor in Economics, Federal University of Uberlândia, Brazil. E-mail: germano@ufu.br www.steeltimesint.com

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July/August 2021

09/07/2021 09:29:09

LATIN AMERICA UPDATE

Fig 1. Mexican long steel production and apparent consumption, 2012-2020 (Mt)

Fig 2. Mexican long steel apparent consumption by product, 2012-2020 (Mt)

Source: Canacero

Fig 3.Mexican exports of long steel products, 2012-2020 (kt)

Fig 4. Mexican imports of long steel products, 2012-2020 (kt)

Source: Canacero

a trend towards retraction until registering 1Mt in 2020. It is worth noting that bars increased its participation to 60% (from 47%) along the examined period, whereas wire rod, wire and drawn products grew from 17% to 25%. Structural profiles diminished their share from 30% to 13%, while commercial profiles maintained a participation level of 3% and rebar dipped from 3% to null. Considering the situation observed in 2020, Mexico was a net exporter of rebar and wire rod, wire and drawn products (0.5Mt each), of structural profiles (0.2Mt) and commercial profiles (0.1Mt) and a net importer of bars (0.5Mt). Although Mr Pessanha’s data has not shown such disaggregation, due to the importance of the automotive industry for the Mexican economy, a considerable amount of imported bar is most probably classified as SBQ. Short-term perspective Mr Pessanha’s final remarks were concerned with future perspectives. It is important to remember that Mexico’s GDP declined July/August 2021

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8.2% in 2020 y-o-y while construction plummeted 17.2%. He mentioned that some analysts believe that Mexican construction activity will expand roughly 5% this year. The national statistics institute estimates that construction is equivalent to 6% of the country’s GDP. Of this value, 68.4% refers to edification, which for its turn

is highly dependent (60.2%) on selfconstruction, which means that a substantial proportion of housing is constructed without the supervision of any engineer or architect. Regarding the different market segments of construction, Pessanha stressed that selfconstruction, residential, and warehouses show good perspectives, in contrast to what would be observed for commercial (offices and shopping centres) and infrastructure. He closed his speech with a message of optimism, because in his opinion there is an international steel super cycle, which is reflected in the Mexican domestic market, by: a) higher demand for steel products than supply in the short-term period; and b) the escalating costs of raw materials (scrap and iron ore, in particular). These factors contribute strongly to current steel prices in Mexico. However, it is difficult to forecast how long these factors will be sustained, but market volatility is expected. Finally, Gerdau Corsa claims to be committed to serving its customers by establishing a close relationship and offering an excellent level of service. � www.steeltimesint.com

09/07/2021 09:29:20

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INDIA UPDATE

Steel mills expand capacity After nearly two years of pause and production cuts earlier this year due to the diversion of a key ingredient – industrial oxygen – for conversion into liquid medical oxygen (LMO), major steel mills across India are gradually expanding capacity to meet emerging future demand for steel. By Dilip Kumar Jha* LARGE Indian steel companies have announced 29Mt/yr of new capacity addition over the next five years to increase their metal output. Mini and micro steel mills have decided to follow suit and take advantage of anticipated huge growth in metal consumption following the government’s plan for a huge infrastructure push. Over the last few years, India’s crude steel production capacity jumped from 128.27Mt/yr in 2016 to 142.72Mt/yr in 2020. However, with many small plants closed due to a nationwide lockdown, effective capacity is estimated to be in between 120Mt to 125Mt this year.

Dolvi plant in Maharashtra. “The ongoing expansion work at Dolvi Works was affected due to the Covid-19 outbreak. The work was suspended because of multiple issues including non-availability of workers and travel restrictions – both domestic and international,” said Jayant Acharya, director of commercial, marketing and corporate strategy at the company. JSW Steel is in the process of making a final decision to take up a new capacity

addition which would include installing a 4.8Mt/yr blast furnace (with a supporting 5Mt/yr steel melt shop) and a 5Mt/yr hot strip mill (HSM). The plant would also have an 8Mt/yr pellet plant and four kilns of 600 TPD Lime Calcination Plants (LCPs), besides a captive power plant, he added. With the expansion of the Dolvi Works, Sajjan Jindal-owned JSW Steel’s total steelmaking capacity will reach 23.1Mt/yr from 18.1Mt/ yr at present.

Foraying companies Of the 29Mt/yr of new capacity, JSW Steel’s contribution is estimated to be over 50% as the company is looking to add 14.8Mt/yr of cumulative capacity across its Dolvi plant in Maharashtra, Vijaynagar in Karnataka and Bhushan Power & Steel facility in Jharsuguda in Odisha. An expansion process for doubling the existing capacity of 5Mt/yr to 10 Mt/yr is proposed at JSW’s * India correspondent www.steeltimesint.com

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July/August 2021

09/07/2021 09:30:47

INDIA UPDATE

Capacity addition on card Steel mills JSW Steel

Capacity

Location

(million tonnes per annum)

Investment (INR billion)

Dolvi, Maharashtra

150

3.8

Jharsuguda, Odisha

JSW Steel

Vijaynagar

Tata Steel

Kalingnagar, Karnataka

Jindal Steel & Power

Angul, Odisha

180

NMDC’s Nagarnar Steel Plant

Angul, Odisha

Bhushan Power & Steel

Source: Company websites

In addition, JSW Steel owns and operates a 12Mt/yr manufacturing facility at Vijayanagar in Karnataka, which is the largest single location steel-producing facility in India, and another 1Mt/yr plant in Salem, Tamil Nadu. The company has also proposed to set up a 13.2Mt/yr greenfield steel plant in Odisha along with a 900 MW power plant for captive usage with an investment of INR 537 billion (US$7.2 billion). Additionally, Ratan Tata-owned Tata Steel has re-started work on the second phase of a 5Mt/yr expansion project at Kalinganagar in Odisha after achieving 100% capacity utilisation on its 3Mt/yr phase one project. In addition, Tata Steel’s Kalinganagar project would entail another 3Mt/yr of casting capacity. Thus, the total project will cost the company INR 235 billion (US$3.1 billion). The project configuration

and costs include investments in raw material capacity expansion, upstream and midstream facilities, infrastructure and downstream facilities including a cold rolling mill complex. The expansion will meet the requirements of automotive,

general engineering and other value-added segments. Once the commercial production starts on the Kalinganagar project, the total capacity of Tata Steel’s India operations would go up to 23.6Mt/yr, which includes an existing capacity of 10Mt/ yr at Jamshedpur, an existing 8Mt/yr at Kalinganagar (including 5Mt/yr expansion) and 5.6 Mt/yr of Tata Steel BSL. “Kalinganagar has been a remarkable story for Tata Steel. The facility is expected to be one of the lowest-cost producers of steel in the world,” said TV Narendran, chief executive officer and MD, Tata Steel. Jindal Steel & Power (JSPL) is looking to add 6Mt/yr to the production facility at its Angul plant in Odisha. “Infrastructure spending in India is bound to jump leaps and bounds and JSPL is fully aligned with the government’s vision of achieving 300Mt/yr steel production by 2030. We firmly believe in the India growth story and its potential to be an engine of global growth. The company will now focus on undertaking an expansion of its Angul steel plant from 6 to 12Mt/yr,” said JSPL managing director V R Sharma. Sharma added that a 3Mt/yr expansion would be commissioned by end-2023 or 2024 and the balance of 3 Mt/yr by end2025 or 2026. Additionally, the government-owned NMDC’s Nagarnar Steel Plant is expected to commission its 3Mt/yr greenfield steel plant. Need for expansion Steel prices in India have jumped exponentially in the last few months despite the second wave of Covid-19, which paralysed work on infrastructure and housing projects. On one hand, steel production was hit due to restrictions on factory operations following a nationwide lockdown and shortage of labour. Gradual unlocking restarted work on stalled projects resulting in a sudden upsurge in metal demand. The Union Ministry of Steel reported up to a 60% jump in steel prices over the last six months. Conclusion Experts believe that the government’s infrastructure plans would create a supply mismatch over the next five years with India’s reliance on imported steel to increase significantly. Steel mills have taken up a long-term strategy to ramp up manufacturing capacity to meet India’s future demand. �

July/August 2021

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www.steeltimesint.com

09/07/2021 09:30:58

CHINA UPDATE

China – carbon neutral by 2060? China has pledged to achieve carbon neutrality by 2060 and peak carbon emissions by 2030. Using research and data, a team of analysts from CRU Group* has provided an in-depth insight into how China plans to reach ‘peak carbon emissions’ across the metals industry. CHINA has set a strategy to ensure carbon emissions peak by 2030. During this transition period Chinese companies need to find solutions to reduce carbon emissions. Carbon neutrality before 2060 is the goal that China has pledged to achieve. The total carbon emissions (including land use, land-use change and forestry activities, LULUCF) in China reached approximately 10.5 billion tonnes in 2019. Carbon emissions from energy activities were estimated to be ~9.8 billion tonnes (or 87% of total emissions). Total carbon emissions from China’s steel industry account for more than 15% of total carbon emissions of the country. The key to ‘peak carbon emissions’ is to reduce and control carbon emissions from both the demand (consumption) and supply side (production) of the commodities market. The fundamental solutions are clean energy production and electrification. Decarbonisation will significantly shift the energy source towards renewable energy and clean energy for steel, aluminium and copper. Electrification will largely alter the demand for steel, aluminium and copper in China, as these metals are used in

the power generation, transmission and manufacturing of new energy vehicles. Structural shift to renewable and clean energy China’s clean energy production strategy is to develop and promote the use of clean energy such as solar power, wind power, hydropower, nuclear power and biomass, in order to limit the consumption of fossil fuels. According to the Chinese government’s plan, energy generation from non-fossil fuels is expected to reach 20% by 2025 and 25% by 2030. Carbon emissions from steelmaking and aluminium smelting account for 98% of total carbon emissions in the metals industry. Steelmaking alone accounts for 80% of emissions, with the aluminium smelting industry accounting for 18%. Therefore, it is extremely important for both steel and aluminium to find efficient ways to reduce carbon emissions. China’s coal consumption per ton of steel has fallen to a globally advanced level, and the iron and steel industry has largely completed its capaScity reduction programme, a campaign to identify and

close outdated and environmentally unfriendly capacity of 140Mt, including induction furnaces. Therefore, there will be limited potential to reduce carbon emissions through these two methods. Electrification will boost demand for copper and aluminium Aluminium, copper and steel are very important materials in the construction of solar power and wind power facilities. For instance, aluminium consumption is around 19kt in the construction of per 1GW solar power generation sets. Electrification is another important way to reduce carbon emissions in China. New energy vehicles are an efficient way to reduce carbon emissions from the power usage end. Electrification also involves the construction of ultrahigh and super-high grid construction, transmitting the solar and wind power from China’s east to west, linking renewable energy generation and electrification. Both aluminium and copper are widely used in grid transmission, charger stations, solar wind, and new energy vehicles. CRU estimates that aluminium demand in energy vehicles and the renewable energy

* A leading commodity market researcher www.steeltimesint.com

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July/August 2021

12/07/2021 06:18:26

CHINA UPDATE

sector will grow by 40% to 8.39 Mt by 2030 from 6 Mt in 2020. The demand for copper, excluding EVs and renewables, would plateau around 2025. Against a background of policy and environmental support, EV and renewable power’s share of total Chinese copper consumption will expand significantly. We forecast that by 2030 around 12% of China’s copper demand will come from these sectors, up from under 4% currently. These sectors will see further expansions in the following decades. It is no exaggeration to say that future growth of the Chinese copper market is almost entirely contingent on a rapid green transition. Greener policies drive quality over quantity for steel CRU expects that Chinese steel demand has reached its peak or will peak shortly because the country is approaching a maximum level of sustainable ﬂoorspace and this is expected to slow construction of buildings going forward. Greener policies are still not constraining steel demand as the material is still required for housing, infrastructure and transport. While steel demand slows overall, developments in the services and technology sectors suggest a shift in the focus of growth towards more advanced steel grades compared to the historical focus of steel products used in traditional buildings and infrastructure construction, such as rebar and HR products. For instance, the development of renewable energy is expected to become faster. China’s ambition for new wind and solar energy installation will generate a total of 120 Mt of steel demand in the next 10 years. Although the annual addition is below 2% of total steel demand, this is a July/August 2021

