Steel Times International Digital November 2016

INTERNATIONAL BUSINESS

BESSEMER DAY 2016

INNOVATIONS

STEEL AND THE SEA

Scotland’s iconic Dalzell steel works re-opens

The Institute of Materials and its steel division celebrate in style

A mammoth 23-page section devoted to new products

The first in a series of articles about steel’s relationship with the sea

www.steeltimesint.com Digital Edition - November 2016 - No.4

INNOVATIONS – A BUMPER ISSUE OF NEW PRODUCTS STI NOV digital.indd 1

01/12/2016 12:22:21

Innovative technologies for the metals industry

Cold rolling ยง Strip processing ยง Chemical processes Thermal processes ยง Mechanical equipment Automation ยง Extractive metallurgy www.cmigroupe.com DE SIG N | ENGINEERING | COMMISS IO NING | TE C H NIC A L A S S IS TA NC E & TR A INING | A F T ER- S A L ES

3269_15-CMI_Metals_Ann A4.indd 1

28/05/15 10:10

CONTENTS DIGITAL EDITION - NOVEMBER 2016

INTERNATIONAL BUSINESS

BESSEMER DAY 2016

INNOVATIONS

STEEL AND THE SEA

Scotland’s iconic Dalzell steel works re-opens

The Institute of Materials and its steel division celebrate in style

A mammoth 23-page section devoted to new products

The first in a series of articles about steel’s relationship with the sea

www.steeltimesint.com Digital Edition - November 2016 - No.4

INNOVATIONS – A BUMPER ISSUE OF NEW PRODUCTS STI NOV digital.indd 1

01/12/2016 12:22:21

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com

Picture courtesy of Kocks Test Assembling of a 6-stand 3-roll RSB SCS® 370++ at the KOCKS workshop at Bremen. The core component of the future-oriented RSB SCS® is the real-time closed-loop control system SCS® (Size Control System) acting in combination with 3-roll stands adjustable under load (AUL) and/or under-load inter-stand tension control. The SCS® operation is supported by a new and innovative bar gauge called 4D Eagle, developed in co-operation with Automation W+R GmbH, based on the light section principle and featuring the highest measuring frequency available in the industry.

The RSB SCS® will currently be delivered to Korea.

1

6

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

2 Leader

44 History A blast furnace in a pub

4 International business Scotland’s iconic steel works 6 Event report IoM3’s Bessemer Day 2016

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

35

11 Innovations Products

Chief Executive Officer Paul Michael SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com Steel Times International is published eight times a year and is available on

40 Steel and the sea Safety on the sea bed

subscription. Annual subscription: UK £173.00 Other countries: £247.00 2 years subscription: UK £311.00 Other countries: £445.00 ) Single copy (inc postage): £39.00 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 2016

4 ISSN0143-7798

www.steeltimesint.com

Contents.indd 1

Digital Edition - November 2016

01/12/2016 12:26:23

2

LEADER

Is Sanjeev Gupta the Patron Saint of UK steel?

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

Digital Edition - November 2016

Leader.indd 1

At the beginning of 2016 the bombshell was dropped: Tata Steel announced that it was selling up and pulling out of the UK – bad news for the British steel industry, bad news for British steelworkers and bad news for yours truly as a string of radio and television interviews followed in quick succession. I had to bone up on facts and soundbites to satisfy the insatiable appetite of the British mass media.

And now the year is drawing to a close – it’s 1 December as I write these words – and while it would be easy to say that the British steel industry is still awaiting a decision on ‘the big one’ (what to do with Port Talbot?) the official rumour is that some kind of merger or joint venture between the Indian steelmaker and ThyssenKrupp of Germany will take place.

The big stumbling block? The British Steel pension scheme.

There’s nothing worse than uncertainty, but there are some lights at the end of the tunnel. A report by Graham Ruddick in the Guardian, a UK national newspaper, last week claimed that Tata was set to commit to UK steel for the next decade, ‘including the vast Port Talbot works’, but as Ruddick

pointed out in an article published on 28 November in the same newspaper, despite a deal struck with Sanjeev Gupta’s Liberty House – to purchase Tata Steel’s speciality steels division for £100 million – the future of the rest of Tata Steel UK remains unclear. In short, 11,000 anxious British steelworkers approach the festive season with furrowed brows.

But if one of the lights at the end of the tunnel is Lord Bhattacharyya’s ‘major announcements about growth in Tata Steel’, then mention must be made of Sanjeev Gupta, the brains behind Liberty House. He will go down as the Patron Saint of the UK steel industry and the saviour of thousands of British steelworkers’ jobs.

Liberty’s planned purchase of Tata’s speciality steels division is just the tip of the iceberg. When the company recently re-opened the Dalzell steel plant in Motherwell, Scotland, the Scots celebrated the survival of their steel industry and the saving of 270 jobs. Liberty has a strong ‘green’ agenda, promoting melting and upcycling of scrap using EAFs, and if market conditions allow, Liberty will reopen the Clydebridge steelworks too.

www.steeltimesint.com

01/12/2016 11:41:51

Pub_PMR_base_Mise en page 1 01/07/2016 09:39 Page 1

redex

The Strip Processing Equipment Company

TENSION LEVELER for Tinning Lines

PMR MULTIROLL « Perfect Flatness at your fingertips ! »

REDEX advanced Tension Multiroll Levelers guarantees a perfect flatness, whatever the incoming strip quality: up to 50% improvement in overall quality can be achieved in comparison to conventional solutions.

REDEX design provides the smoothest, the most progressive alternative bending, and the most stable process on the market.

The major tinplate producers, such as Arcelor Mittal, TATA Steel, US Steel, UPI, AHMSA, ILVA, ERDEMIR, have already adopted the REDEX PMR Multiroll Leveler and got the immediate benefits from its outstanding performances and from the full service provided by REDEX.

> Extreme compactness, allowing easier integration in existing lines > Extremely high stiffness, making the PMR fully suitable with the high speed of the latest and most innovative tinning lines.

> 100% in-house manufacturing (machine-tool precision standards)

redex

European Headquarter > Ferrieres - France Services Centers > Europe, Americas, Asia Worldwide Setting-up and Maintenance service

Find out more about our equipment portfolio

www.strip-processing.com T. +33 2 38 94 42 00 | info@redex-group.com

4

INTERNATIONAL BUSINESS

Scotland’s iconic steel works Working in conjunction with Liberty House Group, the Scottish government may very well have saved the country’s steel industry. By Lynn Cielec* IN a move that promises to revitalise Scotland’s steel industry and bolster the United Kingdom’s economy, Liberty Steel last month officially reopened the Dalzell steel plant in the town of Motherwell in Lanarkshire, Scotland, reports Reuters. The plant is Britain’s largest steel plate mill, and its reopening could not have come at a more critical moment.

Overcoming obstacles Just over a year ago, things were not looking bright for Scotland’s steel industry.

The Dalzell plant and its sister works in Glasgow were owned by India-based Tata Steel, which halted operations at both facilities in December 2015. Shutting down the plants cost roughly 270 people their jobs, dealing a catastrophic blow to the local economy and Scotland’s broader industrial prospects, according to the Guardian.

“Eighteen months ago, the outlook here looked very bleak indeed, the steel industry looked as if it might be on its last legs in Scotland,” First Minister Nicola Sturgeon told reporters and the 200 guests attending the opening ceremony. “But we made a commitment to the workers here that we would leave no stone unturned.”

In the spring of 2016, the Scottish government brokered an “unusual backto-back deal” between Tata and Liberty House Group, in which the government bought the plants from Tata before immediately selling them to Liberty.

Liberty paid a symbolic fee, taking on the plants’ environmental and investment costs instead. Since then, the company has spent the last “five months rebuilding the workforce and recommissioning equipment” at the Dalzell site, according to a 28 September press release.

A struggling industry The mill’s reopening comes amid fears over Brexit-fuelled job losses and an already struggling Scottish industrial sector, with North Sea oil experiencing a steady decline. A year ago, Tata announced it would be cutting 1,200 jobs – including the 270 at the Dalzell plant – due to cheap Chinese imports, a strong pound, and high electricity costs.

Now, the Scottish government and Liberty House are working hard to prevent such drastic layoffs.

About 120 staff have been recruited to work the plant, roughly 70% of whom are former Dalzell employees, and Sanjeev Gupta, executive chairman of Liberty House Group, hopes to increase that number to 200.

A real future “There is an impressive spirit of partnership here and a determination to give the Scottish steel industry a real future,” Gupta said at the Dalzell opening. “From our side we promised we would get this important plant open again by the autumn and today we are proud to be fulfilling that promise.”

The importance of Dalzell’s reopening to Scotland and the steel industry cannot be overstated. According to chief executive of Liberty Steel UK Jon Bolton, the reopening of the plant is absolutely critical. “Without it restarting, there wouldn’t be a steel industry in Scotland,” Bolton told the BBC. “It’s not just about boosting the steel industry, it’s about the economy.”

On a local level, the plant is expected to bring in approximately £15 million per year. Nationwide, Britain consumes 700kt of plate steel every year, using the material in everything from shipbuilding and construction to mining and oil production.

The market is growing about 3% annually.

Liberty hopes that the Dalzell mill will initially produce 150kt/yr, before ramping up to its full capacity of between 400 to 500kt/yr. Company spokespeople say the plant has already secured a “significant number of orders” from the energy and construction sectors. Gupta also disclosed that the company was working to reopen the Clydebridge steelworks in nearby Cambuslang “as market conditions allowed.”

“This is a fantastic day for Dalzell workers, for Motherwell and for Scotland’s steel industry,” First Minister Sturgeon said.

“Restarting steel production has only been possible thanks to the tremendous team effort of everyone involved in the steel taskforce to find a viable future for this site, meaning workers here in Lanarkshire can once again produce world-class products.”�

* Lynn Cielec is the industrial business unit manager at Midwest Industrial Supply.

She is an experienced executive sales director with a proven track record of results and sales growth.

Digital Edition - November 2016

International Business.indd 1

www.steeltimesint.com

01/12/2016 08:18:35

We know the art of steel! www.danieli-froehling.de

Backing your competitiveness with sophisticated solutions.

Our COLD MILLS are advanced mill configurations designed from plant user’s perspective and available for all strip and foil applications. Our TRIMMING LINES combine perfect cutting tolerances with highest operation speeds. Danieli Fröhling SLITTING LINES are able to cut up to 130 cuts at a time and can be equipped with the best braking and recoiling units available on the market.

Contact us – discover the benefits!

Rolling mills ♦ Slitting lines Trimming lines ♦ Cut to length lines Electrostatic oilers ♦ Services

6

EVENT REPORT

IoM3’s Bessemer Day 2016

On 13 October, the Institute of Materials (IoM3) and its steel division, the Iron and Steel Society (I&SS), celebrated its Bessemer Day. For the second year running, the event was held in a steel-producing region with the help of a local society of IoM3. This year’s hosts were Swansea University and the South Wales Materials Association (SWMA). Bessemer Day was supported and sponsored by Harsco Metals and Minterals, Primetals Technologies and Tata Steel. By Mick Steeper*

THE principal event of Bessemer Day is the delivery of the Bessemer Lecture by the recipient of the Bessemer Gold Medal.

The 152nd Bessemer Laureate is Professor Alan Cramb of the Illinois Institute of Technology, and his lecture was entitled Steel Processing Technology – Potential Futures.

Alan Cramb completed his undergraduate degree in metallurgy at Strathclyde University in his native Scotland, and his accent remains unsullied by 40 years in the United States, at some of its most auspicious steel locations. His current berth in Chicago marks a return to the city if not to the state, since his first appointment

was at Inland’s Indiana Harbor works, and his workplaces between include Bethlehem Steel and Carnegie-Mellon University where he teamed with the 2004 Bessemer Laureate, Professor Dick Fruehan.