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shift in the share of renewables in China’s energy mix from 28% to 47% over the same decade. China’s journey towards carbon neutrality will involve shifting the focus in the direction renewable energy. This is particularly the case for aluminium, where renewable power is expected to rise from 16% today to 27% by 2030. Solar power has the largest potential for growth in the aluminium industry. Hydrogen energy is expected to be widely used in the steelmaking sector, but for now these technologies are not commercially viable. On the consumption side, decarbonization efforts require building a low carbon infrastructure on which

the economy can operate – this includes smart grids, solar panels, wind turbines and electric vehicles – this infrastructure requires a lot more aluminium and copper. We expect consumption of aluminium and copper in low carbon infrastructure to increase by 40% and 292%, respectively between 2020 and 2030. Unlike base metals, total steel demand will not be a huge beneficiary of green policies, although there will be increased demand for certain niche metals. For further insights and data, go to the following link for more information: https:// www.crugroup.com/knowledge-andinsights/insights/2021/china-s-2060-carbonneutral-goal-what-the-metals-industry-canexpect-from-emissions-policies/ � www.steeltimesint.com

12/07/2021 06:18:36

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14/04/2021 08:34

INNOVATIONS

Leybold introduces new vacuum pumps Leybold’s new DRYVAC DV 500 and DV 800 screw vacuum pumps are claimed to compress completely dry, meaning without operating lubricant in the compression chamber, and, therefore, are claimed to be ideally suited as backing pumps in food packaging or in pumping sets in heat treatment or coating systems, as they have significant advantages over oil-lubricated piston or rotary vane vacuum pumps. According to Leybold, the screw design with a specially adapted variable pitch, means high efficiency due to low power consumption requirements and, therefore, minimal maintenance compared to oil-lubricated vacuum pumps, which minimises operating costs. Leybold claims that the robust screw vacuum pump offers high particle and condensate compatibility. According to the company, the pumps offer a consistently high pumping speed over the entire vacuum range.

Leybold is a pioneer in dry vacuum technology and has several different screw vacuum pumps in its product portfolio. In contrast to oil-lubricated piston or rotary vane vacuum pumps, the DRYVAC models offer a temporally stable pumping speed curve. The DRYVAC DV 200, 300, 450 and 650 systems have been supplemented by the more powerful DV 800 and the highly energy-efficient DV 500. The DV800 and DV500 have superseded the DRYVAC DV200, 300, 450 and 650 models and are claimed to offer ‘significantly more performance’ according to Leybold. The DV 800 is based on Leybold’s DRYVAC DV platform and, it is claimed, sets a benchmark in this size class. The fact that the DV 800's dimensions are directly derived from DV 650-models makes changeover and integration easier for the user. According to Leybold, the DV 800 opens up new possibilities

for applications where a higher pumping speed is required. In traditional markets, this is the case in many applications, such as load locks or packaging machines. In new areas, such as battery manufacturing, a higher process speed means cash for the customer. The DRYVAC DV 500 and DV 800 are equipped with an adaptable and networkable frequency converter and IE3 motors. Monitoring via a cloud platform can also be implemented on request and is available as standard from Q3. Leybold claims that the compact construction of the DRYVACs enables a Roots vacuum pump to be installed as a booster. A combination of the DV 1200 and DV 1600 pumps round off the portfolio for even higher pumping speeds, says the company. For further information, log on to www.leybold.com

Brokk relocates to offer better customer service Brokk, a world’s leading manufacturer of remote-controlled demolition machines, has relocated its Monroe, Washington, headquarters, bringing administration, sales, training, parts and service under one roof for better customer response and a more streamlined operation, the company believes. According to Brokk, the new facility provides an additional 7,000 square feet (650 square metres) over the company’s former locations, creating more room for in-house mechanical training for customers. The move also increases equipment and parts inventory for both Brokk demolition robots and Hydrodemolition equipment from sister company Aquajet, providing greater availability and faster delivery throughout the region. The new facility will function as Brokk’s and Aquajet’s North American headquarters and the main parts distribution centre for North America. Lars Lindgren, president of Brokk, said that the company had grown exponentially in North America, expanding to include three facilities and a sales network reaching every corner of the con-

tinent. “The new facility gives us ample room to stock more inventory and offer more services to better serve our West Coast customers,” he said. The added space at the new facility allows Brokk to increase in-house training for robotic demolition and Hydrodemolition equipment. The company has always offered on-site training with each machine commissioning and customized training thereafter through its facilities in Washington, Stanhope, New Jersey, and the demonstration and service centre in St. Joseph, Missouri. The new facility accommodates classroom space and a state-of-the-art maintenance bay, similar to the amenities available at the demonstration and service centre. This opens up greater opportunities for personalized in-depth mechanical training on in-stock Brokk and Aquajet equipment from an experienced technician. With the relocation, West Coast customers will now have convenient access to courses tailored to their team and unique applications to increase safety, productivity and machine utilization. The new facility increases inventory capacity for an array of standard and specialty parts for all

Brokk models — from the compact .6-ton Brokk 70 to the heavy-duty 11-ton 900 – as well as older Brokk models. The facility houses Aquajet Hydrodemolition robots, parts and accessories. Brokk believes that by bringing all departments together it can optimize logistics for faster parts processing. The company claims that most orders placed by 3:45 pm for in-stock parts are available overnight to customers across the country, minimizing unscheduled downtime. For further information, log on to www.brokk.com

July/August 2021

innovations.indd 1

09/07/2021 09:38:00

INNOVATIONS

ArcelorMittal commissions EAF roof and elbow ArcelorMittal Industeel Belgium has installed and successfully commissioned a new Spray-Cooled™ Electric Arc Furnace (EAF) Roof and Elbow with Systems Spray-Cooled of The System Group. The execution of the project included: laser scanning the melt shop, basic and detailed engineering, design and supply of a new EAF Roof and Elbow, design and supply of new 2-point pick gantry arms, and the accompanying equipment that replaced the existing tubular equipment. The full scope, in conjunction with partner tripleS GbR, also included roof alloy chute modifications and RTD monitoring. The conversion from

www.steeltimesint.com

innovations.indd 2

a standard 4-point gantry pick roof to a 2-point cantilever roof and the addition of a complete handrail around the outside of the roof has significantly opened up the access to the roof and delta area allowing Industeel the ability to easily and safely change electrodes, deltas and the elbow. Industeel, Systems, and tripleS claim they met the challenge of the pandemic and safely started up the EAF with all of the safety protocols being strictly followed. The project was initially awarded in September 2019. Due to COVID, the equipment was delivered in August 2020 and start-up/commis-

sioning delayed until October 2020. The new spray-cooled roof and elbow upgrade brings significant safety and maintenance improvements to Industeel, it is claimed. Industeel’s decision to install Spray-Cooled™ equipment was based on the need for the safest, most environmentally friendly, lowest cost option (supply and maintenance) along with the extended life and performance for water-cooled equipment. For further information, log on to www.tsg.bz

July/August 2021

09/07/2021 09:38:46

INNOVATIONS

Chinese steelmaker issues FAC for KOCKS Chinese steelmaker Nanjing Iron & Steel Co Ltd has issued a Final Acceptance Certificate for a three-roll reducing and sizing block (RSB) 500 ++/4 in 5.0 design from KOCKS GmbH of Germany. According to KOCKS, the equipment is the answer to Nanjing Iron & Steel’s expanding and demanding market for medium and large size

July/August 2021

innovations.indd 3

SBQ products. The new equipment operates at NISCO’s 800kt/yr medium bar mill as the finishing unit for the production of straight bars within a dimensional range from 50mm to 160mm. Apart from the RSB, KOCKS was responsible for the thermo-mechanical rolling process including five water boxes and a full automation package.

The low-temperature rolling process is applied for sizes up to 130mm. Beside the RSB 500 ++/4, NISCO is also operating an RSB 370++/4 in its small mill since 2013. For further information, log on to www.kocks.de

www.steeltimesint.com

09/07/2021 09:39:21

INNOVATIONS SPECIAL: TRANSPORTATION

The K25L offers unrivalled safety for heavy loads Transport safety was top of the agenda for SCHEUERLE, part of the TII Group, when it set about developing its latest modular K25 platform vehicle. The company focused on the transport safety aspect of loads with a high centre of gravity.

The relevance of Scheuerle’s decision is easy to understand when you consider the transportation of increasingly powerful wind turbines. The company further claims that its K25L scores favourably through maximum stability when transporting construction machinery or plants. The energy industry, claims Scheuerle, is developing increasingly more powerful wind turbines. The increased dimensions and the related high centre of gravity of the load require an extremely stable means of transport with an especially low loading area. With this in mind, Scheuerle developed the K25L series to ensure the maximum stable and flexible transport of such products. That letter L in the product designation is also important as it means ‘low’ and indicates the low platform height along with the use of larger tyres. The K25L is an extraordinary piece of equipment. It boasts a track width of 2,100mm along with an external width of 3,000mm – that’s over

10% more than competitor offerings, the company claims. The large track width considerably reduces the risk of accidents caused by overturning when transporting wind tower segments with large diameters and, therefore, ‘greatly enhances work safety levels’, says Scheuerle. According to Scheuerle, the technically possible axle load of the K25L is up to 23 tonnes or up to 13.9 tonnes at 80km/hr. The tyres are claimed to be larger and more robust: 285/70R 19.5. In spite of the lower tyres, the lowered platform height is 875mm (loaded) or 910mm (unloaded) and this means that driving on uneven surfaces is very safe. The maximum steering angle of +/- 60 degrees ensures optimal manoeuvrability, Scheuerle claims. Lifting and lowering is carried out with the help of a power pack unit (PPU) from the Z19 series, a low-emission piece of equipment in accordance with the European Commission’s Stage V non-road emission standards. Scheuerle claims that the highest negative and positive bending moment on the market creates economic flexibility for the operation through additional loading options. This offers particular advantages, claims the company, for products such as tower segments or nacelles (machine housings) that feature high point loads in combination with a high centre of gravity, and

Optimised for meeting the requirements of the wind power industry: the newly-developed K25L from Scheuerle. It is claimed to be an ideal solution for transporting loads with a high centre of gravity.

innovations.indd 4

those whose centre of gravity lies far outside the support centre as is the case when transporting long goods with the help of swivel bolsters. The K25L has a 30% higher torsional stiffness compared with similar products on the market, and this guarantees cornering safety during transportation. EBS ensures enhanced breaking performance and a shorter braking distance, claims Scheuerle. Depending on the truck tractor, a diagnosis is possible from the driver’s cab. Likewise, connecting to a smartphone is possible. Another safety feature is the headlights on each invidiual bogie as they enable the driver to comfortably negotiate the route at night. Scheuerle claims that the K25L fulfils the requirements of platform vehicles with two to six axles. They can be combined with goosenecks, drawbars, swivel bolsters, bridges and tower adaptors and can be used in ambient temperatures reaching minus 25 degrees. In addition to the windpower industry, the K25L can be used in the construction sector and for the transport of plant and machinery with high centres of gravity.

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

The Transporter Industry International Group (TII Group) belongs to the Rettenmaier entrepreneurial family and is a globally active manufacturer of heavy-duty and special vehicles. It is comprised of the Scheuerle, Nicolas, Kamag and TIIGER brands, and has a workforce of around 900 employees.

09/07/2021 09:39:29

INNOVATIONS

SMS group wins Chinese mill revamp order Chinese steelmaker Panzhihua Steel & Vanadium Company Ltd has awarded German plant builder SMS group the order to modernize its 1,450mm hot strip mill in Panzhihua, Sichuan Province. The Panzhihua mill has been in operation since 1996 and the company plans to use the modernization as a way of enhancing the flexibility of the hot strip mill, which currently produces 2.4Mt/ yr of thin-gauge strip, and boosting capacity to 3Mt/yr. The revamp will also further enhance the flexibility of the mill in terms of product mix, which includes carbon steels, silicon steels and titanium strips. The scope of the project for SMS group includes the finishing mill, a laminar cooling system and a down-coiler group, which will all be completely renewed. SMS will supply the engineering and the main components. A new seven-stand finishing mill will be erected behind the existing equipment and new mill stands will be equipped with hydraulic screw-down systems, hydraulic loopers and Continously Variable Crown (CVS) plus shifting and bending systems. In addition, the X-Pact® profile, contour and flatness process model (PCFC) will

be installed. This will enable the customer to roll high-grade materials in compliance with the most exacting demands on geometric strip dimensions and tolerances. According to SMS group, the design of the laminar cooling line will provide very high flexibility in terms of cooling rates and cooling patterns,

enabling Panzhihua to produce highly demanding modern steel grades and be prepared for future demands. Flow meters for process control will assure high repeatability of operation to meet the highest quality standards. The coiler area, which consists of two down-coilers, will be completely replaced, includ-

State-of-the-art production facility for Hitachi Hitachi High-Tech Analytical Science (part of Hitachi High-Tech Group), has opened a new hightech manufacturing facility in Shanghai, China. The state-of-the-art 4,118 sqm facility in Laigangxin Bay Technology Innovation Park, Minhang District, has been designed to support a rapid upscaling in the development and production of high-tech analysis equipment, to meet increased demand worldwide. The new site combines the company’s two existing Shanghai locations into a single facility. As the company’s China headquarters, it will support robust demand for analytical equipment from a booming Chinese industrial sector, as well as supplying thousands of companies worldwide with advanced quality control solutions. Dawn Brooks, managing director of Hitachi High-Tech Analytical Science, commented: “As industrial production rapidly picks up round the world, our customers are focusing on optimizing their efficiency and quality control processes, through the smart application of analytics and data. Businesses are returning leaner and more focused on reducing wastage and optimizing throughput, while achieving the highest levels of quality needed for today’s high-performance materials and goods. We’re applying this smart factory approach to our own production and with our new China facility we’re perfectly placed to support our customers on this journey”. The new Hitachi High-Tech-Analytical Science China site employs over 100 specialists engaged July/August 2021

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09/07/2021 09:39:43

INNOVATIONS

ing its related side guiding systems. The modernization activities for the complete mill will be carried out during only two shutdowns. Thanks to SMS group’s modernization know-how, the necessary downtimes can be significantly reduced, with major activities being carried out in parallel to the running production. During the first shut down, scheduled for September, the laminar cooling line will be replaced and a roller table bridge installed behind the existing finishing mill. Once installed, it will be possible to perform the foundation work for the new finishing line while the plant is in operation. During the second shut down in July 2022, the new finishing mill will be installed directly behind the existing mill together with the new coiler area. At the same time, the existing mill will be dismantled and the entry equipment relocated. The first hot strip is scheduled to be rolled in October 2022. With this revamp – which entails the renewal of all quality-relevant equipment – Panzhihua Steel & Vanadium will expand its product mix to include thin-gauge and high-strength hot strips, while increasing the availability of the mill and, as a result, its production capacity. For further information, log on to www.sms-group.com

in the development, manufacture and sale of the company’s high-tech benchtop and portable X-ray fluorescence and laser-induced breakdown spectroscopy instrumentation, essential to production and end-product quality control as well as compliance and safety assurance applications in hundreds of industries worldwide.

Bondal – for noise reduction Thyssenkrupp Steel (TKS) has introduced Bondal, which it describes as a proven sandwich material for noise reduction in vehicle construction. The latest application tests with the composite in electric vehicles, says TKS, show its potential for optimizing the acoustics of electric motors and their power control units. According to TKS, electric motors are quieter than conventional combustion engines – another advantage for the environment and people, aside from their exhaust-free powertrain. However, electric powertrains generate noise inside the electric vehicle that people find particularly unpleasant. This can be eliminated by a relatively small component made of Bondal, a sandwich material that significantly reduces the noise emission of the so-called inverter. The inverter is a central component in every electric powertrain that converts direct current from the battery into alternating current for the motor and, depending on load condition, produces high-frequency sound emitted via the cover of the inverter housing. This unpleasant noise is a significant comfort issue that cannot be satisfactorily solved currently with conventional materials and without secondary acoustic measures. Components formed from Bondal also offer air-borne sound damping properties and can thus minimize the unpleasant noise in electric cars, according to TKS. This effect is obtained through the special structure of Bondal: the material is a steel-polymer-steel composite. Two steel sheets are bonded into a laminate under high contact pressure by a thin, adhesive polymer layer. This sandwich structure has a significant noise dampening effect. Compared to

the solutions used today, this component, made of Bondal, with a weight of approx. 1.5 kg, can be recycled easily, it is claimed. Bondal is particularly well suited for components which are excited to vibrate. Today, it is used for ship interior finishing, in the manufacture of glass containers, in rail vehicle construction and in the powertrain and car body sectors in the automotive industry. Bondal is just one example for the varied applications of steels for e-mobility. TKS says it has an holistic strategic approach to this topic: as part of its Strategy 20-30, the steelmaker is developing its plant on Essener Straße in Bochum into a centre of excellence for e-mobility over the next few years. The capabilities in the field of so-called non-grain oriented electrical steels are once again significantly strengthened by investments in plants; for instance, in a new double reversing mill and a new annealing and isolating line. This will make it possible to produce thinner and stronger grades, which are the basis for more powerful electric motors. These, in turn, are indispensable for the transition to e-mobility. The market for electric cars is growing. Currently, there are already 70 models available on the German market; there are as many as 140 models when foreign manufacturers are taken into consideration. Various studies predict that the share of electrically powered vehicles in Germany will go up to 40% by 2030.

For further information, log on to www.thyssenkrupp-steel.com

For further details, log on to www.hitachi-hightech.com/hha

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09/07/2021 09:39:50

INNOVATIONS

Bumax fasteners for Slussen project

Primetals

London headquartered Primetals Technologies has entered into an exclusive license arrangement with Metso Outotec Oyj (Metso Outotec) to use Metso straight grate iron ore pelletizing (SG-IOP) technology for the Indian market. The agreement means that Primetals Technologies can further strengthen its offering of iron ore pelletizing plants for customers in India. The license provides Primetals Technologies the exclusive right to develop pelletizing plants in India based on Metso SG-IOP reference projects with grate sizes ranging from 272 to 816 square

BUMAX, a leading Swedish manufacturer of premium stainless steel fasteners, has been chosen to supply high strength and corrosion-resistant fasteners to global construction giant Skanska for the high-profile Slussen infrastructure project in Stockholm, Sweden. Skanska has ordered approximately 15,000 premium fasteners from BUMAX for the project and they will be used on the new water lock’s sluice hatches. The Slussen area of central Stockholm is being redeveloped with a new stainless steel sluice and flood gates to help the region cope with the anticipated sea level rise over the coming century. It is a massive and essential nine-year SEK15.8 billion (US$1.6 billion) project in the heart of the city and one of the biggest infrastructure projects in Sweden in recent decades. It includes road and rail infrastructure as well as rebuilding the lock and sluice system and is expected to be completed in 2025. Skanska was commissioned to provide new stainless steel sluice and flood gates for the project. The gates are among the largest of their type in the world and are designed to resist corrosion in the brackish water environment over a 100-year lifespan. As they cannot be removed once they are in operation, their strength and corrosion resistance are of great importance. The gates simply cannot be allowed to fail during their long lifespan. Skanska turned to BUMAX to provide premium high strength and corrosion resistant stainless steel fasteners for the Slussen sluice hatches. The company ordered approximately 15,000 fasteners for the project and all of them from BUMAX. The July/August 2021

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fasteners specified were a mixture of BUMAX 88 (A4/316L) and BUMAX SDX 109 (Super Duplex), which are claimed to provide high strength and excellent corrosion resistance. This solution catered for conditions posed by brackish water from Lake Mälaren and also the higher salinity of the seawater from the Baltic Sea. Bob Hamberg, purchase manager at Skanska, said that BUMAX was able to provide stainless steel fasteners that met with the high strength and corrosion resistant requirements of the Slussen project. Around 90 different types of BUMAX fasteners were ordered, the largest being the BUMAX SDX threaded rods M48x1225 and M36x1125, in class 80. Due to the size and strength of the largest rods, BUMAX collaborated with RISE (the Research Institute of Sweden) and used specialist testing equipment to test the mechanical strength of the fasteners. These tests showed that the rods could reach loads of 886kN (over 90 tons) prior to yield and 1,221kN (over 124 tons) on fracture. “BUMAX premium fasteners are simply the best for extremely demanding projects like the Slussen project,” said Lars Holm, managing director, BUMAX. “We are obviously happy to be selected as a supplier by such a distinguished construction company for such an essential infrastructure project, and we look forward to providing fasteners to many similar projects around the world in the coming years.” For further information, log on to www.bumax-fasteners.com

The Hyper UC-mill supplied to the Maruichi Sun Steel Joint Stock Company (SUNSCO) has produced its first coil at the company’s Ho Chi Minh steel mill in Vietnam. According to Primetals Technologies, the supplier of the equipment, the mill is the first of its kind in the country, and by adopting the smaller diameter work roll drive with MH Spindle, which is capable of withstanding high loads, it can reduce rolling loads and maintain the high shape control capability of the UC-mill. The new equipment was purchased by SUNSCO to service growing demand for thinner cold-rolled materials. The scope of supply for Primetals covered complete mechanical and electrical equipment as well as the supervision of installation and commissioning. The mill is capable of processing thin sheets of 0.1mm in thickness and 1,250mm in width. The UC-Mill was developed by Primetals to realize a high reduction capability and shape controllability in high tensile steel (HSS) rolling. It can be used for rolling high grade non-directional electrical steel sheets and sheet products and can use work rolls with smaller diameters. SUNSCO is part of the Maruichi Group and was established in 1996; it was the first 100% foreign capital-invested steel company in Vietnam and it produces and sells molten zinc, 55% Al-Zn galvanized steel coil, colour-coated steel coil and steel pipe. The company’s products are used mainly for civil and building construction, structural uses, furniture, bicycle and motorbike parts as well as other industrial uses, claims Primetals. For further information, log on to www.primetals.com www.steeltimesint.com

09/07/2021 09:40:15

exclusive deal with Metso Outotec

metres implemented in India over the past decades. This complements the company’s existing portfolio of circular pelletizing plants. The license agreement is a result of Metso Outotec’s merger clearance process in India. The combination of Metso’s Minerals business and Outotec was conditionally approved by the Competition Commission of India (CCI) in June last year, subject to the transfer of Metso’s SG-IOP capital equipment business in India to a suitable buyer through a technology licensing arrangement. The license enables Primetals to design, engineer, supply and commission pelletizing plants based on Metso SG-IOP tech-

nology and to engage in respective aftermarket services in India. Aashish Gupta, executive vice president and global business unit head (upstream) said that Indian pellet plant capacity was expected to grow significantly in coming years to meet growing demand for steel in India. He said the agreement with Metso Outotec will enable Primetals to provide its customers with proven and reliable technology for iron ore pellets production. “Primetals Technologies also offers circular pelletizing plants for smaller capacities up to 2Mt/yr and this agreement with Metso Outotec

supports our activities to provide iron ore pellet plants up to 8Mt/yr in India,” he adds. Primetals Technologies’ pellet plant offerings will be complemented by its environmental portfolio (MEROS off-gas cleaning technology) as well as advanced automation systems for travelling grate technology. Maximized localization of engineering services and manufacturing of equipment through Primetals Technologies India will increase the attractiveness of offerings for the Indian market. For further information, log on to www.primetals.com

Hyper UC-mill for SUNSCO facility in Vietnam

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09/07/2021 09:40:23

INNOVATIONS

Self-contained robotic welding systems The ArcWorld standard robotic systems available from Yaskawa are claimed to be ideal for replacing, or supplementing manual welding required in metal manufacturing applications. It is claimed that these fully integrated systems offer the distinct advantage of being self-contained, so it’s a bit like buying any machine tool: You choose the size of machine you need and a location to install it and away you go. According to Yaskawa, there has been increased usage of robotic systems across a wider range of manufacturing applications where investment in state-of-the-art technology is making a significant contribution to maximising efficiency. Welding applications are a good example of where the availability of new, highly flexible, space-saving systems are helping manufacturers to integrate robotics into their welding and fabrication processes. Yaskawa’s ArcWorld HS Micro and RS Mini systems are claimed to be easy to install, operate and relocate in a small footprint of either 2.3 sqm for the Mini, or as little as 1.4 sqm for the Micro. Both offer the possibility for operators to double their output with up to half the preparation time, compared to manual welding. The Micro system is supplied complete with robot and controller and its hinged door opening provides many options even if it is a very small, compact system. The Mini has a revolving door and table, which mean maximum flexibility within a compact system.