As a world authority on the metallurgy of steelmaking and casting in particular, but also as an insightful observer of the operational practices of the industry and of their economic context, Professor Cramb has seen most of the world’s major plants at first hand.

His Bessemer Lecture consisted mainly of a future view, but also incorporated as deep a history of iron as it is possible to deliver, with an explanation of the atomic reactions

that produce the elemental constituents of planets from stellar hydrogen. Ancient artefacts made from meteoric iron came next, then in a rush to the present came a review of the achievements of Henry Bessemer, and a recognition that Sir Henry was at least as much an innovative and entrepreneurial businessman as he was a technologist.

Disruptive technologies The most memorable part of the lecture, however, was a series of projections of disruptive technologies that could transform the modern steel industry. These were finally consolidated into three scenarios. In the first

* Chair of the Iron and Steel Society, a division of the Institute of Materials, Minerals & Mining Digital Edition - November 2016

Bessemer.indd 1

www.steeltimesint.com

01/12/2016 10:31:49

EVENT REPORT

of these, the recycling of steel will increase, making the use of electric arc steelmaking as prevalent throughout the developed world as it already is in the United States, where 65% of steel tonnage today derives from scrap. The thermochemical primary plant in widespread use today will meanwhile become recognised and valued in a ‘second life’ as a waste disposal technology, for direct power generation, for the hightemperature recycling of hazardous materials and as a concentrator of volatile wastes.

The second scenario anticipates a parallel decline in integrated steelmaking.

Operations that convert ore to semi-finished rolled products in a single location will continue, but only in limited geographic locations. Many countries that process ore today will instead opt to roll and process cast product from elsewhere, and these same economies can be expected to turn more towards mini-mill principles, operating at lower volumes and providing feedstock to local manufacturing operations. A general trend to downstream integration is foreseeable, with many steelmakers seeking closer partnerships with end users.

In the third scenario, a trend towards powder-based component manufacture is foreseen. A key business driver in this respect is the ability to produce highmargin products at low volumes without a high initial capital investment. Another is compression of the time from prototype to commercial component. This implies an increasing research focus on in situ alloying, with the possibility of an eventual outcome in the post-rolling alloying of generic lowcarbon thin sheet.

Awards Preceding the Bessemer Lecture, the other Iron and Steel Society awards for 2016 were made. The Hadfield Medal was presented to John Beeley of Outokumpu, in recognition of the turnround of the group’s Sheffield operations and the securing of continued bulk stainless steelmaking in the UK as a result of his leadership.

Professor Pierre Montmitonnet of PARISTECH in France received the Dowding Medal for his lifelong work on the modeling of forming processes, while Andy Backhouse of Outokumpu was awarded the Stokowiec Medal. The Colclough and Thomas Medals were awarded to Adam Bannister and Dr David Anderson respectively. At the time of nomination www.steeltimesint.com

Bessemer.indd 2

both worked for Tata Steel, but the fastevolving landscape of the UK steel industry leaves their current attribution (though not the value of their contributions) uncertain.

Finally the Adrian Normanton Medal (for the best paper on liquid steel processing in Ironmaking and Steelmaking) and the Frank

7

and IoM3’s President Professor Mike Hicks, who had earlier presented the medals. Paul Burke also spoke in his capacity of President of the hosting local society, the SWMA. Their collective words gave testimony to the metallurgical prowess of the region, and there was conviction and confidence in the

Alan Cramb (left) and Mike Hicks, president of IoM3

Fitzgerald Travel Award went to a group headed by Dr Julian Steer of Cardiff University and to Dr David Penney of Swansea University respectively.

These workplaces were, of course, incidental to their awards, but nonetheless conveniently equitable at a ceremony taking place in South Wales.

The evening concluded with a dinner at Swansea’s National Waterfront Museum.

Speakers included Swansea University’s vice chancellor Professor Richard Davies, who had earlier given a thoughtful Vote of Thanks following the Bessemer Lecture,

speeches and in the room that this will continue in years to come.

Envisaging the future for steel The early part of Bessemer Day is given over to the Bessemer Masterclass.

Supporting companies and universities are invited to send potential business leaders as delegates, and so this part of the programme provides a platform for the men and women who are likely to lead the UK steel industry in future time. As such, their feedback is always of interest.

Digital Edition - November 2016

01/12/2016 10:31:55

8

EVENT REPORT

demand external help, especially to reduce energy costs and to accelerate research on making high quality steel from scrap.

Casting rolling unit in Duisburg Bruckhausen. Molten metal is turned into thin slabs of 48-53mm thickness

The 2016 topic, chosen as usual by the Bessemer Laureate, was ‘Envisaging the Future of the UK Steel Industry’. The 27 delegates self-selected into three teams of nine and took part in a debate. Each team was required to present its vision of a successful future industry as part of the UK economy, including a justification in terms of competitiveness and investability.

The first team to speak had Katie Daehn of the University of Cambridge as its proposer and Anton Levsiushkin of Harsco as seconder. This team strongly advocated the development of steel recycling, stating that all new capacity worldwide should be electrometallurgy-based and that the grades not yet conducive to manufacture from scrap can be made in sufficient volume for foreseeable future demand using existing integrated plant. A persuasive case was also made for the greater flexibility of electric steelmaking in smaller-scale operations. The industry can help itself by concentrating on downstream value-adding, but it must also

Service through the supply chain The second team to speak had Jonny Hauser as proposer and James Walker as seconder. Both work for Tata Steel. This team identified the key to competitive success as being service through the supply chain. Regional companies can differentiate themselves more effectively through their service proposition than is possible through their product. The emphasis should be on defending the existing UK assets, initially by maintaining operations at minimum economic volumes but with the expectation of future growth, since steel demand will perpetually rise. This team further emphasised the need to communicate positively about the industry, stressing its green credentials and its national importance, now and in future.

The third team to speak had Tom Taylor of Tata Steel as proposer and a pair of seconders, Shaun Earl from the University of Sheffield and Stephen Spooner from the University of Warwick.

This team acknowledged the validity of both the earlier pitches, while stressing the importance of timing and a managed transition to preserve a successful national industry. The long term destination will be recycling as the dominant mode of production, but adding value through the current operations is the short-term imperative. Product differentiation should not be discounted either (with examples of aluminised press-hardened strip and coated rail being described). Their closing pitch was an exhortation to recognise that the goal is not to make steel per se, but to serve markets.

Steel’s strong and vital future A vote to identify the winning team by a show of hands was adjudged a draw.

Professor Cramb in his role of principal mentor summed up: there were three great pitches, all well considered and all recognising that the UK’s main competitive proposition is, in fact, its process knowledge and its R+D capability.

It was also striking that there was a substantial consensus running through the propositions, and that the differences were intelligently and respectfully discussed.

All those present agreed that steel in the UK has a strong and vital future, and that the most important contribution that we can all make to this future is to champion the industry together.

The remaining Masterclass delegates were: James Balmer, Rebecca Bolton, Des Brennan, Panagiotis Christopoulos, Nathan Clark, Sam Clark, Matthew Clayton, Matthew Cowan, Matthew Dennis, Sam Dixon, Gebril El-Fallah, Rhys Faulkner, Richard Hawke, Julian Herbert, Shaumik Lenka, Richard McDowell, Michael Rabaiotti, Heather Rowland, James Russell and Dane Sexton.

Thanks are also extended to the industrial and academic mentors who gave their time: Martin Cox, Geoff Hale, Peter Morris, Cameron Pleydell-Pearce and Ken Ridal.

If you would like to learn more about Bessemer Day and/or the Iron and Steel Society, please contact geoff.hale@iom3. org.

Remember too that nominations for the 2017 Bessemer Gold Medal (as well as for the other steel awards mentioned in this article and indeed for all of the Institute’s awards and prizes) can be made on-line and will remain open until 15 January 2017. �

HigH TemperaTure BarCode Tags and LaBeLs

Westmoreland, nH 03431 usa / www.polyonics.com / +1.603.352.1415 / info@polyonics.com Digital Edition - November 2016

Bessemer.indd 3

www.steeltimesint.com

01/12/2016 10:31:58

©

BICOM_13622.02 1.08.2016

Vacuum Solutions

Vacuum pumps are essential for modern heat treatment processes. Dry screw pumps offer best performance in more demanding metallurgical applications. They are also preferred if end users want to minimize their maintenance demands.

DRYVAC dry screw vacuum pumps provide high process throughput and system uptime. Insensitive to dust and vapors, DRYVAC pumps ensure a long-time stable vacuum supply with low maintenance needs.

RUVAC WH 2500-FC / DRYVAC DV 650 adapter version

The innovative DRYVAC SYSTEMS excel in combination with high vacuum RUVAC pumps particularly well in typical processes like brazing, soldering, nitriding and plasma-nitriding.

DRYVAC SYSTEMS are suited best where products with high surface contamination are treated or where the process emits aggressive gases as e.g. acidic flux vapor.

DRYVAC dry vacuum solutions utmost efficiency for your processes!

Leybold GmbH Bonner Str. 498 · D-50968 Köln

Shop our products online: www.leyboldproducts.com

LV_Anz_HeatTreatment_DryPumps_EN_210x297.indd 1

T +49 (0) 221-347-0 F +49 (0) 221-347-1250 info@leybold.com

www.leybold.com

26.10.16 14:05

GUNNING ROBOTS

FOR IMPROVED

HOT REPAIR of EAF, Ladle, RH

Steel Times International Buyers’ Guide & Directory The Buyers’ Guide and Directory is the essential guide to steel manufacturers, producers, suppliers of plant equipment and services to the steel industry. It provides comprehensive listings, product information and key contact details.

Order your copy now from just £78*

* Free for paid subscribers

For information on how to be listed contact esmehorn@quartzltd.com VELCO GmbH Haberstraße 40 42551 Velbert (Germany) info@velco.de • www.velco.de Tel +49 (20 51) 20 87-0 velco and sti.indd 1

www.steeltimesint.com

30/11/2016 09:31:49

INNOVATIONS

11

PANalytical launches benchtop X-ray powder diffractometer PANalytical, a leading global supplier of analytical X-ray instrumentation and software, has introduced Aeris, its new X-ray powder diffraction (XRD) bench-top instrument.

According to PANalytical, ease of use is one of the key aspects of its new piece of equipment, which is claimed to offer fast and precise phase information of the materials analysed.

It is claimed that Aeris is accessible for everyone, thanks to its built-in touch screen with intuitive interface that directly displays all results.

Aeris is designed for low cost of ownership as it only requires a single-phase power outlet and neither needs cooling water nor compressed air. However, it incorporates many technologies proven on PANalytical’s high-end systems, and its performance exceeds typical bench-top X-ray diffractometer performance.

“Data quality and speed of data acquisition have so far only been observed on full-power systems. Additionally, Aeris is the first bench-top XRD system that is fully automatable and can easily be incorporated in industrial production control.

“As many industries have specific demands for their materials’ analysis, Aeris editions are available, which have been tailored to the specific needs of the cement, mining and metals industries. They provide fast and precise mineralogical phase information, which can be used for control and optimisation of the production process.

The Research edition of Aeris, on the other hand, is designed for quick XRD

scans in any laboratory and is easily accessible for students, says PANalytical.

Aeris’ ‘unique 2D option’ makes it an ideal instrument for teaching XRD. Harald van Weeren, product manager at PANalytical says: “We at PANalytical are proud that we have succeeded in developing an XRD instrument that is so easy to use and at same time delivers such excellent data quality so quickly. This makes Aeris the ideal instrument for everyday X-ray diffraction analysis for everyone.”