It is claimed that both systems are designed to allow quick jig changes, which are crucial when helping to reduce set-up time and improve production output. Furthermore, it is argued that improved operational consistency by never missing a weld and ensuring the same quality of weld at the end of the shift as at the start, means reduced ‘spatter’ which improves the fettling capacity. Both systems incorporate a MOTOMAN-AR900 robot with YRC1000 controller, a start/stop button panel and fume extraction hood. They also feature a platform and casing with dark

green polycarbonate glare shield protection and CE-marking. The Yaskawa Motoman ArcWorld Micro and Mini robotic welding systems are pre-engineered, pre-assembled and shipped ready to weld. According to Yaskawa, they represent the latest generation of cost-effective automated solutions for welding applications and can be configured with a choice of welding power source.

For further information, log on to www.yaskawa.eu.com

RHI Magnesita and Gerdau’s blockchain initiative RHI Magnesita, a leading player in refractories, and Gerdau, the largest steel producer in Brazil, are joining forces for a joint project using blockchain technology. The project, called Refrac Chain, is designed to measure performance contracts between RHI Magnesita and Gerdau. All data and transactions, which were previously tracked manually, will be recorded in blockchain and financial calculations and measurements will be made by a dedicated programme. According to RHI, the two companies started their collaboration because information security is a crucial asset that is increasingly gaining ground in relationships between businesses. In addition, the use of distributed technology has a fundamental impact on companies conducting large volumes of transactions. Stefan Borgas, CEO RHI Magnesita, commented: “Digitalization and Industry 4.0 are radically changing the way we work together. This impacts all areas of the business – from sales to production. Blockchain will leave no stone unturned in our industry. This key technology not only brings more security and reliability, it redefines the partnership between companies and creates July/August 2021

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opportunities to trust each other in a way that was not possible before.” The joint project allows for the traceability of processes and information exchange between RHI Magnesita and Gerdau. The blockchain platform began operating this year exclusively at a Gerdau site in Minas Gerais, Brazil. The intention is to expand the solution to other company operations. Vinicius Moura, general supply manager at Gerdau, said the project is aligned with the company’s objective of generating value for the entire steel network. “We seek solutions that meet the challenges of the business, in partnership with our suppliers in order to guarantee the operational excellence of our units. This initiative brings reliability, speed and agility to the process, and reflects the journey of digital transformation that Gerdau has been going through in recent years,” he said. Led by RHI Magnesita and Gerdau, the project helps to guarantee a continually high performance of the refractory products supplied to the steel industry. Tasks that were previously performed manually using spreadsheet calcu-

lations will now be done by the platform. RHI believes this will reduce repetitive work, speeding up the process while simultaneously increasing the transparency and security of contractual information. Gustavo Franco, CSO RHI Magnesita, explains: “Blockchain technology has enormous potential also for our industry. Establishing a secure and holistic data network with Gerdau will enhance even more our historical partnership. By driving workflow efficiencies and automated data transactions, reliable insights are provided to both parties, increasing agility in decision-making and confidence in the operations of our contracts.” According to the specialists in charge of the project at Criptonomia, Antonio Hoffert and Gleisson de Assis, this is an unprecedented use of blockchain in the steel industry. The new software combines technical, legal, and commercial workflows in one interface. “It builds a common ground of trust, with validation steps by different representatives from both companies,” says Hoffert. For further information, log on to www.rhimagnesita.com www.steeltimesint.com

09/07/2021 09:40:25

INNOVATIONS SPECIAL: LUBRICANTS

CONDAT’s eco-lubricants for steelmakers CONDAT believes that it can be a ‘lever of innovation’ to respond to contemporary challenges, such as climate change, diminishing resources and pollution. The company wants to support the efforts of its customers who are engaged in responsible trading and an awareness of social and environmental issues. CONDAT Group’s commitment to contemporary challenges was initiated several decades ago. The company claims that its fundamental values are focused on the phrase ‘build to last’. Guided by this historical value since 1854, CONDAT has been pursuing a long-term strategy that it believes has contributed greatly to its longevity. The company considers itself one of the forerunners in the development of industrial lubricants and other specialty products that offer a reduced environmental impact without compromising performance or user safety. As an example, the company launched its first biodegradable lubricants 20 years ago.

CSR commitments and assessments Since their publication in 2010, the guidelines of the ISO 26000:2010 standard have been a guide for CONDAT decision-making and actions. Although this standard does not lend itself to certification, it provides the right guidelines for all companies that believe social responsibility and environmentally friendly behaviour are key factors for success. In 2018, CONDAT went a step further with its CSR policy by joining the international ECOVADIS platform. As a member, CONDAT’s CSR performance is assessed annually by an independent body according to 21 criteria divided into four themes: Environment; human resources and human rights; business ethics; and responsible purchasing policy. In 2020, CONDAT was awarded Silver by ECOVADIS, recognizing its far-reaching sustainability and CSR policy. This achievement places the company among the top 25% of best-rated global companies and among the top 6% of companies in the lubricants sector.

A self-scoring system To provide customers with a better understanding and total transparency on its products, CONDAT has established the Lubriscore® system. Lubriscore® is a CONDAT self-scoring system that weighs the product properties based on life cycle criteria: Raw materials and design; production; transport; usage; and end of life. This rating takes into account impacts on people and the environment and is mindful of the state of knowledge and any changes of regulation at the time of assessment. A higher score is applied in case of compliance with a label or certification; as for example, an ECOLABEL-certified product. Based on a points system and on the answers www.steeltimesint.com

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given to around 20 questions, Lubriscore® grants – or not – the product with an associated number of stars. The more eco-designed a lubricant is, the higher the number of stars. The ratings range from 0 to 3 stars. By choosing a star product, the customer is opting for an eco-designed alternative. LUBRISCORE® ratings are available for a wide range of CONDAT lubricants, including metalworking fluids, wire drawing soaps, cold heading oils, hydraulic oils, die lubricants, cooling lubricants, hardening/quenching fluids and maintenance lubricants.

Eco-designed ﬁre resistant hydraulic ﬂuids? Part of CONDAT’S eco-designed product offering, CONDAT D46 and D68 are hydraulic fluids that have been widely used for many years in all industries, including steel, where protecting employees and equipment against fire is essential: for example, in steel making plants, continuous casting workshops, hot and cold rolling operations. CONDAT D fluids are claimed to prevent fire propagation and are self-extinguishing. According to CONDAT, they significantly reduce the risks presented by the use of a mineral oil in hydraulic installations, for example, when a pipe breaks or when oil is sprayed out due to leaks near a flame. The CONDAT D fluids range has all specifications requested to control users’ maintenance costs and consumption: high oxidation resistance, anti-wear properties and a high viscosity

index. CONDAT claims that its D fluids show very good results on hydrolysis resistance thanks to the high-quality level of the product formulation. The company has very stringent requirements regarding the quality and type of synthetic esters used in the product’s formulations. Other characteristics besides hydrolysis resistance are important factors in the success of the product, such as a high flash point (also dependent, on the quality of the synthetic esters), a high additivation level, which, it is claimed, ‘offers excellent anti-wear behaviour and equipment protection’. Overall, CONDAT D products are said to last 30% longer than other products on the market. Through premium fire-resistant hydraulic fluids, CONDAT says it offers steel industry operators the chance to make savings on their lubrication budget and maintenance costs. These fluids are biodegradable and non-toxic and are classified WGK1 according to to the latest Hygiene Institute standards. They allow users to limit their pollutant rejects and adopt an environmentally friendly behaviour. CONDAT further claims that its D fluids meet the latest Factory Mutual Global approval tests and have been certified ‘Approved Fire Resistant Fluids’. CONDAT D lubricants received a three-star Lubriscore rating and this ‘perfectly illustrates the concept of Responsible Performance that the company targets’, says CONDAT. For further information, log on to www.condat-lubricants.com July/August 2021

09/07/2021 09:40:28

SPECIAL STEELS

Swiss army knives still cut it From preparing meals around a campfire in the wilderness to fixing a faulty toaster in a city apartment, the multi-purpose Swiss army knife embodies both adventure and reliability in a pinch. With the help of molybdenum, this durable product ‘still cuts it’ and remains popular around the world. By Karlee Williston* THESE compact multi-functional tools can scale a ﬁsh, strip bark, remove a splinter, start a fire or tighten a screw. With 83 possible uses, depending on the model, Swiss Army Knives can also open a bottle or can, check the temperature, file fingernails, chisel, prune or strip the coating off an electrical wire. With so many applications, this acclaimed pocket knife is still one of the most trusted tools for hobbyists and handymen from Bangkok to Berlin. The history of a trusted companion Members of the Swiss military received the first version of the knife complete with a blade, reamer, screwdriver and can opener in 1891. Six years later, the Officer’s Knife was introduced, which included the socially-essential bottle popping corkscrew. Building on its military success, the versatile tool became an international phenomenon. In 1945, the knife’s popularity spread like wildﬁre across the Atlantic when US soldiers stationed in Europe during World War II

were excited by its functionality and quality. The inventor and world’s top producer of this iconic product is Victorinox, the knife manufacturer and watchmaker based in the picturesque Swiss town of Ibach. The humble Swiss army knife has come a long way in its 130-year history. Every day some 45,000 are produced in an array of colorful styles and designs, and engineers continually improve their durability and versatility. And it’s the molybdenum in the steel blade, among other elements, that keeps the knives operating at the sharp end. Bracing nature’s extremes The combination of tradition and advanced technology means molybdenum is a vital component in the manufacture of the knife. The EN 1.4110 martensitic stainless steel used for the blades contains 0.5% to 0.8% molybdenum, which makes it wear and corrosion resistant, enabling the knives to maintain a sharp edge. These are key features for such a dependable product,

where regular use is possible even in the most challenging of environments. Swiss army knives’ proven utility in cities, oceans, mountains and even in outer space, is a testament to their enduring appeal. In 1978, NASA purchased 50 pieces of the Master Craftsman model for use aboard the Space Shuttle Enterprise. As anyone who has opened a toolbox in zero gravity will understand, chasing tools as they ﬂoat around the space lab is not a great way to make necessary repairs. The all-in-one nature of the pocket knife consolidated most of the tools into a hand-held device – problem solved. In fact, during the 1980s, the Master Craftsman was renamed the “Astronaut” knife for its storied use in space. Extraordinary performance of the knives is found closer to home as well. During a recent trip to Egypt for a TV documentary, Sir Ranulph Fiennes, a worldrenowned explorer, tutored his younger cousin, Joseph Fiennes, on defusing an anti-tank mine with the trusty knife. It is

*Editor, MolyReview July/August 2021

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SPECIAL STEELS

1. This pocket knife features a fork, suitable to spear bread for the good old Swiss standby, Fondue – and a corkscrew, to open an accompanying bottle of wine. 2. Batteries of polishing and sharpening machines at the workshop in 1943. Even today, some knives are still assembled and sharpened by hand. 3. Small-series and custom pocket knives are still assembled by hand. Large-series knives use a fully automated process.