For further information, log on to http://xrdiseasy.com

SGL Group downsizes management board SGL Group plans to reduce its board of management from three to two members as part of a ‘strategic re-alignment’.

Dr. Gerd Wingefeld’s contract has been terminated prematurely and he will leave the business at the end of 2016, having been a member of the board of management since 2008. His contract wasn’t due to expire until September 2017. Gerd Wingefeld has been a member of the Board of Management since 2008, responsible, among others, for Technology and Innovation. Dr. Jürgen Köhler, in his role as CEO, will take over responsibility from Gerd Wingefeld.

“Dr. Gerd Wingefeld, a passionate chemist, has devoted his knowhow and energy since 2002 for the benefit of the company. For his dedication and the agreement taken now he deserves our gratitude and respect,” said Su-

sanne Klatten, chair of SGL’s supervisory board.

“Numerous innovations during his tenure can be directly associated with Gerd Wingefeld.

Most recently he has launched four future growth areas as the strategic framework for medium- and long-term innovation and product development,” says Jürgen Köhler. “I wish to thank him for the very good, inspiring and trustworthy co-operation.”

For Gerd Wingefeld, after almost 15 years with the company, leaving it isn’t easy. “However, time has now come for me to begin a new phase of my life,” he said.

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

Gerd Wingefeld

www.steeltimesint.com

products.indd 1

Digital Edition - November 2016

01/12/2016 09:11:21

12

INNOVATIONS

EMT expands environmental testing Element Materials Technology has expanded its environmental testing capabilities in Denver, Colorado, USA. The company has invested in a new thermal vacuum chamber that complements its existing thermal testing and bake-out capabilities, underlining the company’s ability to deliver technical expertise with market-leading operational performance critical to the aerospace and defence industries.

The new capability allows clients to test to extreme temperatures and pressures, from cryogenic temperatures to 150 degrees C, and pressures of up to 1 X 10-7 Torr.

This includes both product qualification testing (PQT) of components and a range of materials testing (MT) services, including sterilisation/de-

contamination for space applications.

Rick Sluiters, Element’s executive vice president for aerospace, said there was significant demand within the local Aerospace market for more extreme testing capabilities.

“We now have a fully comprehensive set of capabilities in environmental testing demonstrating our commitment to the Aerospace and Defense supply chain,” he said, adding that Element’s technical expertise is such that very few organisations can provide this type of service, with the requisite level of quality control and project management demanded.

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

Rick Sluiters of EMT

ESAB’s handheld plasma cutters

The Cutmaster Series of portable air plasma cutting systems are available from ESAB Welding & Cutting Products. They range in output from 20 to 120 amps and produce a recommended ‘quality’ cut on material from 6 mm to 40 mm, claims ESAB. The recommended cut capacity equals the system’s true cut capacity, says ESAB. “A recommended cut has a smooth cut face with little or no dross and requires little or no rework or grinding, all of which improve productivity and quality,” the company claims.

The Cutmaster range provides additional output when needed and offers a maximum cut thickness that ranges from 60% to 150% greater than the recommended cut. As a result, claims ESAB, they eliminate the concept of having to trade up or purchase a machine larger than the end-user needs.

Four products in the Cutmaster Series (the 60, 80, 100 and 120) share common features, including a tubular ‘roll bar’ to protect the Digital Edition - November 2016

products.indd 2

front and rear of the power supply and make them easier to carry. A trigger latch prevents hand fatigue during longer cuts, as it allows the operator to release the trigger while the system keeps cutting. Colour-coded LEDs on the front panel indicate pressure status and set-up errors.

An Auto Pilot Restart feature instantly reignites the pilot arc while cutting expanded metals such as grates and chain link fences. Each unit comes as standard with the 1Torch (6.1 or 15.2 m cable options), but also accepts mechanised and automated torches. Primary power options are 50/60 Hz, 400V, 3-phase CE unit.

cut of 32 mm. It provides a 12 mm cut at 635 mm per minute, which is 25% to more than 100% faster than competitive models and weighs just 19.5 kg. It can also be used for medium duty gouging applications when fitted with the correct torch consumables.

• The Cutmaster 80 features an 80-amp output, has a genuine cut of 25 mm and severance cut of 38 mm. It weighs 19.5 kg.

• The Cutmaster 100 features a 100-amp output, has a genuine cut of 35 mm, a severance cut of 45 mm and weighs 28.1 kg.

• The Cutmaster 40 enables users to switch from 1-phase, 208 – 230VAC primary power to 115VAC primary and produces a genuine cut on 12 mm material, cuts a maximum thickness of 15 mm material and weighs 11.8 kg.

• The Cutmaster 120 features a 120-amp output, has a genuine cut of 40 mm, a severance cut of 55 mm and weighs 28.1 kg.

• The Cutmaster 60 features a 60-amp output, has a genuine cut of 20 mm and severance

For further information, log on to www.esab.co.uk www.steeltimesint.com

01/12/2016 09:11:22

ARL easySpark OES Revealing the power of metals analysis The NEW Thermo Scientific™ ARL easySpark™ benchtop metals analyzer is designed to meet the challenges and demands of small to medium-sized metal manufacturers that need high-quality and cost-effective OES analyses.

With its unique multi-grating/CCD based optical design, the ARL easySpark provides full elemental coverage, optimal resolution and stability - delivering high performance for all critical elements. Combined with the intuitive Thermo Scientific™ easyOXSAS software suite, the ARL easySpark benchtop OES enables non-experts to reveal the power of metals analyzer in metal and alloy production.

Find out more at www.thermofisher.com/easyspark For Research Use Only. Not for use in diagnostic procedures. © 2016 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified.

14

INNOVATIONS

New rose joints from WDS offer versatile control WDS Component Parts (WDS), a UK-based standard parts manufacturer, has released a new range of male and female threaded rose joints, including stainless steel- and zinc-plated variants.

Comprised of an internal bearing, a runner and a durable body they are claimed to offer ‘a perfect solution to applications where components may require a precision articulating joint’.

According to WDS, rose joints are an optimum selection where misalignment of components may occur, such as in steering or suspension systems.

Rose joints respond to linear actuation or change in length to the strut or rod they are attached to, allowing articulation through a wide range of angles in operation. The swivelling bearing clings to the strut or rod, reacting to changes of rod positioning to allow total control at a wide variety of angles.

Rose joints were first used on aircraft, but can now be found on all terrestrial and marine vehicles – while also being heavily used for industrial machinery applications.

The swivel bearing offers increased versatility in operation compared to a clevis joint, which restricts travel to a 90° angle.

WDS rose joints feature a wear-resistant bearing in either hardened steel, 404 or 303 stainless steel. “Every rose joint includes a PTFE composite liner or runner, offering a low friction co-efficient and self-lubrication, allowing smooth operation and minimal wear. Bodies are available in either durable stainless or corrosion resistant zinc-plated mild steel. Brass bushes are standard across the entire range; with each joint offering a maximum swivel of 13° in operation,” said WDS. The new range complements the company’s already comprehensive standard parts offering and are available at no minimum order quantity, with next day delivery possible for most of the UK. Components from the WDS range can be ordered online, over the phone or via the Leedsbased trade counter operated by the company.

WDS offers free 2D drawings and 3D CAD models for download on the website.

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

Engineers and innovators offered chance to develop their own ideas with ABB The IdeaHub is recruiting hardware and software innovators worldwide to take on the challenge of transforming the role of drives in an industrial setting. It is hoped that those recruited will improve the design, use and operation of drives or find entirely new uses for them.

The IdeaHub, working on behalf of ABB, will help those who apply to secure ‘uniquely tailored support packages to maximise their venture’s commercial potential, including funding, research and development expertise, customers and markets’ or what is known as a ‘funded concept acceleration sprint’.

According to ABB, electric motors play an important role in our everyday lives and businesses.

“They move and run basically everything we need for business or pleasure,” says the company.

“All these motors run on electricity. In order to do their work of providing torque and speed, they need the corresponding amount of electric energy. Drives work by converting fixed frequency AC power into variable frequency, variable voltage AC power.” ABB says that ‘this technology controls the way motors use electricity and not only helps save energy, but also reduces scrap and maintenance costs.’

Several versions of AC drives exist: variable speed drives (VSD), variable frequency drives (VFD), adjustable frequency drives (AFD) and inverter drives.

The IdeaHub ran its first programme for ABB in 2015 and attracted over 130 applicants and, ultimately, 12 finalists were selected for ‘pitch day’ in London. Six ventures received offers of support and collaboration.

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

The IdeaHub in action

Digital Edition - November 2016

products.indd 4

www.steeltimesint.com

01/12/2016 14:30:11

FUTURE STEEL FORUM 2017 14-15 JUNE • SHERATON WARSAW HOTEL • WARSAW

Applying Industry 4.0 to the steel industry FROM THE PUBLISHERS OF STEEL TIMES INTERNATIONAL What is Industry 4.0 and how can it assist the global steel industry in its quest for greater efficiencies? Two questions, among many others, that will be answered by the experts at the Future Steel Forum in Warsaw in June 2017.

The Future Steel Forum is a live discussion of the issues surrounding Industry 4.0 or ‘smart manufacturing’ and will endeavour to cover all bases, including the all-important subject of cyber security, the role of human beings in the factory of the future, how to survive a cyber attack and the allimportant process safety and control.

Speakers from academia, the steel industry and the world of steel production technology will explain the key concepts behind the digitalisation of steel manufacturing. Myths will be exploded, ideas challenged and terminology explained.

For more details contact: Paul Rossage International Sales Manager +44 (0) 1737 855 116 paulrossage@quartzltd.com See full details online at

www.FutureSteelForum.com

Official Media Partner

Organised by:

www.FutureSteelForum.com

FSF_A4_Print_Ad.indd 1

24/08/2016 10:59

16

INNOVATIONS

Oman steelmaker orders complete minimill SMS Group has been contracted by Moon Iron & Steel Co. S.A.O.C. (MISCO) of Oman to build a new rebar production minimill – the first of its kind in the Middle East.

The plant is being built on the Sohar Industrial Estate, Sultanate of Oman, and operation will commence in 2018.

The steelworks will feature a 140-tonne AC electric arc furnace, a 140-tonne ladle furnace, and a five-strand continuous billet caster. On completion, the plant will be capable of producing 1.2Mt/yr of billets, out of which 1.1Mt/yr are rolled into 8mm to 40mm rebars.

The fully-continuous rolling line is equipped with 14 stands arranged in a horizontal and vertical configuration followed by two high-speed finishing blocks with six “V” type mill stands each. The roughing and intermediate trains are designed as HL (housing-less) stands. The “V” blocks are designed for highly efficient and productive finish-rolling of rebars up to 50 m/sec.

The high-speed delivery system (HSD) enables material rolling speeds of up to 41 m/sec.

According to Sasikumar Moorkanat, MISCO’s CEO, the project’s top priorities were the lowest possible energy consumption and minimal emissions. With these demands in mind, SMS group developed Continuous Mill Technology (CMT) and has taken the basic minimill concept one step forward.

“The direct linking of the rolling mill with the steelworks guarantees short distances. Rolling takes place without time lag by exploiting the casting heat,” says SMS. “CO2-intensive reheating furnaces can be dispensed with. Instead of an oilor gas-fired furnace, an inductive heating system is employed. This system does not reheat the billets but only equalises the temperature profile.

The induction heater gives you perfect control of the starting temperature for the rolling mill – according to the billet speed. This solution requires much lower investment costs. By eliminating the complete reheating stage, energy costs and the impact on the environment are markedly reduced.”

SMS group is responsible for the complete electrical and automation package that includes Level-1 and Level-2 process control.

“In addition to seamlessly integrating the process functional units, with the implementation of the state-of-the-art process solutions already highlighted, the automation system will allow MISCO to meet all possible market demands with built-in capabilities for plant-wide production planning, scheduling, tracking and reporting,” SMS group explained.

SMS group supplies minimill for rebar production to Moon Iron & Steel The new line can roll 1.1 Mt/yr of rebars from 8mm to 40 mm

Rebar steel from 8mm to 40mm

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

Digital Edition - November 2016

products.indd 5

01/12/2016 09:11:26

INNOVATIONS

Moon Iron & Steel has contracted SMS group

17

Safety relief valves – all you need to know Safety relief valves protect from excess pressure by targeted release of vapours and gases. David Breil, product specialist at German manufacturer WITT, talks about these passive protective devices Who benefits mostly from safety relief valves?

Anyone who operates pressurised systems, components or plants. These valves are typically fitted onto pressurised gas tanks or loop line systems, which, for instance, work with an operating pressure of 16 or 25 bar. Safety relief valves prevent serious accidents by relieving pressure before excess pressure can build up and become dangerous to systems and people.

What are the dangers?

Process safety issues can exist, through design or operation. Excess pressure can build up rapidly and exceed the material's burst limit. Safety relief valves are a last line of defence to prevent damage.

You also offer special TÜV approved valves – why is this?

Witt always checks the entire production line before delivery, piece-by-piece. Each device’s set pressure testing is witnessed and signed-off by a TÜV inspector. Consistent with our certification to the Pressure Equipment Directive, this individual approval is prescribed for the higher-pressure models. However, we also offer this service for all models in the lower pressure range. In this way, our customers receive an external certificate that guarantees extra peace of mind with regard to safety.

Does this mean that safety relief valves are only required for high pressures?

Not at all. Excess pressure can also have undesired consequences when working with low pressures, for instance, below 500 mbar. In these cases, it is less about life and limb, but rather about its effects on the quality of the products or devices used. I am referring to applications such as transport receivers for highly sensitive high-tech products, isolator and glovebox systems or industrial furnaces under a protective atmosphere. Even minor pressure fluctuations can put the process at risk. This area in particular is where the sensitive Witt valves of the AV series with opening pressures of 5 mbar can prove their strengths.

How do safety relief valves work?

Our valves are spring-loaded and direct-acting.

This means that as soon as the opening pressure is reached, a spring-loaded component gives in, opens the valve and releases the excess pressure.

It then closes automatically after equalising the pressure. A renewed increase in pressure will open it again.

For which pressure range can these valves be used?

Witt safety relief valves can cover an extremely wide operating range. The opening pressure can be set from 5 mbar to 45 bar, depending on the model. Thus, even minimal increases in pressure can be detected. This is important when it comes to protecting highly sensitive systems or housings. At the same time, they have a high venting output of up to 970 m?/h at temperatures ranging from -60 °C to +270 °C. And because they are small, they can be installed just about anywhere, and in any orientation.

However, the orientation needs to be known in advance for safety valves in millibar range, so that Witt can set the opening pressure to suit the system's operating pressure. www.steeltimesint.com

products.indd 6

David Breil

What other selection criteria are there for safety relief valves?

The type of gas plays an important role. We use brass as a standard housing material for technical gases. In most cases, aggressive or corrosive media require stainless steel equipment, which is used for securing biogas plants, for instance.

Aluminium is another possibility. Besides the housing, even the seals must be adapted. We have different materials available depending on the type of gas.

For further information, log on to www.wittgas.com Digital Edition - November 2016

01/12/2016 09:11:29

18

INNOVATIONS

Digital Edition - November 2016

products.indd 7

www.steeltimesint.com

01/12/2016 09:11:32

INNOVATIONS 19

Combilift sells its 30,000th unit

Combilift, the Irish specialist manufacturer of multi-directional forklifts, straddle carriers and other handling solutions for long loads, containers and palletised goods, recently celebrated a milestone in the company’s history.

The 30,000th Combilift to roll off the production line was officially handed over to its new owner during the recent CeMAT materials handling and logistics trade fair in Hannover, Germany.

Managing director Arno Sorger accepted the Combilift C14000 model on behalf of his company, Haslinger Stahlbau, a major steel construction company based in Southern Austria and with facilities in Vienna, Munich and Dresden in Germany and Dunavecse in Hungary.

Haslinger Stahlbau’s construction projects include production facilities, logistics centres, aircraft hangars, bridges, sports complexes as well as industrial power plants. The company processes around 40kt/yr of steel to realise these projects and the new C14000 is its eighth Combilift.

A variety of models from a 4t capacity Combi-CB counterbalance design truck, and 8, 12 and 14t models from the Combi-C Series are in operation across Haslinger sites to ensure safe and productive handling and storage of its very heavy loads.

Combilift has made its mark since it was established in 1998. Impressive year-on-year growth has enabled what started as a small company offering a niche product to now be a major global name.

Combilift MD Martin McVicar commented: “The amount of customisation featured in every model we produce makes the total of 30,000 units manufactured to date a very impressive achievement and I’d like to acknowledge the dedication and hard work of the Combilift team.

But, of course, thanks must also go to customers such as Haslinger Stahlbau who put their faith in our products time and again and thus enable us to continue to be the market leader in our manufacturing segment.”

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

www.steeltimesint.com

products.indd 8

Digital Edition - November 2016

01/12/2016 09:11:34

20 INNOVATIONS

ABB improves process insight Electrification products specialist ABB claims that it has launched a product that goes further than existing conventional and fibre-optic mold temperature measurement technologies to help metals producers enhance operations within the continuous casting process.

The OptiMold Monitor, claims ABB, can be used to measure, monitor and analyse data, and can help optimise operations in real-time. Highly accurate sensor data can provide valuable information on a broad range of mold

parameters including real-time meniscus profile, speed and symmetry, early sticker detection and crack warnings.

With over 4,000 fibre-optic measuring points per complete mold, the OptiMold Monitor’s spatial resolution is more than 20 times greater than that offered by conventional temperature measurement technologies, says ABB. As a result, the OptiMold Monitor can provide particularly accurate and detailed visual imaging of mold conditions critical to determining quality and productivity in continuous casting.

Productivity boost with Combi-SC Since structural steelwork fabricator Frank H. Dale took delivery of its Combilift Straddle Carrier (Combi-SC) it has been able to speed up loading and un-loading procedures and significantly reduce the number of potential forklift movements by thousands a year, resulting in safer working practices and a reduced environmental impact on-site Steel fabricator RH Dale was established in 1932 and manufactures structures for its clients throughout the UK in the industrial, commercial, retail and leisure sectors. The company offers a complete steel design, detailing, fabrication and erection service.

Managing director Paul Read and production director Jon Minton were keen to find a more efficient and safer alternative for handling both raw and fabricated materials outside of the factory environment. Wherever possible, they prefer to fabricate and load on a ‘just in time’ basis, which allows steelwork to be safely loaded directly on to trailers in the loading bays. But if a project is delayed, steelwork has to be stored outside. The side loaders previously used for this were uneconomical, untidy and involved many forklift movements around the yard to lay out the steelwork, which was individually picked up again and re-loaded when due to go on-site.

“We first saw the Combi-SC in the United States in use at a steel fabricator and thought it could be the answer for us and we were right,” said Read. “If customers put back a project we no longer have the headache of where to accommodate the material or of tying up lots of trailers and having to hire additional ones at extra cost.

We just lift loads off the trailers, store them in the yard and re-load when required. It could take two operatives a whole shift to re-build a load, but with the Combi-SC one lift puts a ready-assembled load onto a trailer in less than an hour.”

The nature of Frank H. Dale’s business means

that materials are all irregular lengths and the make-up of loads varies constantly. The 35t capacity Combi-SC incorporates a patented load stabilising feature, which allows full loads of non-uniform lengths to be lifted with no risk of swing during transit, even when the weight is unevenly distributed. “The guys from Combilift worked closely with us to design the stabilising feature and they will create a bespoke product rather than just selling you something ‘off the shelf’ that only partly works,” said Paul.

The 17 multiple lift points on each side of the beam allow operatives to fix the drop chains in the most suitable position according to each load. Two lateral bars, which serve as supports below the load, can then be pivoted into place to provide a secure base, enabling the Combi-SC to travel over relatively rough ground with a very stable load.

The machine’s ability to lift from ground level has also resulted in more compact storage in the yard, potentially doubling the storage space compared with the side loader system – a major advantage as the 12-acre site is pretty much full to capacity. Loads can be stacked closely side-byside thanks to the SC’s ability to traverse aisles of just 1650mm. The number of trailers needed has been reduced from 29 down to 16, which is beneficial from a space perspective and has resulted in financial savings on trailer maintenance and upkeep.

“The beauty of our Combi-SC is that we can assemble and lift a mix of, for example, 3m,

5m, 6m beams or longer in one load with the minimum of fuss,” explained Read. “We can now easily move, load or offload hundreds of tonnes of materials a day, and we have drastically reduced forklift movements, which is always beneficial from a safety point of view.”

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

Digital Edition - November 2016

products.indd 9

01/12/2016 09:11:40

INNOVATIONS

Mold temperature measurement technology is used to visualise conditions in the near-meniscus area crucial to determining yield and steel quality in continuous casting.

The OptiMold Monitor provides 2D mold temperature maps, which make it simple for the operator to view current temperature gradient data in real-time. Access to historical data also allows for more in-depth analyses of multiple events around the meniscus, can increase operator know-how and lead to fewer caster disturbances.

When combined with an electromagnetic stirring/braking device, such as the latest generation of the FC Mold (Flow Control Mold), the OptiMold Control can be used to increase control of molten steel flows and significantly reduce inclusion defects for all casting conditions online and in real-time.

“The OptiMold Monitor can turn data insights into direct action and generate real value for our customers” said Anders Lehman, head of ABB’s metallurgy products business. “It can be used on its own to gain fundamental understanding of mold conditions, or together with an advanced electromagnetic device, to help metals producers

unlock new opportunities that increase quality and productivity and reduce operating costs in the era of industrial digitalisation.”

21

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

Digital Edition - November 2016

products.indd 10

01/12/2016 09:11:47

22

INNOVATIONS

Fives assists steelmakers around the world

Stay warm by getting fleeced this winter Dickies, a global manufacturer and supplier of workwear, has announced the introduction of a range of winter warmers, including a range of fleeces. The Brookton is claimed to be perfect for steelworkers who need lots of pockets: there’s one on the sleeve, one on the chest and another two hip pockets.

Part of the company’s two-tone range is the Two-Tone Micro Fleece; with a close fit and a handy thumb hole on the cuff it is said to be perfect for layering.

The Eisenhower fleece is bonded with Sherpa lining and comes with knitted cuffs and hem, side handwarmer pockets and contrast fabric panels on the sleeves.

The most versatile winter garment, however, must be the three in one Abbot jacket, which is waterproof, has a zip guard, concealed hood, reflective piping and a micro fleece inner jacket.

The inner and outer jackets can be worn separately.

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

Digital Edition - November 2016

products.indd 11

Global industrial engineering group Fives has been busy all around the world, servicing the needs of steelmakers.

When Lusosider Acos Planos SA, a Portugese subsidiary of Brazilian steelmaker CSN, wanted a furnace revamped, it turned to Fives.

Lusosider produces flat steel products and, due to improved market conditions, wanted to increase production on its continuous galvanising line (CGL). Fives will implement a major revamping of the company’s horizontal furnace, supplied earlier to the plant. The modification, including the installation of an additional jet cooling unit in the cooling area, will remove the existing bottleneck.

According to Fives, the Lusosider revamping project should increase CGL productivity by 10% and will be completed in December 2016.