4. Knife blades are stamped out of a strip of stainless steel, leaving behind scrap to be recycled (left). The raw stainless steel edges are smoothened by tumbling in a deburring machine, filled with abrasive ceramic media (middle). Each blade is heat treated to make it hard yet tough (right). © Victorinox

little surprise that such a compact, sturdy design ﬁnds use in the most extreme of environments. However, the Swiss army knife is not just at home in intense situations. It can also be found in the New York Museum of Modern Art, the MOMA, which recognized its seminal design in 1977. A cutting-edge process While the pocket knife is certainly its most famous product, the company is also renowned for its household and professional knives. In total, over 135,000 knives are made each day at its Swiss factory. The ﬁrm designed and built many of the machines used in the manufacturing process in-house to guarantee the quality of the more than 600 types of knives it produces, including 400 types of pocket knives. Molybdenum also plays an important role as an integral part of the manufacturing process. Each knife blade is stamped from a strip of stainless steel. The tools required for the stamping process need to be hard, tough, and long-lasting. www.steeltimesint.com

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The tool steels used for these stamping tools contain up to 4.5% molybdenum to ensure that each knife is cut as precisely as the one before. Once the raw blade is stamped out of the stainless steel strip, it is ground to its final wedge shape and precisely sharpened. These stamping and grinding processes inevitably produce a lot of ‘waste’ material. However, nearly 100% of it is reclaimed for recycling. The solid 5. Even grinding dust is captured and compacted into pellets, convenient for recycling at the steel mill.

cut-offs are easy to collect, but the ﬁne grinding dust is more elusive. To capture it, a custom machine separates the ground stainless steel particles from the cooling liquid used during the grinding and polishing processes. It then compresses the collected particles into pellets, which are returned to the steel producer to be recycled into new stainless steel. Of the 2,400 tonnes of steel purchased each year, nearly 1,200 tonnes go into the actual knife blades and other ﬁnished products, with the remaining 600 tonnes of cutoffs and 600 tonnes of particles being recycled. Constant improvements of the production, recapturing and reuse of waste streams ensure the high-quality knives are manufactured efficiently and sustainably. Compact and stylish, with a wide range of features, the Swiss army knife is appealing to users everywhere – city dwellers, farmers, intrepid travellers or groundbreaking pioneers. Molybdenumalloying improves both the manufacture and the performance of this quintessential tool. � July/August 2021

12/07/2021 06:39:33

Incorporating the BIFCA Standards Seminar

ONLINE EVENT 14-15 SEPTEMBER REGISTER TODAY

The future is now when it comes to furnace technology

Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials. But how can energy-intensive manufacturers work towards making this future a reality? Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Could we be doing more? This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life.

FROM THE PRODUCERS OF

Topics will focus on: r Industry 4.0 (the Furnace of the Future) r Furnace Maintenance r Heat Treatment r Energy Efficiency r Testing & Measurement r Retrofitting r Emerging Technologies r Operations & Productivity Alongside the two-day virtual conference, participants will also be invited to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resources and information. IN ASSOCIATION WITH

ASSOCIATION PARTNER

ORGANISED BY

www.furnaces-international.com

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07/06/2021 11:45

ARTIFICIAL INTELLIGENCE

Smart steelmaking through digitisation As Artiﬁcial Intelligence (AI) emerges as the frontier of world-changing technologies, there is an urgent need for systematic development and implementation of AI to understand its real impact in the next generation of industrial systems, namely Industry 4.0 which encompasses the Internet of Things, Machine Learning and Big Data. By I Banerjee*, M Shrujan*, and S Singh* DIGITALISATION of steelmaking started some decades ago, but received a strong acceleration by the introduction of ‘Industry 4.0’ and now directly impacts all units of an integrated steel plant. With the advent of technologies such as the Internet of Things (IoT), Artiﬁcial Intelligence (AI), Machine learning (ML) and Big data techniques, the digitalisation programme for the steel industry has obtained the necessary impetus which was lacking for years. Historically, Machine Learning and AI have been perceived as black-art techniques and there was often a lack of compelling evidence to convince industry that these techniques would work repeatedly and consistently to justify the return on investment. At the same time, the performance of machine learning algorithms is highly dependent on a developer’s experience and preferences. Hence, the success of AI in industrial applications has been limited. On the contrary, Industrial AI is a systematic

discipline, which focuses on developing, validating and deploying various machine learning algorithms for industrial applications with sustainable performance. It acts as a systematic methodology and

discipline to provide solutions for industrial applications and function as a bridge connecting academic research outcomes in AI to industry practitioners such as steel plants.

Fig 1. Stages of innovation

*The authors are with the Research and Development Centre for Iron and Steel, Steel Authority of India Ltd e-mail indranil@sail.in www.steeltimesint.com

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ARTIFICIAL INTELLIGENCE

Manufacturing sophistication Organisations need a clear strategy to realise the benefits of intelligent manufacturing. Without crisply defined business objectives for the intelligent factory, ambitious projects, such as IoT-based data collection and advanced analytics, can wander into oblivion. Not only that, but advanced analytics, if not implemented correctly, could fail to achieve the expected return on investment and could even increase costs and risks. Knowing where an organisation is going and what benefits to expect is essential. But to start, management needs to know about the current state of the manufacturing unit. The three stages of manufacturing sophistication are ‘standard’, ‘automated’, and ‘intelligent’ (Fig 1).

Fig 2. Data ﬂow in a Big Data system

This paper brings out some key enabling frontier technologies being leveraged by the steel industry, to improve upon quality and productivity parameters. Implementation A lack of connectivity in shop floor and unintelligent manual processes often stand in the way of getting quality products out of a factory in time. For large industries such as an integrated steel plant, one of the greatest challenges in achieving intelligent automation is the misalignment of processes and workflows that could support automated decision making. Also connectivity with legacy automation systems and data reliability are issues that need to be taken up as challenges. Connecting Internet of Things (IoT) devices and using cognitive capabilities to align workflows and processes are crucial capabilities of intelligent manufacturing plants. But these plants do not depend on just one or two technologies to work their magic. Intelligent plants are created by leveraging potent combinations spanning automation, artificial intelligence (AI), the IoT, edge computing, cloud, 5G, additive manufacturing, and digital twins to transform their operations. Deploying this vast array of technologies is complex July/August 2021

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and requires both IT and Operational Technology (OT) skills to build and execute. Migration from legacy automation systems also has to be adopted in an aggressive manner. The return on investment can be worth the effort. Intelligent manufacturing can facilitate improvement in on-line defect detection by as much as 50%, and improvement in yields by 20%. In most cases manufacturers also report intelligent automation has increased revenues by almost 8%.

Standard factories monitor performance based on historical data. Typically upgraded plant operations offer technologies and concepts such as Manufacturing Execution Systems (MES), which track and monitor current data about the production life cycle and operations. The goal is to help ensure efﬁcient processes. However, standard factories have typically not yet infused stateof-the-art technologies, such as machine learning or connected IoT, into their lean manufacturing practices. The automated factory leverage the advancement in robotics. In steel manufacturing, robotics is playing a major role. There are many activities which are hazardous and monotonous such as sample and temperature collection from liquid metal, zinc pot dross removal in galvanizing lines and so on. Steel manufacturing ﬁnds

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ARTIFICIAL INTELLIGENCE

many applications of real-time analytics and predictive models . Typically, manufacturing automation is based on control systems and programming languages that are not fully capable of adjusting to complex changing conditions, both internal and external. For example, as the automation industry moves toward more open protocols, collaborative robots (cobots) and other transformative enablers ﬂourish. Automation facilitates innovations such as lot-size-one, selfhealing factories, and putting robots to work in areas where human interaction is required. The latest automation technology can engage in data sharing and co-creation within the manufacturing framework, learning from other units, and enabling plant optimisation as a whole. Smart factories or Intelligent manufacturing is the utilisation of real-time data analysis, artiﬁcial intelligence (AI), and machine learning in the manufacturing process to accomplish process optimisations. By processing real-time data from machine sensors and applying AI and ML, it is possible to predict critical events and take preventive action to avoid problems. Some of the most prominent examples in steelmaking are breakout prediction for casters, cobble prediction in hot strip mills, and Basic Oxygen Furnace (BOF) converter end point prediction using off-gas analysis. The ‘Smart Factory’ depicts an intelligent factory that is self-optimised yet does not remove decision-making power from humans. The base prerequisite is the integration of machines, applications, and people, and, of course, applying AI to assist in self-learning processes and actionable insights.

Fig 3. Bearing vibration analysis

have speciﬁc impact on: • Manufacturing/maintenance processes optimisation by leveraging the collected information enabled by intelligent sensors that are more widely deployed within steel plants.

• Access to data that was not accessible or monitored before (because of constraints on range, power, size and location). • Network convergence based on the IPv6 protocol leveraging the wide range of specialised sensor networks supporting this

Key enabling technologies A smart factory can feel, hear, and see, with a focus on quality control. It can also provide information about equipment and production process status in various languages. To do this it needs several enabling technologies. Internet of Things Today, the Internet of Things (IoT) is usually presented as being the frontier technology that will largely inﬂuence our lives in a way similar to the impact of the global spreading of the internet or mobile communications. Considering the case of the steel industry adopting Integrated Intelligent Manufacturing, IoT is foreseen to www.steeltimesint.com

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ARTIFICIAL INTELLIGENCE

Fig 4. Smart sensing and edge computing

core protocol. • Productivity enhancements by enabling the integration of mobile and virtual reality (VR) applications interacting in real time with objects, materials, machines and information systems. Nevertheless, IoT still has to address strong challenges especially related to security and reliability of data so that reliability of operation is ensured. Big Data technologies For the steel industry there is huge scope for the application of Big Data. A generally agreed deﬁnition of Big Data is based on the characteristics of the data and the volume of data to be handled, which is huge. The data has to be processed at high speed. Data sets are made of data of a great variety of formats. By managing this massive volume and variety of data, it is possible to take into account several data sources and build a powerful data analysis system. Using a Big Data analytical approach, it is possible to develop predictive analysis systems, real-time monitoring, and reactive systems. Also state-of-the-art process visualisation systems can be developed. The concepts of Big Data are implemented into a data processing software stack which is made of a number of layers (Fig 2). Cyber Physical Systems A Cyber Physical system (CPS) is one that connects real (physical) objects and processes with informationprocessing(virtual) July/August 2021

AI in steelmaking.indd 4

objects and processes by open, partially global and at all times interconnected information. Optionally, a CPS uses local or remotely available services, has a Human Machine Interface (HMI) and offers the possibility for the dynamic adaptation of the system at runtime. Cyber Physical Systems are typically based on embedded systems which collect data from sensors and inﬂuence processes by actuators. They are connected with digital networks and use data and services and communicate with plant personnel via Human Machine Interfaces. In steel manufacturing, small components of the production machinery could become a CPS in the future – for example a bearing. If this bearing has an oscillation sensor and an embedded small processor to evaluate the sensor data and to predict the remaining lifetime based on a suitable model, and if it is connected to the global information network of the company to inform a higher level decision system about its prediction result, then it is a Cyber Physical System (Fig 3). Smart sensing and edge processing Smart sensor nodes are key enablers of predictive analysis. They gather and log pre-processed secure data to be displayed in visualisation tools and used in other processing algorithms. Smart sensor nodes can also process data and detect anomalies by reducing computational latency. For example, smart sensor nodes can detect a small rise or a sudden increase in temperature indicating a probable device issue and future reliability problems.