Meanwhile, in India, Tata Steel, the flagship company of the Tata group, has taken on Fives to upgrade the Level 1 control system at the

www.steeltimesint.com

01/12/2016 09:11:52

INNOVATIONS

23

New handbook from Hunt Valve steelmaker’s existing gas-fired pusher type reheating furnace.

The furnace in question is installed at the merchant mill of Tata’s Jamshedpur works. It has an hourly capacity of 72 tonnes and was originally commissioned in 1958. The furnace has a single loop controller and instruments for furnace heating control.

According to Fives, the complete changeover of the heating control system will include Fives’ advanced proprietary technologies and know-how. Fives will design and supervise the erection and commissioning of a PLC-based furnace control system, including logic and HMI development for the heating system.

Across the Atlantic in the USA, Fives was awarded the contract to supply a breakthrough furnace level 2 automation system for a US steelmaker. The existing automation system operating at the slab reheating furnace is to be replaced by Virtuo, a new digital system developed by Fives to optimise furnace performance and guarantee product quality, Fives claims.

The upgrade will allow the US steelmaker to increase final rolled material quality, reduce yield loss and significantly reduce gas consumption and scale formation.

“The Virtuo system has been developed as an optimised solution for reheating furnaces, strip processing lines and associated services,” said Fives.

The tuning of furnace burners is something that steelmakers in all four corners of the world entrust to Fives. The company claims that a regular burner tuning ‘significantly reduces gas consumption and optimizes burner life’ while at the same time reducing maintenance operations and providing safe operating conditions. “The burner tuning service offers improved operating costs for a very justified investment,” Fives said.

Specialised services, including on-site assistance, repairs, consulting, remote monitoring, upgrade, feasibility studies and contract performance are all services offered by Fives.

In addition, the company also offers training programmes for process line operators and maintenance staff designed to upskill them on combustion and thermal expertise, burner tuning and instrument calibration.

US-based Hunt Valve has issued a High Pressure Water Valve Selection and Maintenance Handbook to help plant and maintenance engineers increase the safety and reliability of their high-pressure hydraulic systems.

According to Hunt Valve, the handbook provides water valve technology recommendations, system design parameters and maintenance tips for a variety of high-pressure hydraulic applications.

Brad Sterner, president and CEO of Hunt Valve, said that safety, dependability and reliability are very important to both military and industrial manufacturers around the world. He said that Hunt Valve, an expert in what he called ‘extreme engineering’, was dedicated to supplying these industries with top product technology and the expertise required to help manufacturers select and maintain harsh duty valves in demanding environments.

The handbook is designed to help plant and maintenance engineers optimise their military and industrial applications by selecting the right high-pressure water valves; choosing the optimal valve materials; minimising valve leakage; and realising the benefits of preventive maintenance.

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

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

www.steeltimesint.com

products.indd 12

Digital Edition - November 2016

01/12/2016 09:11:57

24

INNOVATIONS

NEXTSENSE opens US office NEXTSENSE, a high-tech company from Graz in Austria specialising in non-contact measurement technology, is strengthening market presence in the USA by opening its first subsidiary in Atlanta, Georgia. The new office will serve as a sales and service co-ordination centre. By 2020 the company expects to employ more than 100 people all over the globe.

“Intensifying our presence in the USA is an important step for our ambitious growth goals.

Only this way we can fully exploit the great market potential and take the local interest comprehensively into account,” explains Clemens Gasser, CEO of NEXTSENSE GmbH. The company, founded nine years ago, has developed a contactless and handheld profile measurement system called CALIPRI, which can be moved freely around the object to be measured. Different versions of this technology are developed and produced in Graz and are relied upon by major players in the automotive, railway and metal industries.

“By 2020, we want to triple our sales and increase the number of employees by well over 100,“ said Gasser.

He said that opening the US office was the ‘first milestone’ in the course of NEXTSENSE’s international expansion. Next year, the plan is to open another subsidiary in China.

“In the future, we want to be closer to our customers.

Direct contact is particularly important for us, because only this way we can react fast enough to the needs of our demanding market,” Gasser said.

For further information, log on to www.nextsense.at

Global Insulation Company of the Year named Paroc Group, a leading European manufacturer of energy-efficient insulation solutions, has been named Global Insulation Company of the Year 2016 at the 11th Global Insulation Conference held in Hamburg, Germany, in September.

Paroc has won the title for the second time, repeating its 2012 success.

The Finnish company, which claims to have built a reputation for innovation, product performance, technical expertise and sustainability, was given credit for its highly innovative, yet sustainable approach to the insulation market.

Digital Edition - November 2016

products.indd 13

The award was largely based on the company's pioneering role in attention to environmental effects.

Paroc won Insulation Product of the Year 2015 for its general insulation slab, Paroc eXtra.

The company has production plants in Finland, Sweden, Lithuania, Poland and Russia and sales offices in 14 European countries.

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

www.steeltimesint.com

01/12/2016 09:12:00

INNOVATIONS

25

Common causes of motor failure Modern electric motors may be more efficient and reliable than their ancestors, but they can still fail sometimes. Martin McGuffie* explains the three common causes of electric motor failure and how maintenance staff can reduce the impact equipment failure can have on business.

How long do electric motors actually last before they break down? The answer is often disputed, with some manufacturers stating 30,000 hours and others suggesting they can power through for up to 40,000 hours. However, most manufacturers are in agreement that electric motors last much longer when maintained properly.

Understanding the state of an electric motor’s health requires a range of tools and techniques, as well as thorough record-keeping and regular maintenance. This allows the engineer to identify trends or weak points more easily.

Weakened insulation Nearly half of electrical failures in motors begin with weakening of the insulation around individual wires in the motor coils.

This is often caused by thermal stress, contamination and movement of the winding due to the magnetic forces during start-up and shut-down of the motor.

Overheating can also cause the winding insulation to deteriorate quickly — for every 10 centigrade rise in temperature, the insulation life is cut in half. Overheating can occur when the power quality is poor or when an electric motor is forced to operate in a high-temperature environment.

Contamination Contamination is another one of the leading causes of motor failure. Contaminants include airborne dust, dirt or any abrasive substance that finds its way into the motor. When they come into contact with the motor, foreign bodies can cause denting of the bearing raceways and balls resulting in high vibration and wear.

Luckily, preventing contamination is fairly easy.

The main sources of contamination include dirty tools, work areas and hands. Foreign matter in lubricants and cleaning solutions can contaminate motors.

To help reduce contamination failures engineers should keep work areas, tools and fixtures clean. Also, when laying out the space, companies should try to keep motor assemblies and operation areas away from grinding machines to reduce the amount of foreign bodies that might contaminate the motors.

Lack of maintenance A well-planned preventative maintenance programme is the key to dependable, long-life operation of motors and generators. It also helps reduce unscheduled production stoppages or long repair shutdowns.

The first step towards preventative maintenance is understanding how often tests need to

be carried out on the motor. This varies, depending on the age, condition and quality of the machine, as well as the environment it operates in.

Static tests are an easy method of identifying weaknesses within the motor winding. The tests focus on winding and insulation resistance, as well as turn-to-turn and phase-to-phase insulation condition.

With the right equipment, these tests can be performed without taking the motor off-site, thus minimising downtime.

Motor testing and analysis equipment can survey all insulation and windings in AC and DC motors, coils and generators. During a site visit, Euroserv attends with the all-in-one tester, providing customers’ maintenance staff with an analysis of the condition of the impedance, capacitance, phase angle, resistance, insulation and step voltage.

Motor failure can cause downtime, meaning companies can lose thousands of pounds every minute when operations are stopped. Instead of exposing themselves to downtime, customers should request regular motor testing and analysis, ideally every six months, to ensure their electric motors are healthy, efficient and reliable.

For further information, log on to www.euroservltd.net

* Service manager, CP Automation

Testing is crucial, says CP Automation

www.steeltimesint.com

products.indd 14

Digital Edition - November 2016

01/12/2016 09:12:01

26

INNOVATIONS

Portable high-speed performance Starrett, the band saw blade and machine specialist, has launched a new portable, battery-powered band saw machine designed for professional installers and contractors working across multiple sites.

The S1005 machine’s lightweight and compact design allows for safe and easy transportation, making it the ideal product for users across a range of trades. With a blade speed of 170m per minute, the hand-held saw is ideal for high performance cutting across a wide range of materials including conduit, trunking, pipe, box section, armoured cables, unistrut and much more besides.

Weighing just 4kg, the battery-powered S1005 band saw features a durable design, allowing fast cuts with a high quality surface finish. For repeated use on the move, the saw features a 20 V lithium-ion long-life battery with a charge display.

Digital Edition - November 2016

products.indd 15

“The S1005 portable band saw machine combines portability with performance to provide fast, high-quality cuts.” said John Cove, Starret’s marketing manager. “Many contractors struggle on-site as band saws can be too restrictive and heavy, meaning they cannot be safely and easily transported, there is also the obvious issue that mains power may not be available. That’s why we have designed our latest machine to simplify the cutting process for installers without compromising on the quality of the cut itself.

According to Cove, the machine’s 0.35mm thickness Starrett Univerz Bi-Metal blades are ideal for cutting a huge variety of materials. The Starrett material reduces the stress on the blade, potentially creating up to 50% more blade life than band saw blades in competitive machines.

“The blade’s high durability provides consistent and repeated cutting with the quick release lever allowing for easier blade changes that shorten

and simplify the cutting process,” Cove said.

“This makes the machine ideal for all types of contractors, allowing them to work freely without the potential design or user restraints that other band saws can create.”

The S1005 portable band saw has a one-year warranty and comes with a free Starrett tool bag, free Starrett Univerz band saw blade and free secondary 20 V lithium-Ion powered battery.

For further information, log on to www.starret.co.uk

www.steeltimesint.com

01/12/2016 09:12:03

INNOVATIONS

27

Optical width measurement system for strip and plate mills US-based NDC Technologies, a global provider of precision measurement and control solutions, has introduced the W200 width measurement system for strip and plate mill applications.

According to NDC, the W200 uses the most advanced stereoscopic measurement technology to accurately and consistently measure product width across a range of process conditions. The system enables mills to optimise processes, yield and product quality.

“Our new W200 width measurement system is designed to be installed above the roller table in hot strip and plate mills, and provides high-resolution true width measurement from an ultra-stable optical bench with long-life lasers,” says Mike Ramsey, director of sales for the metals business at NDC Technologies. “This system incorporates over 30 years of NDC/IRM experience in manufacturing optical width and flatness gauges for the metals industry. Advantages include flexible scalability to meet unique application requirements, the highest measurement performance driven by

the most advanced technology, and the lowest cost of ownership.”

The W200 width measurement system is a complete platform that includes an easy-to-use operator interface, a powerful real-time operating system for continuous width measurement, plus network communications to the mills’ control platform and management reporting systems. It comprises a single enclosure including the sensor components and NDC’s reliable Totally Distributed Intelligent (TDi) platform architecture that has been proven on thousands of applications since 2006. This modular design ensures both parts and operational commonality for all W200 width and Rometer flatness measurement products throughout the mill.

Depending on the application, the W200 uses a combination of cameras, laser line projectors and laser point sources to accurately measure the product width. For strip temperatures above 800oC, the gauge measures the radiant energy to determine the edge location. For locations with a cooler strip, front light technique is used.

Additionally, to compensate for strip curvature, laser point sources are added to measure the strip height across the entire width. The W200 multi-stereoscopic measurement technique and unique edge detection software measures the true strip width, regardless of strip movement, tilting, bouncing and strip curvature. Its reliable smart cameras and long-life lasers are backed up with real-time performance monitoring for high reliability.

The W200 system can also be equipped

with NDC’s Beta LaserMike LaserSpeed length and speed gauge for crop shear optimisation, marking and cutting control, discrete coil and plate length, elongation and differential speed applications.