Gateways are either implemented to collect and process data from several smart sensor nodes or to act as a connectivity bridge to enable secure connection to the Cloud using ethernet, Wi-Fi, cellular or LPWAN. Edge processing combines and distributes processing power among smart sensor nodes and gateways with the aim of sending the right data at the right time to enterprise-level systems where more advanced analyses can be performed. It is a distributed, open IT architecture featuring decentralised processing power, enabling mobile computing and Internet of Things technologies. Data is processed by the device itself or by a local computer or server, rather than being transmitted to a data centre for processing. Processing at the Edge can also use Machine Learning and Artificial Intelligence (AI) algorithms to enhance smart sensor node and gateway mission profiles and to broaden the scope of anomaly detection and classification (Fig 4). Conclusion Perhaps most of the promise and success of Industry 4.0 and the Internet of Things for steel plants depends on effective Machine learning, Artificial Intelligence, Big Data, and other advanced analytic techniques. If comprehensively implemented these technologies can provide digital twin virtualisation, insight, and predictability. In addition, organisations also need to understand the details of how customers use their products in the field and how products age and their reliability deteriorates or when they would need maintenance. � Bibliography [1] Jay Lee, Jaskaran Singh, Moslem Azamfar ‘Industrial Artificial Intelligence’ [2] A Guzman, S Ishida, E Choi, A Aoyama ‘Artificial Intelligence Improving Safety and Risk Analysis: A Comparative Analysis for Critical Infrastructure’ Proceedings of the 2016 IEEE IEEM [3] Jay Lee, Hossein Davari, Jaskaran Singh, Vibhor Pandhare, ‘Industrial Artificial Intelligence for industry 4.0-based manufacturing systems’ 2213-8463/ 2018 Society of Manufacturing Engineers (SME) [4] Bo-hu LI , Bao-cun HOU , Wen-tao Yu, Xiao-Bing Lu , Chun-wei Yang, ‘Applications of artificial intelligence in intelligent manufacturing: a review’ Li et al / Front Inform Technol Electron Eng 2017 18(1):8696 www.steeltimesint.com

09/07/2021 14:43:28

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OXYGEN STEELMAKING

Intelligent BOF steelmaking Tenova’s i BOF® platform is a comprehensive array of BOF automation and process control modules designed to increase productivity and yield, reduce fugitive and particulate emissions and lower operating costs for all phases of the BOF process from charge management through to secondary metallurgy and degassing. By Dr. DJ Zuliani* Tenova’s iBOF® platform provides control and optimization across all BOF steelmaking process steps (Fig 1). The i BOF® process modules include slop control, endpoint control, auto tapping and slag carryover control as well as charge management and level 2 automation (Fig 2). Each can operate independently and can be added individually or as a complete i BOF® solution. Tenova also offers a BOF post combustion control module for increased scrap melting, and secondary metallurgy modules for degassing endpoint control using insitu laser off-gas analysis and for alloy cost optimization, which are beyond the scope of this article. iBOF® Digitalized Systems enable standalone iBOF® modules to communicate and thereby work together as part of an ‘intelligent’ network. iBOF® control modules Slop Control Slopping occurs when molten slag foams uncontrollably and spews from the converter mouth. Unless a deliberately

Process phases Fig 1. Tenova’s i BOF® platform provides control and optimization across all BOF steelmaking process steps

conservative blowing practice is employed, most BOF shops will encounter slopping once the rate of CO generation peaks after silicon oxidation. Table 1 outlines the substantial savings attainable with better slop control [1,2,3,4]. Fig 3 illustrates how Tenova’s slop control module functions [4]; • an accelerometer attached to the lance carriage, continuously monitors lance vibration; • proprietary software analyzes the vibration data in real-time;

• specialized cameras facilitate tuning of the slop detection model; • the System is tuned to alarm 2040 seconds before visible slopping with minimal false alarms; • the slop alarm triggers dynamic mitigation (lance height, O2 blowing rate, CaO); and, • once the slopping threat has ended, the system dynamically returns to standard blowing conditions (Fig 4).

Fig 2. i BOF® modular platform

Fig 3: Schematic of Tenova’s slop control module

• Director, Tenova Goodfellow Inc, Canada. Email: doug.zuliani@tenova.com July/August 2021

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OXYGEN STEELMAKING

Fig 4. Lance proﬁle (bottom line) and oxygen ﬂow (top line); normal conditions (Region A),

Fig 5. Slop detection and mitigation benefits verified in five European BOF vessels [2]

dynamic slop mitigation (Region B) with dynamic return to normal blowing

Table 1. Savings with effective slop control (USA steel plant)

The beneﬁts of Tenova’s slop control module are summarized in Fig 5; to date, 10 Tenova slop detection systems have been successfully installed in North America and Europe with six additional systems currently pending. Fig 5.

Table 2. Veriﬁed savings on low carbon heats using Tenova’s endpoint detection system

Endpoint control Poor endpoint control manifested as reblows, overblows or blowing down high/ mid-carbon grades to ~0.04%C before ladle recarburization causes yield and productivity losses, elevated tap ppm [O], increased slag FeO and excessive tap alloy

consumption. To ensure a robust, low cost endpoint solution, Tenova’s latest generation endpoint control module includes: • real-time mass and energy (‘M&E’) balance software incorporating fundamental thermodynamic and kinetic

Fig 7. Application of the multipoint NextGen® analyzer system to a 3 BOF shop

Fig 6. Tenova’s patented NextGen® hybrid extractive/laser system

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OXYGEN STEELMAKING

Table 3. Conﬁrmed savings with a catch carbon practice using Tenova’s endpoint detection system Fig 8. Left. Predicted sec-

Fig 9a and 9b. Upper – turn down too early at high [%C]

by-sec evolution of slag

when using 0.1%P hot metal can result in [%P] exceeding

chemistry

the 0.015% max spec. Lower – overblowing the heat can result in [P] revision

Fig 9a Fig 9b

equations to better model the nonequilibrium near-end of blow conditions when carbon, iron and phosphorous oxidation can occur concurrently; • patented NextGen® hybrid extractive/ laser off-gas analysis technology, proprietary off-gas velocity and temperature sensors and a PLC link provide all the measurements needed to close a precise real-time M&E balance (Fig 6). NextGen®’s multipoint capability reduces hardware, installation costs and maintenance by enabling continuous, simultaneous off-gas analysis on multiple BOFs with a single central cabinet (Fig 7). With the real-time M&E balance, Tenova’s technology provides a precise endpoint solution:[5] • Reliable [C] and temperature endpoint control for low carbon grades: By eliminating assumptions or statistical models, Tenova’s M&E balance approach is capable of predicting endpoint carbon to within 0.01% and temperature within 17 °C on about 90% of low carbon heats, thereby generating signiﬁcant operating cost beneﬁts (Table 2). Typically, low carbon heat savings range from $1.00 - $1.25 per tls. • Catch carbon practice for mid- and July/August 2021

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high- carbon grades: Stopping a blow with precision at higher carbon levels is difﬁcult; Tenova’s catch carbon endpoint detection system has demonstrated a 60% reduction in endpoint standard deviation on mid/high carbon grades thereby avoiding recarburization in the ladle, higher operating costs, higher tap oxygen levels and increased tap alloy consumption. Table 3 shows using a 0.05% ‘catch carbon’ practice instead of an 0.04% recarburization practice reduces endpoint [O] ppm and tap alloy consumption with savings between $1.65- 3.15 per tls. • Complete slag and bath chemistry prediction from start-to-end of heat: Tenova’s fundamental model predicts the evolution of both slag and bath chemistries from start-to-end of heat providing a valuable data base for i BOF® digitalization advanced analytics and continuous improvement. Fig 8. • Improved phosphorous endpoint control: Tenova’s endpoint model predicts near-end of blow [P]. With 0.04%, HM [P], the endpoint carbon window to hit < 0.015% [P]max is quite wide and phosphorous reblows are rare. However, Fig 9 shows that, at 0.1% HM [P], early

turn-downs and over-blowing can both result in over spec [P]. i. Auto-tapping Tenova uses specialized software, cameras and image recognition to automatically and safely control BOF tapping. The aim is to maintain the optimum tilt angle, maximize the ferrostatic head over the taphole, delay the onset of a vortex and minimize slag entrainment in the tap stream. Typical auto-tapping benefits are summarized in Table 4. The i BOF® Auto-tapping solution incorporates many specialized technologies which can be configured to either enable fully automated tapping without operator intervention or to provide an optimum tilt angle guidance curve for the operator to follow. In both cases, the aim is to maximize the ferrostatic head over the taphole and avoid an early slag vortex which causes excessive slag carryover. Furnace lip camera for ‘slag on the lip’ detection A ladle view camera and car positioning algorithm confirm ladle positioning and freeboard. www.steeltimesint.com

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OXYGEN STEELMAKING

D A

C A. Furnace lip camera for ‘slag on the lip’ detection B.Ladle view camera, car positioning algorithm conﬁrm ladle positioning and freeboard C. Stream and slag detection camera D.HMI display – system information, tap-time calculation and optimum furnace trajectory

Charge management with optional level 2 Charge management is critical – it balances raw material costs against productivity, yield and steel quality requirements. i BOF® charge management properly evaluates all these factors and provides a comprehensive management tool that includes a static charge model together with scrap optimization and ferro-alloy optimization models to maintain the lowest cost scrap mix while ensuring correct steel chemistry. Tenova’s optional level 2 is a fully open, flexible supervisory system that executes the charge management models in the correct sequence using the correct data to properly account for production delays, changes in HM temperature and chemistry, changes in scrap densities and chemistry, flux requirements and grade specifications. Fig 10. Effective charge management is critical to the BOF process from defining the HM/ scrap ratio, optimizing the scrap mix, trim additions and tap alloys and defining the end of the blow. Fig 11. www.steeltimesint.com

Oxygen in steelmaking.indd 4

Table 4. Tangible and non-tangible beneﬁts with Tenova’s auto-tap technology

The i BOF® static charge model allows the steel plant to tailor its specific operating constraints from ‘must have’ to ‘high priority’ to ‘relaxed’ – the model uses a least squares method to find the optimum solution; if it is unsolvable, the best suboptimal solution will be calculated. Fig 12. Confirmed i BOF® charge management benefits include: • 1.5% reduction in reblows; • 0.15% increase in yield • 62% of heats stopped within 10% of target • Improved ppm [O] and [P] endpoint control • Offline optimization analysis i BOF® DIGITALIZATION Fig 13 shows that individual steel plants can install one or more i BOF® control modules and then add the corresponding i BOF® digitalization which enables each module’s process control computer to connect to Tenova’s digital diagnostic centre via the internet.

To comply with each steel plant’s data security protocols, data from the onsite i BOF® control modules can be transferred either in batches, continuously, or on demand/request to a remote server. Tenova offers two data storage options to meet each plant’s highest security requirements: the highly secure Microsoft Azure Cloud, or a secure dedicated Tenova server. In compliance with each steel plant’s data security protocol, i BOF® digitalization creates a large data pool for the installed i BOF® control module(s). As shown in Fig 13, Tenova created a digitalized programme, Service 4.0, that provides ongoing service, support and continuous improvement functionality for each i BOF® control module – each steel plant can tailor the level of Service 4.0 coverage that best meets its priorities. Service 4.0 is designed to provide each steel plant with the following functionality: • Performance monitoring: Tenova uses the incoming data to monitor each i BOF® control module including both hardware and process control model performance. July/August 2021

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OXYGEN STEELMAKING

Fig 11. Charge Management touches every part of the BOF Process

Fig 10. Tenova’s i BOF® Charge Management and level 2 supervisory system

Fig 12. i BOF static charge model provides the optimal charge mix solution with

Fig 13. Tenova’s i BOF® Digitalized System of Onsite

complete user ﬂexibility

Process Control Modules connected to Tenova’s Off-Site Digital Diagnostic Centre

Where appropriate, monitoring also uses Tenova’s proprietary digital image recognition software to seamlessly provide image acquisition, analysis, event conﬁrmation, severity recognition, image registration, registered image comparison, and improved performance. As noted above, data is transferred from each i BOF® control module to the Tenova digital centre cloud or steel plant dedicated server either in batches, continuously or on request; • Dashboards: The incoming data are used to generate real-time KPI-driven dashboards that are displayed on each i BOF® control module’s web-based HMI. These dashboards are designed to provide steel plant management with a rapid assessment of hardware health, maintenance and repair status, and process control model performance; • Model tuning portal: Tenova provides a web-based portal for steel plant users to upload data to retrain an existing i BOF® model whenever the dashboards indicate declining performance. Data can be quickly uploaded, the model is automatically retrained on the new data set, and a performance report is issued to July/August 2021

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assess the new model. If desired, the newly tuned model can be downloaded, quickly installed, and used on the next heat; • Remote access: When required, Tenova engineers can request remote access to an i BOF® control module to enable prompt, low-cost technical support and rapid system diagnostics and repairs; • Advanced cross-correlation data analysis: Tenova’s data scientists use advanced analytics and machine learning on the large i BOF® data pool to assess the performance capabilities of each i BOF® control module. In addition, the entire data pool is analyzed to identify cross-correlation between various installed control modules – for example, determining the crosscorrelations between slop frequency and endpoint prediction, or correlating the rate of CO generation with slop initiation; • Continuous performance improvement: i BOF® digitalization allows monitoring of each process control model’s performance to identify when adjustments are required, to maintain peak performance by rapidly and retraining process models, to install software patches as required, and to develop cross correlation algorithms that

further improve system performance.

References 1. Shakirov, M., Boutchenkov, A., Galperine, G.; Schrader, B., “Prediction and Prevention of Slopping,” ISSTech 2003 Conference Proceedings, p. 655-666, 2003 2. Scipolo, V. Zuliani, D., Todorovic, I., “Update on Tenova’s Intelligent i BOFTM Technology and Slop Detection System (SDS)”, AISTech Conference, Indianapolis In, 2014 3. Evestedt, M; Medvedev A.,” Model-Based Slopping Detection in a Top-Blown Steel Converter,” Department of Informational Technology, Uppsala University, Sweden, 2007 4. Kaﬁe, J.; Babaei, B.; Scipolo, V., “ BOF Slop Detection – Savings Potential with Real-Time Slop Detection & Mitigation Technology”, AISTech Conference, Cleveland, OH, 2015 5. Zuliani, DJ; Scipolo, V., “i BOF® Technology Improves BOF Process Control, Endpoint Detection & Slop Mitigation”, AISTech Conference, Pittsburgh PA, 2016 www.steeltimesint.com

12/07/2021 06:44:42

WELDING

UK welding standards must improve The authors of this article who have a combined 90-years of experience as welding engineers argue that welding engineering, in all its aspects, has fast become a forgotten and disrespected science and technology, to the detriment of the performance of welded structures produced by the United Kingdom welding fabrication industry resulting in a potential danger to health and safety. By D W Holden* and E J France** TO justify what needs to be done to improve the welding skills of the UK welding workforce, let us answer a possible question that could be put to people in general and yes maybe to politicians. Question: What skills are more important to the UK economy, ‘computing’ or ‘welding’? Answer: It all depends on how you look at the question. Most people would answer that it is computing. However, the reality is that it is, in fact, welding. The reason why welding is so important is that computing is entirely dependent and reliant upon a constant supply of electricity. Constant electricity supply is dependent upon the welds that hold the generation

plant together being of appropriate quality, such that there is no loss of power due to premature equipment failure. If we allow welding to become a ‘forgotten technology’ and the welders produce inadequate weld quality in power plant, then power cuts resulting from poor weld quality will become more frequent and exceed any back up battery supply, and then there will be ‘no computing’. Therefore, welding is a more fundamental requirement than computing. Establishing this fact underlines an urgent need to enhance the skills of welders. Question: Where are the next generation of welders to come from and how are they to be educated and trained?

Apprenticeships in industry Current apprenticeships in the welding industry are seriously flawed. This comment must be taken as fact if progress is to be made in training welders. The welding fabrication industry is vast, it includes many welding processes, materials, specifications and standards, and, therefore, the numbers of new skilled welders required is considerable. Some companies train apprentices, mostly leaving it to the older welders within their company to pass on skills, but such training will only involve welding techniques, materials and standards that are applicable to that company. If the product of the company is, say, garden gates, this feature would determine the

*Holden Tech Weld I – Welding development engineer and consultant **Dr E J France – M Weld I – welding consultant e-mail: enquiries@ejfranceconsulting.co.uk www.steeltimesint.com

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WELDING

structures are everywhere, peoples’ lives are at stake on oil rigs, chemical plants, pressure vessels and nuclear installations etc, and we train welders on a 12-week course! This is an unacceptable state of affairs, as well as dangerous and absurd.

Fig 1.Illustration of automation of welding processes using a welding robot

level of training. Alternatively, should the product be nuclear pipe work, then again this would influence the training level. This is a serious drawback for the welding industry as it produces variable levels of skill from company to company and confusion for the welders. Another aspect of irresponsibility in welding, within many companies, is the attitude of management to training. This attitude is of a disparaging nature, with comments such as: ‘just watch what he does over there ‘. Welding to management is regarded as simply a means to an end, rather like painting or wiring a plug, it is not important, anybody can do it! One hopes that any reader of this article appreciates how dangerous this attitude is, especially in relation to aspects of health and safety when welded fabrications are put into service. Everyone should be worried by this reality.

reality is a very basic level of practical skill is taught, with a limited number of welding processes, due to restricted amounts of material being available. There are other courses available, for example, evening classes providing, typically, a 12-week short course. The authors have personally witnessed welders who, after being trained for 12 weeks, were subsequently dismissed for their poor skill levels shown in industry. Whoever designed these short courses have no understanding of the most complex of journeyman professions and should be severely criticized, such courses are a waste of time and government money. Health and safety rules are now very strict, welded

On-the-job training Training ‘on-the-job’ is one of the worst methods of training apprentices adopted by welding fabrication companies. It is a technique that breeds bad working practices, welders passing on their own unverified methods they have used for many years. Some of these welding methods may be good, but generally they are bad – with short cuts predominant. In companies, welders who are training apprentices can be subjected to time restraints derived from production demands, this leaves less time for on-the-job training and leads to low skill attainment and confusion. In the welding industry, young people and apprentices hear about ‘coded welding’, with its high skill requirements, they then ask but what is it? Very few, if any colleges, train apprentices with a view to becoming a ‘coded welder’. How does one obtain this coded level of welding ability? Welders need to be trained to recognize they have to achieve the ‘common objective’ in a welded joint1. The training required can be implemented by enriching the welder training courses based upon the City and Guilds philosophy, which should be government sponsored and supported. At this point we can now accurately define what is a truly skilled welder:-

Part or full time study Some companies allow day release, the co-author of this article, D W Holden, has taught in colleges that are involved in this activity and has witnessed the standards that can and cannot be attained. The City and Guilds Institute courses have stood the test of time by way of basic theoretical knowledge, but the practical welding skill level falls short of what industry requires. Despite this, the philosophy of these courses are sound, all that is required is enrichment. The current July/August 2021

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09/07/2021 14:51:36

WELDING

‘A welder is a person who has developed the ability to implement those techniques which are known to suppress and control imperfection levels that can occur in a weld, when any welding process is applied to a joint, in accordance with an approved and/or qualified welding procedure or instruction’2. The importance of the person Over recent years in the welding fabrication industry, misguided management have tried to resolve the lack of skills by thinking that they can replace welders with automated welding machines (Fig 1). Now we briefly explore the effects of the automation of welding processes. • Question: Does robotic automation in the application of welding a joint produce welds faster than a manual techniques? True answer: No – but, yes, if one is prepared to accept and tolerate a level of imperfection and defectiveness in the finished welded joint. • Question: Does a welding robot actually carry out welding? True answer: No. This is a fact as indicated below!

needed to fulfil this function is considerable practical welder skill, experience and individual ability. This is an illustration of why it is vital welders need and receive the initial and appropriate training to satisfy the needs of the welding fabrication industry. The professional welding engineer Welding engineers come mainly from an academic background with a university degree, usually in materials science or nowadays a welding degree. Some organisations regard this as the only qualification necessary to be given the title of ‘European Welding Engineer’. This way of thinking should be challenged as the duties of a welding engineer go far beyond materials and how they react when welded together. All degree educated welding engineers have to realise that to be regarded as a professional they must obtain many years of practical and industrial experience. Questions to be answered in production There follows six examples of practical knowledge required, although there are many more inevitably.

• Which welding process will give the quality of product with an economic speed of manufacture? • What is the operator skill level within the company? • Which are the welding specifications to comply with to maintain a standard for quality? • How do we train our welding operators to reach these standards? • Which welding sequence must be adopted to control weld distortion? • What are the welding parameters and process manipulation techniques to produce a satisfactory weld procedure? A few companies may employ a person whose role as welding development engineer would be to have the practical skills to develop and select the following: • The appropriate welding processes and welding parameters for the joints, • The manufacturing techniques, • To train and test welding operators and to provide welding engineers with welding parameters to generate procedures. To establish good and effective welding parameters by means of development

• Question: Does a welding robot need a skilled welder to operate it? True answer: Yes, most definitely. • Question: What advantage over manual welding techniques and application of welding processes does a welding robot provide? True answer: Consistency of weld quality only. The correct use of welding robots in industry provides an insight into the importance of, and requirement for, skilled welders. This will be a surprise to the uninitiated and why the UK economy still desperately needs more skilled welders, as the truth indicates that automation does not directly replace welders in reality. Automation of a welding processes actually makes the individual welder more productive; it cannot replace the welder. When a skilled welder is in the weld joint development mode, the result is derived by trial and error, ie an empirical approach. The applicable weld procedure to make the joints for a fabrication, such as the need for high integrity fabrication as illustrated in Fig 2, is the MIG welding process. What is www.steeltimesint.com

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Fig 2. Developing manual welding on a prototype austenitic stainless steel container for spent nuclear fuel container. Pic courtesy D Holden

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WELDING

involves years of practical experience and a good theoretical knowledge. Many companies today may operate with just a welding engineer in total control, some with no welding engineering input at all, and some leave the welding at the total discretion of the welders. This is where the problems begin. A few examples of burgeoning problems witnessed during the authors’ long careers are mentioned here, some of which could bring about a catastrophic failure: • Welding engineers obtaining weld parameters from books, or asking the welder or the foreman or even guessing – the latter being the most dangerous action to take. Welding is an empirical science which means development of procedure is mandatory. • Question: Where is your company welding engineer? Response: “I am not a welding engineer, just a planning engineer, I get the weld parameters from the welders”. A true quote from a weld audit of a crane manufacturer, this remark should frighten every one and indicates aspects of the decline of welding fabrication. The engineering virus was deeply engrained in this company. • Question to welder – Where do you get the parameters for welding that joint? Answer – “My work mate tells me what to use”. This could lead to a mistake that produces a very defective welded joint that prematurely fails in service and gives rise to injury or even a fatality. • What is a weld procedure for? “We don’t use procedures, we leave it to the welder”. A quote frequently to be heard in welding fabrication companies these days. Readers of this article should be really worried by this behaviour by management in the welding fabrication industry today. It is accepted that some knowledge of metallurgy/materials science is indeed necessary for consideration to be given the title of a skilled welder or indeed a ‘welding engineer’. However, without some practical experience and its potential contribution to an individual’s knowledge base, one would fall well short of requirements and be open to severe criticism. These comments should form part of the enrichment of welding training courses given in educational establishments. Question: Do welding apprentices July/August 2021

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and student welding engineers receive the appropriate training in all aspects of welding engineering? True answer: No, therefore this situation needs to be remedied and quickly. Conclusions • More government money is needed for companies to give day release to trainees. • Welding courses need to adapt and adopt the techniques required to increase the skill level to satisfy industry. Short courses in welding should be scrapped immediately. • Colleges should undertake a greater range of courses for advanced coded welding, after basic training to City and Guilds level. • College tutors and/or instructors should be subjected to training in current welding practice through periods in industry to advance their knowledge, where they require it. • A better appreciation of welding by management is needed. • The attitude to welding engineering by management that ‘just anyone can do it’ must be consigned to the rubbish bin, otherwise welding fabrication will fall into disrepute and the decline will continue. • Management need to be reminded that ‘welding’ is not just about pressing a button and the joint being held together, this is not an acceptable criteria for a welded structure, no matter what the

service duty of it is. • There is a need to change people’s attitudes towards welding before management find themselves facing a judge in court for bad welding practice, if and when somebody has been injured or killed, due to premature failure of welds on a structure. • It should be an accepted fact that there is no shortcut to successful practical application of welding processes with a high level of proficiency. To illustrate an important industrial point, if for example we are to have a UK-based steel industry in the future, then we need the next generation of the metallurgical and welding workforce in all its aspects to be forthcoming. A considerable amount of the steel produced in the future, in all its product forms, will inevitably be required to be weld fabricated. The question here is, by whom, and where will they be welded? This is especially relevant when we observe the decline in respect of welding engineering and technology in the UK. �

References 1 ‘The nature of welding and its relationship to the steel industry’ Steel Times International Vol 44 No 6 Sept 2020, p 22 – 27, E J France. 2 ‘What can be learned from the welder’ Welding and Cutting Journal 7 No 4, 2008, E J France.