The W200 network capability integrates Level 1 & 2 plant networks providing connectivity with many common PLCs and automation platforms.

The architecture includes a network of single board industrial computers (DBRIC’s) that are designed for the harsh metals environment.

Each DBRIC has unique, dedicated functions for measurement processing, laser monitoring, communications and enhanced product reporting.

Finally, W200 system maintenance is simplified with straightforward troubleshooting and report tools. This rugged system offers reduced system complexity with high reliability, malware resistance and low installation costs.

For further information log on to www.ndc.com and www.laserspeedgauge.com.

Aumund and Sweidan offer spare parts in Riyadh

.

Aumund Fördertechnik GmbH, Germany, and Sweidan Industrial Services, Riyadh, have opened a new spare parts stock at their Riyadh Warehouse. The new facility will mean that www.steeltimesint.com

products.indd 16

parts will be instantly available, according to Aumund, and this is of particular importance in the case of emergencies when getting the machine running again is top priority.

A local Aumund supervisor will be available to support the customers.

Aumund says it offers a high level of after

sales service along with top quality products.

For on-site services local Aumund supervisors are ready at any time to assist the customers for many reasons, including troubleshooting, technical advice, installation supervision, preventive maintenance and equipment inspection.

For further information log on to www.aumund.com Digital Edition - November 2016

01/12/2016 09:12:05

28

INNOVATIONS

Kasto’s high performance bandsaw Kasto, a German metal sawing and storage equipment manufacturer, has introduced a high performance, economically-priced bandsaw.

The KASTOwin pro AC 5.6 boasts short cutting times, long blade life and intuitive operation, the company claims.

According to Kasto, the automatic machine is optimised to extract the best possible performance from either a bimetal or tungsten carbide tipped (TCT) blade. It is claimed to be ideal for cutting solid material, tubes and profiles, particularly in steel production and stockholding, as well as machine manufacturing and the automotive industry.

It is also claimed to ‘significantly increase production speed and efficiency’ and, depending on the type of blade and the material being cut, it can reduce processing times by up to 50% or more.

A space-saving milling machine

Böhler Edelstahl’s modernisation plans Böhler Edelstahl GmbH & Co KG (Böhler Edelstahl), part of the special steel division of voestalpine, has contracted Primetals Technologies (Primetals) to modernise the flat rolling block at its Kapfenberg plant in Austria. The plant will be equipped with a new drives and automation system known as the ‘RollMaster’ and specially developed for long product rolling mills. The equipment will handle the generation and management of pass schedules.

According to Primetals, the project is designed to increase plant availability, improve product quality, boost energy efficiency and cut maintenance costs. Modernisation work is scheduled to take place during a one-month plant shutdown mid-2017.

The flat rolling block consists of three horizontal and two vertical stands, and produces flat bars in widths ranging from 43 to 205 millimetres and in thicknesses from 4.5 to 86 millimetres. A hydraulic drive system and a now obsolete, proprietary automation system have been in use since commissioning in 1988. Spare parts supply and adequate servicing can no longer be ensured. As a consequence, Böhler Edelstahl decided to ask Primetals to modernise the automation and drives system.

In previous years, Primetals has equipped the continuous rolling mill in the multi-line rolling mill and the roughing stand of the blooming mill with new automation and drives technology, and Digital Edition - November 2016

products.indd 17

supplied new drives for the six-stand HV-combination mill.

Primetals will supply new main and auxiliary drives with Sinamics S120 frequency converters, a new operator control and monitoring system based on Simatic PCS7, and new main gearboxes. The elimination of the hydraulic systems will reduce maintenance costs and increase plant availability, which will, claims Primetals, boost the productivity of the rolling line. Energy requirements as well as the consumption of hydraulic oil and cooling water will fall substantially. In future the ‘RollMaster, specially designed for long product rolling mills, will handle the generation and management of the pass schedules. This software is the link between the production planning system and plant automation.

Primetals will also handle engineering, manufacturing, commissioning and customer training.

Böhler Edelstahl employs more than 2,000 people, and produced some 162kt of steel in fiscal 2016.

The company specialises in the production of long products and open-die forgings made of tool steel, high-speed steel, special materials and nickel-based alloys. It was founded in 1991 and is a wholly-owned subsidiary of voestalpine Edelstahl GmbH. For further information, log on to www.primetals.com www.steeltimesint.com

01/12/2016 09:12:07

INNOVATIONS

For precise and infinitely variable control, the product’s electromechanical downfeed is controlled via two ballscrews, each with a servo drive. There is a retraction unit for separating the blade from the material in order to protect the cut surface when the saw head moves back – and this also helps to minimise tool wear.

The drive unit and sensor are separate from the working area, ensuring reliable, trouble-free operation. Access to the machine is good, despite compliance with CE safety standards.

The saw band is driven by an 11 kW, frequency-controlled motor, delivering adjustable cutting speeds from 12 to 150 m/min and providing plenty of capacity for TCT sawing. ‘Trum’ guides mounted at the return side of the blade dampen vibration, promoting accurate sawing and prolonging tool life.

Maximum cutting capacity is 560 mm and the smallest dimension that can be cut is 25 mm x 25

ne

mm. The band guide arm adjusts automatically to material width. The shortest residual length is 10 mm for individual offcuts and 35 mm in automatic operation, enabling operators to minimise waste.

Two electrically driven, easily replacable, plastic brushes keep the teeth free from chips and are automatically adjusted throughout their service life.

Having an installed weight of 4.3 tonnes and a rigid welded structure with vibration-optimised ribbing, the KASTOwin pro AC 5.6 ensures quiet operation, short processing times and accurate cutting. A powerful coolant pump and large reservoir serve to reduce wear on the teeth further, especially when sawing difficult-to-machine materials.

The bandsaw comes with EasyControl, a high-performance control unit that is easy to use and reduces idle times in automatic operation

F. Zimmermann, a leading supplier of high-tech milling solutions based in Germany, has recently launched the FZ40 compact, a space-saving portal milling machine designed for high-speed machining of strong and high-strength materials.

The FZ40 is a compact, powerful machine based on the proven FZ33 compact and offering the same space-saving dimensions, according to Zimmermann. Its primary applications are efficient machining of steel, cast iron and titanium.

It

29

for maximum output. All parameters can be optimised to match the type of blade and the material being cut.

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

has an inherently rigid monoblock structure that allows it to be set up easily and rapidly.

Zimmermann is targeting customers who are engaged in heavy-duty cutting and want to focus more on tool making.

Zimmermann claims that the FZ40 compact is especially suitable for machining workpieces made of steel, cast iron and titanium. It features a new VH60 2-axis milling head with a spindle power of 63 kW, a spindle speed of 15,000 rpm and a torque of 300 Nm. It is available with an HSK-A100 tool holder.

While having all the advantages of Zimmermann’s FZ33 compact, the FZ40 has been enhanced for heavy-duty cutting. The portal is bigger and more rigid and the base plate has been strengthened. It can hold workpieces weighing as much as 16 metric tons.

Eight additional mounting elements are provided for greater stability and the side walls, which are filled with special concrete, rest on the machine bed, making it possible to erect the machine on a solid industrial floor – without special machine foundations. The end result is that users have greater flexibility during set-up.

The FZ40 compact can machine steel components quickly and economically on 5 axes, Zimmermann claims.

It achieves short throughput times, high availability and high precision and, thanks to the standardisation of assemblies, the modular construction of the machine and the stocking of assembly parts, the FZ40 compact is offered at an attractive price and with fast delivery.

For further information, log on to www.f-zimmermann.com

www.steeltimesint.com

products.indd 18

Digital Edition - November 2016

01/12/2016 09:12:08

30

INNOVATIONS

Continuous billet caster for Orissa Metaliks Concast (India) Ltd., a Primetals Technologies Group Company, has received an order from Indian steel producer Orissa Metaliks Private Limited (Orissa Metaliks) – steel products producer Orissa Metaliks is part of the Rashmi Group – to supply a three-strand continuous billet caster for the company´s production site near Kharagpur, West Bengal. The plant is designed to produce 384kt/yr of carbon steel billets with a cross section of 100 millimetres for further processing to commercial rebars. The aim of the project is to increase capacity. To save energy, the casting machine is designed for hot direct rolling of billets to rebars without reheating. The plant start-up is scheduled for November 2016.

The caster has a machine radius of 6 metres, a metallurgical length of 11 metres and a curved

Digital Edition - November 2016

products.indd 19

tube mold. Maximum casting speed is 4.1 metres per minute. Concast (India) is responsible for designing, engineering and manufacturing of ladle support, tundish and tundish support, mold and oscillator, straightener segments, secondary cooling, dummy bar system and pusher and cooling bed.

The hot charging system will be provided by Orissa Metaliks. Concast (India) will provide the hot charging system and basic automation (level 1) and HMI system and will take care of installation and commissioning of the casting machine.

In 2010, Concast (India) supplied a three-strand caster to Orissa Metaliks.

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

www.steeltimesint.com

01/12/2016 09:12:13

INNOVATIONS

31

The last of three converters In September, the last of three LD (BOF) converters supplied by Primetals Technologies (Primetals) commenced operation at SSAB’s Raahe, Finland works.

The first converter was started up in October 2015, the second in May 2016.

With almost unchanged space requirements, the new converters have a larger reaction volume. The maintenance-free Vaicon Link 2.0, which will be used as the converter suspension, minimises stress caused by heat-induced deformation and has a longer useful life, says Primetals.

A blowing lance tip geometry adjusted to the new converter geometry, bottom stirring and a slag stopper improve the metallurgical properties of the steel produced. A new refractory concept will ensure a long converter lining campaign.

SSAB Europe Oy is part of the SSAB group, a leading global producer of Advanced High Strength Steels (AHSS) and Quenched and Tempered Steels (Q&T), strip, plate and tubular products, as well as construction solutions. The group has an annual steel production capacity of 8.8Mt (metric tons) and operates production plants in Sweden, Finland and the USA. The integrated steel mill in Raahe is said to be the largest production facility of its kind in the Nordic countries.

Raahe’s existing converters each have a tapping weight of 125 metric tons. Primetals will replace them with three converters featuring a detachable bottom and a bottom stirring system.

According to Primetals, the converter has an optimised geometry, which enables a larger reaction volume as well as a new concept for the refractory lining which has a longer useful life. Primetals’ remit embraces the engineering of the converter vessels, trunnion rings and Vaicon Link 2.0 maintenance-free suspension systems.

The converters feature the Vaicon Stopper to minimise slag transfer on tapping. The tip of the blowing lance is adapted to the new converter geometry, which improves the blowing process and, therefore, the metallurgical properties of the steel produced. Primetals is also responsible for monitoring pre-assembly and installation work as well as commissioning.

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

The last of three LD BOF converters for SSAB’s Raahe works in Finland

www.steeltimesint.com

products.indd 20

Digital Edition - November 2016

01/12/2016 09:12:15

32

INNOVATIONS

SMS workshop services leading US steelmakers

SMS Technical Services (SMSTS) has opened a new service and maintenance workshop close by to Big River Steel (BRS) in Osceola, Arkansas, USA. SMSTS will take care of all service and maintenance activities for Big River Steel’s compact strip production (CSP) plant on the molds and segments of the casting plant and the rolling mill components (annual production 1.6Mt). The company will also be in charge of two on-site roll shops servicing the hot and cold rolling mills.

According to SMS group, its CSP system ‘combines cost-effective and environmen-

tally friendly production with high productivity and excellent strip quality’. With a CSP caster, claims SMS group, liquid steel is cast into thin slabs, which, after temperature equalisation in a tunnel furnace, are rolled in the rolling mill without roughing.