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PERSPECTIVES Q&A: SHELL LUBRICANTS

Continuously innovating Shell Lubricants coped admirably with supply disruptions caused by the global pandemic and has continued to service its customers. The company is busy across a number of steel-using sectors, such as automotive, packaging and construction, and is currently working on several major steel contracts, says Lee Zorn* 1. How are things going at SHELL LUBRICANTS? Is the steel industry keeping you busy? We are seeing increased demand from our steel customers in several markets. As with many industries, the pandemic has led to supply disruptions across the lubricants market. However, through our detailed business continuity plans, we have been able to keep serving our customers and more. 2. What is your view on the current state of the global steel industry? The steel industry is fundamental to society and visible in every walk of life – be it wind turbines, skyscrapers or automobiles. Steel demand is only going to increase with the rising population and urbanization. Over the coming decade, the steel industry will likely go through an unprecedented change to reduce its impact on the environment. 3. In which sector of the steel industry does SHELL LUBRICANTS mostly conduct its business? We conduct business across several steel-using sectors, including automotive, packaging, and construction, in addition to steel producers, both integrated and mini-mills. 4. Where in the world are you busiest at present? Given Shell has an extensive global reach, we have opportunities in many markets. We have been busy in North America with our acquisition of American Chemical Technologies and then in Japan with the re-entry into that market. We are also working on some exciting new product developments, which are keeping our R&D teams busy.

Industry 4.0 in the steel industry is expected. Technological progress is advancing faster than ever. The introduction of technology to automate processes and deliver insights for predictive maintenance will help improve safety, decrease cost, and boost returns for customers. Shell Lubricants Solutions has recently commercialized Shell Remote Sense, an online monitoring system with advanced analytics to monitor oil conditions in real-time to gain actionable insights. This allows us to respond to issues before they happen and helps our customers reduce unplanned downtime, optimize their maintenance, extend equipment life and increase productivity. Solutions like this will be adapted in the steel industry in the near future. 5. Can you discuss any major steel contracts you are currently working on? Shell Lubricants Solutions recently acquired the assets of American Chemical Technologies, which expands and enhances our offer to the steel sector, including fire-resistant products, new synthetic technology, and a range of new greases. As a result, we are currently working on several major steel contracts and look forward to helping reduce their total cost of ownership. 6. Where does SHELL LUBRICANTS stand on the aluminium versus steel argument? Shell Lubricants Solutions works with both the aluminium and steel sectors and has a strong customer base in each. 7. What are your views on Industry 4.0 and steelmaking, and how, if at all, is SHELL LUBRICANTS using it?

8. Hydrogen steelmaking appears to be the next big thing. What’s your view? Post-pandemic, the industry will be faced with new pressures to reduce carbon emissions. To reach sustainability goals at a large scale, steel producers will need to look to alternative solutions. Shell Lubricants Solutions is here to assist in the sustainability journey. Being part of the broader Shell organization, we have access to experts in areas such as hydrogen. We are already working with the steel industry on decarbonization pathways and can only anticipate more demand for low carbon offers in the future. 9. In your dealings with steel producers, are you finding that they are looking to companies like SHELL LUBRICANTS to offer them solutions in terms of energy efficiency and sustainability? If so, what can you offer them?

*Shell general manager, B2B Direct Sectors July/August 2021

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PERSPECTIVES Q&A: SHELL LUBRICANTS

Yes, absolutely. Sustainability is an area where our customers are very keen on improving their performance. Shell offers multiple solutions to help customers meet their efficiency and sustainability goals through our ‘avoid, reduce, and offset’ approach. Beyond the energy efficiency solutions possible from some of our higher-tiered lubricants, we recommend our renewable energy supply to avoid emissions, Shell Energy Inside to reduce emissions, and Shell Carbon Solutions to offset carbon emissions. 10. How quickly has the steel industry responded to ‘green politics’ in terms of making the production process more environmentally friendly and are they succeeding or fighting a losing battle? We have seen many of our steel customers take significant steps to improve their environmental performance, and the maturity of these initiatives varies by country. This is a long-term commitment to achieving these goals, and we believe these steps will continue to build scale over the coming years. 11. Where does SHELL LUBRICANTS lead the field in terms of steel production technology? Shell Lubricants is continuously innovating and delivering world-class products and services for our steel customers. This has contributed to our leadership as the preferred global lubricants supplier for the 14th consecutive year.

to steel lubrication requirements. We extend and receive best practice learnings across regions to ensure local mill competitiveness when it comes to products and services we provide to reduce overall costs while bringing carbon reduction opportunities to our customers. 14. What is SHELL LUBRICANTS’ experience of the Chinese steel industry? Shell Lubricants Solutions has a significant presence in China and is a very credible supplier to the steel industry, working with both major local OEMs and end customers. 15. Where do you see most innovation in terms of production technologies – primary, secondary or more downstream? Probably still with secondary steel, given the newer equipment that we see and where the OEMs tend to play a more prominent role. 16. How optimistic are you for the global steel industry going forward and what challenges face global producers in the short-to-medium term? Despite challenges from the pandemic, I’m optimistic that the steel industry is moving forward. And demand will grow as the impact of the lockdowns reside and society adjusts to the ‘new normal.’

17. What exhibitions and conferences will SHELL LUBRICANTS be attending over the next six months? At this time, we have no plans to travel to exhibitions and conferences in the US market. 18. SHELL LUBRICANTS is headquartered in the Netherlands, but what’s happening steel-wise in the country? The Shell headquarters are in the Netherlands. In terms of steel production, the country has a small percentage of the overall steel tonnage produced worldwide. 19. Apart from strong coffee, what keeps you awake at night? Not getting to visit customers. Due to the pandemic, travel has been limited over the past year, like everyone else, so we miss those more traditional connections. 20. If you possessed a superpower, how would you use it to improve the global steel industry? It will be important that the steel industry drives cost competitiveness into its programmes while pursuing sustainable development mandates. From a holistic point of view, it will be essential to deliver on these clear accountabilities and vision share between company corporate initiatives and drivers and the plant operations. �

12. How do you view SHELL LUBRICANTS’s development over the short-to-medium term in relation to the global steel industry? We are putting a lot of emphasis on the steel industry and we are very excited by its potential. Although a relatively complex industry versus some of the other industries we serve, we are known for our expertise and partnership approach to help our customers reduce costs while maximizing productivity. 13. China dominates global crude steel production and is accountable for almost half of global production. How should the industry react to this situation? Shell Lubricant Solutions can speak from a supplier lens in that we bring a global offer July/August 2021

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HISTORY

Recitza ironworks in the 19 century Following on from April’s article on the Recitza ironworks in the 18th century, the following article examines how things progressed into the 19th century and examines refining prior to the puddling process. By Romulus Ioan* FOLLOWING on from the description of the 18th century Recitza ironworks, in modern day Romania, published in the April issue of Steel Times International, cast iron production increased to 561.2 tonnes in 1814 from two furnaces. No 1 furnace was operated intermittently and was shut down for five months for repair from December 1814 to May 1815 after which No 2 furnace was shut down for maintenance. When restarted, the combined output of the two furnaces reached 1016.9 tonnes that year. About half of the iron was sent for refining, while the remainder was used to cast items such as stoves. To refine (decarburize) the iron, four refining hearths and a tilt hammer were in operation at Recitza and a second refining forge was located at nearby VĐliug where there were two refining hearths. Products from the forges were wrought iron bar and semi-finished items such as spades, cart wheel tyres and nails. Together, the two refining forges produced 510.6 tonnes of bar iron for mechanical forging in 1815. Financial losses, which had accrued from the 18th century, continued to grow and in 1830 the works owners, the Vienna Chamber of the Hapsburg AustroHungarian Empire, offered Recitza for sale. However, no buyer came forward so instead investments were made to increase the capacity of the works. In 1840, a puddling

Blast furnace No 1 at Recitza in the 19 century showing a Chibla loading system and Cowper hot-air blast stoves

REFINING PRIOR TO THE PUDDLING PROCESS Cast iron was processed in a ‘Frischfeuer’ hearth which used a reverberatory flame to achieve decarburization. Cast iron from the blast furnace was mixed with an oxidizing layer produced by first placing powdered charcoal on the hearth, then slag rich iron oxides and small pieces of iron ore. The hearth was heated to 1400 - 1450°C and then pieces of cast iron added. These melted and collected on the hearth in globules. As the carbon content reduced, the molten iron started to solidify as a spongy mass. This was forged into bars called ‘Flossen’ then transferred to a second furnace which had a low-level hearth into which a flame was concentrated onto a spot. The whole heart of refining was the way in which the flame was regulated by arranging the tuyere, and the care and timing when slag was thrown onto the red-hot bars as well as the way the bars were moved around, in and out of the hot zone of the hearth into cooler areas. In this way the carbon content was controlled to the level required for the purpose the iron was intended, such as the manufacture of ordnance – bombs, grenades, howitzers and bullets, or more peacefully, cauldrons, axes and other tools. This method of refining iron had a maximum production of two to four tonnes a day and was later to be succeeded by the puddling furnace first developed in England by Onions in 1783 and improved by Cort in 1784. Puddling was not introduced to Recitza until 1840.

* Dr Ioan is executive director of the modern Risita steelworks, part of the TMK Group July/August 2021

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shop was built with 14 reverbatory furnaces for refining, a re-heat furnace, four steam hammers, three circular saws and a shear. Power was supplied by three steam engines rated at 16, 45 and 100HP. Two existing rolling mills were replaced and three further steam hammers, capable of exerting forces of 5330kg, 1680kg and 500kg, installed. In 1845, reheat furnaces for rolling or forging and annealing furnaces were added. The forge was powered by three water wheels and had two refining furnaces, three re-heat furnaces, an annealing furnace, and a chain annealing furnace. A foundry, mechanical processing shop and a gun foundry completed the picture. Four blacksmith shops were added in 1846 powered by a water turbine. In 1855, output from the two blast furnaces reached 6,400 tonnes. Problems were encountered in obtaining uniformly thick bars of wrought iron following refining and the production of more white iron – in which the carbon is present as iron carbide, which makes it more suitable for refining than grey iron

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– was increased by lowering the silicon present in the iron to between 0.45% and 1.10%. Grey iron, in which the silicon level is 1.2% or more, is more ductile than white iron and is hence suitable for casting ﬁnal objects. Houses were built nearby to house the workforce along with a pub and bakery.

Some of the work force were contracted labour while others had permanent positions. The puddling workers numbered 40 and, along with rolling mill operators and mechanical workshop personnel, were paid over double that received by general labourers. �

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DANIELI AUTOMATION

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