SMSTS will also be responsible for the investments related to the construction of the roll shops, for roll shop personnel and for operation. It will also provide roll grinding machines and auxiliary facilities for the roll shops. The company argues that contracts like this are becoming increasingly popular among steelmakers in

North America.

When the BRS steel complex is operational, 50 people will be working in the Osceola service workshop and in two roll shops. Employees will be recruited locally from North Eastern Arkansas and from other SMSTS service locations in the USA. “SMS group has been consistently pursuing the concept of establishing local service branches all over the world.

This helps steel mill operators needing to have components of their plants serviced or repaired save on shipping costs,” the company explained, adding that the new

Daehan Steel Co, South Korea

Digital Edition - November 2016

products.indd 21

www.steeltimesint.com

01/12/2016 09:12:18

33

INNOVATIONS

WST of China order SMS forging press

Osceola workshop offers operators of North American continuous casters a full line of services for any plant components, including repairs, overhauls, service and maintenance.

The Osceola workshop, claims SMS group, offers a service range similar to that available from the group’s Oil City workshop in Pennsylvania, although Osceola will offer more as it has a high-capacity CNC horizontal milling centre for additional machining and turning processes and offers shot blasting and paint spraying cabins.

Also on offer at Osceola will be highgrade plating of copper plates and a local field service for on-site laser scanning or alignment activities.

There are other steel mills adjacent to the new facility – SDI Columbus, Nucor Decatur, Nucor Hickman, Nucor Tuscaloosa, Nucor Yamato and Nucor Memphis – all of whom are long-standing SMS group customers.

Western Superconducting Technologies (WST) of China has ordered a high-speed 63/80-MN two-column push-down open-die forging press with two integrated 25-tonne rail-bound manipulators and an 8-tonne mobile loading and unloading manipulator from SMS group.

According to SMS group, the machine operates with a press force of up to 63 MN and a maximum upsetting force of 80 MN. Commissioning is scheduled for the year-end 2017.

The machine will process high-quality semi-finished products for various applications such as high grade superconducting materials like titanium alloys for superconducting magnets, which are used in the aerospace industry.

The contract also provides for the supply of two rail-bound manipulators synchronised with the forging press to guarantee fast and precise handling of forgings, enabling WST to achieve high stroke rates and expand its existing product range thereby strengthening it’s market position on the international titanium market.

WST is part of China’s State Nuclear Power Technology Corporation.

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

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

South Korean steelmaker modernises mill Daehan Steel Co of South Korea has taken on SMS group to modernise it’s existing shear number three in its VCC line (Vertical Compact Coiler) at ist rebar mill in Pyeongtaek.

The project involved the replacement of the switch and the scrap guiding system of the existing shear with new equipment.

A newly developed high-speed switch and an upgraded automation system enabled the plant to achieve speeds of up to 35 metres per second

www.steeltimesint.com

products.indd 22

without major modifications to adjacent plant parts, according to SMS group.

Modernisation means the VCC line at Daehan Steel has increased throughput to 70 tons/hr.

A new switch was constructed and delivered in five weeks and only three days were needed for assembly and commissioning.

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

Digital Edition - November 2016

01/12/2016 09:12:21

34

INNOVATIONS

Bilstein to modernise rolling mill BILSTEIN GmbH & Co. KG, Hagen-Hohenlimburg, Germany, has contracted the SMS group to modernise its four-stand tandem rolling mill to ensure future production and plant availability.

SMS group will upgrade the system platform to the current state-of-the-art without changing the applications software, thanks to the X-Pact ProBAS automation platform comprising hardware, operating system, system layer and applications software for the basic automation systems. The platform is an integral part of the X-Pact electrical and automation system covering the entire range for metallurgical plants and rolling mills – from basic automation to production planning.

Bilstein’s hardware will be changed from the X-Pact CPCI motion system to the X-Pact Embedded hardware platform. The latter’s controllers are based on Intel multi-core processors and provide the required computer capacity for all applications. SMS group claims to offer a complete solution allowing complex arithmetic operations and control algorithms to be performed.

The application software will remain unchanged and all improvements and optimisations carried out jointly with SMS group over recent times will be retained.

According to SMS group, the modernisation

Digital Edition - November 2016

products.indd 23

concept allows the conversion measures to be implemented within short shutdown periods and the plant to be restarted at minimum risk.

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

www.steeltimesint.com

01/12/2016 09:12:26

INNOVATIONS

It is worth remembering that health and safety in the work place is so important that it has been clearly defined. Personal Protective Equipment at Work Regulations 1992 state that PPE covers “all equipment (including clothing affording protection against the weather) which is intended to be worn or held by a person at work which protects them against one or more risks to their health and safety”.

The stark fact is that engineers could regularly face a multitude of working conditions that could put their own health and safety at risk if they fail to wear the appropriate PPE.

Face protection in the workplace Don’t let health and safety of your face and head fall by the wayside because of complacency in the workplace, argues Rob Haines, sales director of workwear specialist Dickies Safety is a major concern, yet some engineers in the steel industry may feel that protective equipment is too cumbersome for everyday tasks. Yet, when you take into account the sheer range of physical, chemical, mechanical and even electrical hazards, they could be working in one of the most challenging work environments there is.

Indeed, according to British government figures, 76,054 non-fatal injuries to employees happened in the workplace last year.

A report in the British Medical Journal (BMJ) shows that eye injuries that occurred at work amounted to 69.9% of those reported, often caused by projectile perils, but other hazards, such as loud noises, can damage the ears and dangerous air-borne substances, when inhaled, can cause respiratory problems and even death.

“That’s why Personal Protective Equipment (PPE) should be taken seriously” says Rob Haines, sales director of workwear specialist Dickies. www.steeltimesint.com

products.indd 24

Protecting your vision Eye injuries are the most likely to occur in the workplace and these may easily have been prevented had the right eye protection been worn.

Most occur when grinding, sawing or joining.

In those instances, there is a risk of shards flying into the air and potentially into the eye.

Wearing a pair of safety glasses can prevent those injuries and there are plenty of types and styles available on the market, all of which have CE marking approval. These range from those offering unrestricted vision, fogbuster goggles with a thermos lens system resistant to misting, lightweight and even ergonomic goggles that are frameless and can be worn all day. New on the market are safety goggles which have interchangeable temples and head band, are made with a scratch-resistant polycarbonate anti-fog lens and offer a seal of protection against dust or airborne particles, as well as 99.9% UV ray protection.

You may think that because you are wearing glasses you are protected, but eyes can still be vulnerable if not fully covered. In this case over-spectacle safety glasses can be worn. These have been specifically designed to fit well over prescription glasses and still offer protection.

35

Respiratory protection Exposure to airborne particles can be a big health issue that can be countered by the use of a simple respirator or face mask, tested under the standard EN149:2001 and worn over the nose and mouth. Such a device could deflect the risk of poisoning, because it is designed to reduce the wearer’s exposure to the danger.

It is important to assess the risk and chose the right equipment for the environment. Some respirators are designed to protect against higher levels of toxicity than others.

Employers should ensure that their Personal Protection Equipment (PPE) is appropriate, taking the fit and protection levels into consideration.

Just because an item of PPE passes the relevant standard doesn’t mean that all PPE items with that standard meet the exact same levels of protection.

It probably goes without saying that a safety helmet is an essential part of PPE. But, when you need protection from noise, dust and projectiles you could choose one with ear defenders and a wire-mesh face shield and even an internal sweat band to the brow already attached. www.dickiesworkwear.com

Protecting your hearing There’s a simple guideline as to whether or not ears need protecting and it’s this: if you need to raise your voice to be heard at arm’s length away, then protection should be worn.

After-all, a hand drill may be easy to handle but the noise it makes while drilling can reach 97 decibels. A large hammer drill used to bore a hole through an external wall for an overflow pipe reaches a staggering 119 decibels. Alarmingly, if your ears are left unprotected these drills can cause hearing loss in as little as a few minutes.

You can choose a foldaway ear defender with adjustable headband and PVC cushioned cups or for something more lightweight, you can instead choose adjustable foam ear plugs (polyurethane foam ear plugs and polypropylene neck band). Or at the very least wear a pair of soft polyurethane foam earplugs.

Digital Edition - November 2016

01/12/2016 09:12:28

FUTURE STEEL FORUM 2017 14-15 JUNE • SHERATON WARSAW HOTEL • WARSAW

Applying Industry 4.0 to the steel industry

What is Industry 4.0 and how can it assist the global steel industry in its quest for greater efficiencies? Two questions, among many others, that will be answered by the experts at the Future Steel Forum in Warsaw in June 2017.

The Future Steel Forum is a live discussion of the issues surrounding Industry 4.0 or ‘smart manufacturing’ and will endeavour to cover all bases, including the all-important subject of cyber security, the role of human beings in the factory of the future, how to survive a cyber attack and the all-important process safety and control.

Speakers from academia, the steel industry and the world of steel production technology will explain the key concepts behind the digitalisation of steel manufacturing. Myths will be exploded, ideas challenged and terminology explained.

See full details within this brochure and online at

www.FutureSteelForum.com FROM THE PUBLISHER OF STEEL TIMES INTERNATIONAL

Official Media Partner

Organised by:

FUTURE

14-15 June, Sheraton Warsaw Hotel, Poland

STEEL FORUM 2017 14-15 JUNE • SHERATON WARSAW HOTEL • WARSAW

APPLYING INDUSTRY 4.0 TO THE STEEL INDUSTRY Industry 4.0 is a collective term summarising how the implementation of so-called ‘enabling technologies’ can improve the production processes in manufacturing. Enabling technologies, such as Big Data, the Internet of Things and Cyber Physical Systems – to name but three elements of Industry 4.0 – will revolutionise the organisation of the global value chain by creating ‘smart factories’ designed to make an important contribution to the sustainability of the steelmaking process.

The Future Steel Forum will look at how innovative technology can be brought together with the sole intention of revolutionising the way steel is made.

“The goal of Industry 4.0 is the digital penetration of industrial business fields in order to improve the efficiency of production processes.

People, machines and manufactured parts that are involved in this process all become interlinked. An additional factor apart from this interconnection is artificial intelligence. This allows intelligent networks to be created within which machines will learn and optimise themselves in the future. Humans participate in these networks. This allows them to access information about their machines and parts regardless of time and location, assess situations, and intervene where necessary.”

Dr. Hohnhaus, Bystronic.

GET INVOLVED: If you are interested in finding out more, please contact the team below or enter your details on our website www.futuresteelforum.com TO SPEAK:

TO SPONSOR/EXHIBIT:

Matthew Moggridge

Paul Rossage

Editor

International Sales Manager

+44 (0) 1737 855 151

+44 (0) 1737 855 116

matthewmoggridge@quartzltd.com

paulrossage@quartzltd.com

FROM THE PUBLISHER OF STEEL TIMES INTERNATIONAL

Official Media Partner

Organised by:

Commercial packages to promote your brand, products and services If you are interested in promoting your services and products to a niche audience who are interested in increasing efficiencies within their steel manufacturing facilities, then this is a unique opportunity to position your brand alongside leading experts in this field.

There are very limited opportunities available and these will be allocated on a first-come-first-served basis. To express your interest, please get in touch as soon as possible by contacting: Paul Rossage, International Sales Manager +44 1737 855 116 paulrossage@quartzltd.com Please note bespoke packages can also be created for you if you have something specific you want to achieve.

TABLE TOP EXHIBITION SPACE £1,950 This is your chance to display literature about the products and services that you offer. It also provides your organisation with a base at the event where you can meet and network with delegates throughout the day. This package includes a 2 metre space with a draped table and access to power.

FUTURE

www.FutureSteelForum.com

STEEL FORUM 2017 14-15 JUNE • SHERATON WARSAW HOTEL • WARSAW

DELEGATE BAG SPONSORSHIP Sold to: Primetals Technologies/ PSI GmbH Each delegate attending The Future Steel Forum will be given a delegate bag when they register and enter the event. This one-off opportunity gives you the chance to brand these bags with your logo and/or message. Includes: •

•

•

A brochure/pen/pad to be inserted into the pack (to be supplied by the sponsor) Skyscraper advert to run on The Future Steel Forum website for 3 months leading up to the event, linking back to sponsor’s own website Sponsor’s logo to be included on all marketing email shots (where appropriate)

REGISTRATION: Badges and Lanyards £7,950 All delegates will need to collect their badge at the registration area when they arrive at The Future Steel Forum.

This exclusive opportunity gives you branding at the entrance of the event (one of the first things delegates will see when they arrive) as well as branding throughout the pre-event registration campaign. Includes: • • • • • • •

Sponsor’s logo on pre-registration announcement email Sponsor’s logo on online registration page Sponsor’s logo on attendee badges Sponsor’s logo on attendee lanyards (to be supplied by sponsor) Sponsor’s can display posters/banners in the hotel registration area Sponsor’s logo to be included on all e-marketing emails (where appropriate) Opportunity for a representative of the sponsoring company to make a short presentation

CONFERENCE PROGRAMME £4,449 Every attendee coming to The Conference will refer to the official conference programme, which acts

as an essential guide to the event, both while delegates are there and for people planning their visit in advance.

This opportunity is limited to one company and will give you an exclusive branding right. Includes: • Sponsor’s logo printed on the online and onsite conference programmes • Pre-show email with a bespoke message from the sponsor • Sponsor’s logo to be included on all marketing email shots (where appropriate)

OFFICIAL NETWORKING EVENING RECEPTION £7,499 This is an exclusive chance to host an informal evening reception for all delegates, speakers and attendees of the event. Includes: • •

•

•

•

•

•

Large banner with sponsor’s branding in the reception Sponsor’s company literature/goody bags to be distributed as people leave at the end of the reception Opportunity for a representative of the sponsoring company to make a short presentation during the reception to welcome guests Skyscraper advert to run on The Conference website for 3 months leading up to the event, linking back to sponsor’s own website Sponsor’s logo to be included on all marketing email shots (where appropriate) Bespoke sponsor’s email to be sent out inviting all attendees to the reception An opportunity to invite 10 additional guests/staff to attend the reception

DELEGATE LUNCH Sold to: SMS group GmbH One of the most valuable elements of a face-to-face event is the business opportunities and relationship building from informal networking.

Associate your brand within the delegate lunch area with this exclusive opportunity to brand and have promotional materials in and around the

delegate dining area. Includes: • • • •

•

•

Large banner with sponsors branding in the dining area Sponsor company literature to be displayed within the dining area Delegate menus with sponsor branding and message Opportunity for a representative of the sponsoring company to make a short presentation prior to lunch being served Skyscraper advert to run on the conference website for 3 months leading up to the show, linking back to sponsor’s own website Sponsor logo to be included on all marketing email shots (where appropriate)

DELEGATE COFFEE BREAKS Sold to: Primetals Technologies/ PSI GmbH The refreshment breaks in the conference will be an opportunity for delegates to network and take some time out from the presentations and discussions. This is an ideal time for you to promote your brand and services.

Includes: • •

•

•

•

Large banner with sponsor’s branding in the refreshment area Sponsor’s company literature to be displayed within the refreshment area Branded napkins/coasters or cups with sponsor’s branding and message (to be supplied by sponsor) Skyscraper advert to run on the conference website for 3 months leading up to the show, linking back to sponsor’s own website Sponsor’s logo to be included on all marketing email shots (where appropriate)

Find out more now by contacting Paul Rossage: +44 1737 855 116

paulrossage@quartzltd.com

FUTURE STEEL FORUM 2017 14-15 JUNE • SHERATON WARSAW HOTEL • WARSAW

DELEGATE REGISTRATION RATES The conference fee includes a 2-day conference programme, refreshments, a networking lunch and conference proceedings. Delegate registration fees for this conference are as follows:

Early-bird rate (up to 28 February 2017)

£790

Standard rate

£990

Please note the conference fees will also be subject to value added tax where applicable.

CONTACT US CONFERENCE:

SALES:

Matthew Moggridge

Paul Rossage

Editor

International Sales Manager

+44 (0) 1737 855 151

+44 (0) 1737 855 116

matthewmoggridge@quartzltd.com

paulrossage@quartzltd.com

OPERATIONS:

MARKETING:

Maisie Worster

Sophie Wright

Operations Executive

Marketing Executive

+44 (0) 1737 855 016

+44 (0) 1737 855 022

maisieworster@quartzltd.com

sophiewright@quartzltd.com

FROM THE PUBLISHER OF STEEL TIMES INTERNATIONAL

www.FutureSteelForum.com @FutureSteelForum

Join our Future Steel Forum Group

Official Media Partner

Organised by:

40

STEEL AND THE SEA

Safety on the seabed

Germany’s Schoeller Werk, a leading international manufacturer of longitudinally welded stainless steel tubes, makes its own contribution to the necessary quality and planning assurance with its heavy-duty control-line and chemical-injection pipes for the offshore industry. The company argues that technical design is such that they can withstand not only extreme pressure conditions, which prevail in deep seas, but also extremely high temperatures and aggressive liquid media.

By Markus Zimmermann*

EXTRACTION of oil and gas on the high seas demands innovative and complex piping solutions using high-quality materials. It is no longer unusual for oil companies to be drilling for oil at more than 10,000 metres below the surface of the sea. In order to ensure long-term profitability, any source needs to be exploitable for at least 25 years.

Worldwide, there are more than 2,000 offshore drilling rigs and many more individual wells with oil and gas being extracted on a continuous basis. The technical equipment for these installations sets extreme demands on the hand-picked suppliers from the stainless steel industry.

Germany’s Schoeller Werk took up the offshore challenge 35 years ago and for many years has been among the kingpins of the industry.

At its base in the Eifel, the company not only manufactures tubes for the automotive, the chemical and the medical industry, as well as being active in power station and heat exchanger construction, it also creates technologically remarkable solutions for use on drilling rigs.

Oil and gas extraction in Norway For one company alone, TCO Norway, service provider for Norway’s state-owned Statoil enterprise, Schoeller Werk has supplied over 500,000 metres of piping since winning their custom in spring 2014.

At the core of this partnership is a plugdrawn annular pipe made of high-quality

nickel-based alloys nos. 825 and 625. In addition there are austenitic pipes made of class 316 Ti stainless steel. Statoil has defined the pipes as standard for its own specifications.

Apart from a variety of materials, it is necessary to manufacture the various diameters and wall thicknesses, and plugdrawn Schoeller pipes cover all possibilities.

The pipe design and the corresponding quality testing make it possible for the finished solution to withstand internal pressure of up to 2,500 bars without difficulty.

Moreover, the high-quality materials, in conjunction with improved surface quality deriving from the drawing process, can resist the effects of salt water and other aggressive media.

The plugs make things smooth Among the features of the plug-drawn pipes are their geometrically precise curvature and high weld quality. In principle, the basic material is not a factor in this and it is possible to manufacture individual pipes of up to 2,000 metres in length.

An internal mandrel (plug) acts to smooth the inside of the longitudinal weld.

In conjunction with an external mandrel, the initial cross-section of the tube can thus be reduced by up to 50%. All in all, this is a longitudinally welded solution which gives the impression of being a seamless pipe. A

* Head of Team Energy at Schoeller Werk. Email: MZimmermann@schoellerwerk.de Digital Edition - November 2016

schoeller.indd 1

www.steeltimesint.com

01/12/2016 09:01:55

STEEL AND THE SEA

41

(left and right) Schoeller Werk pipe products are used at depths of up to 15,000 metres below sea level. Even there they can withstand extreme pressure conditions and high temperatures.

www.steeltimesint.com

schoeller.indd 2

Digital Edition - November 2016

01/12/2016 09:02:05

42

STEEL AND THE SEA

TIG orbital weld from inside: In order to supply customers with required lengths of 15,000 metres and more, individual pipes are orbitally welded together. X-ray testing ensures the weld is airtight and pore-free.

look at the microstructure of the material reveals that the welded seam can hardly even be detected after the pipe has been drawn. Properties such as these have been key plus points for Schoeller Werk’s offshore customers.

Careful testing of control and injection pipes The offshore industry uses such pipes as hydraulic control lines for safety valves as well as for pumping chemicals into an oil reservoir. In this way, they support the entire extraction process. The injection pipes make it possible for rig operators to use chemicals in a targeted fashion to liquefy the oil and thus improve its flow properties.

During the complex manufacturing process, the pipes undergo various tests in order to ensure the special quality of the products before they are installed. Strips of metal are welded with a longitudinal seam, using the tungsten inert gas (TIG) welding process, and rolled into tubes.

Apart from the obligatory eddy-current testing, the tubes subsequently undergo an air under water (AUW) or ‘bubble’ test.

The tubes are submerged in water and filled with air to a pressure of up to 210 bars. A visual inspection is made along the entire length of the tubes to check that they are airtight. So that Schoeller Werk can supply

its customers with the required lengths of 15,000 metres and more, individual pipes are orbitally welded together and an X-ray is made to check that the orbital weld is airtight and free of any pores.

Before delivery to customers, Schoeller Werk also subjects the control and injection pipes to a hydraulic test. This involves filling the finished coils with hydraulic fluid and subjecting them to pressures of up to 2,500 bars to simulate the extreme conditions sometimes experienced in offshore work.

Service offering supplements manufacturing skill Apart from manufacturing pipes, Schoeller Werk offers its offshore industry customers a comprehensive service package including the encapsulation of pipes with plastic sheathing in so-called flat packs. This means that bundles of pipes can be attached to the extraction tubes and protected from buckling and squashing.

Other services include flushing and filling of pipes whereby the insides are flushed with hydraulic fluid until it reaches the specified ISO or SAE purity classification.

Fluid filtered in this way can remain in the pipes if the customer so requires, meaning that users obtain a ready-to-use product. It is also possible to equip the pipe bundles

Digital Edition - November 2016

schoeller.indd 3

01/12/2016 09:02:11

43

STEEL AND THE SEA

Schoeller Werk’s service package includes so-called flat packs, in which the pipes are sheathed in plastic.

with electrical wiring or stainless steel support cables. Because of their smooth internal surface, plug-drawn pipes are ideal for use as ducting for optical fibre cables transmitting signals using light.

Offshore – a global market In its work with the offshore industry, Schoeller Werk has joined an international market. Apart from Norway and Great Britain around the North Sea in Europe, Russia, Saudi Arabia, UAE, Africa, Asia, Australia and South America, all count among key target regions for Schoeller control-line and chemical-injection pipes. �

Injection pipes allow chemicals to be used in the extraction process in targeted fashion to liquefy the oil and thus improve its flow properties.

Digital Edition - November 2016

schoeller.indd 4

01/12/2016 09:02:26

44

HISTORY

Main photo: The Kynnersley Arms, a Grade II listed building in use as a public house since the late 19th century Below: The blowing arch of the Leighton furnace in the cellar of the Kynnersley Arms

Finding the spot: The Kynnersley Arms is on the B4380 at Leighton, about two miles northwest of Buildwas, between Ironbridge and Shrewsbury.

Post code SY5 6RN OS grid SJ 6103 0553 - Access to the cellar is from the car park

A blast furnace in a pub Located approximately three miles (4.8km) west of the famous Coalbrookdale industrial complex in Shropshire, England, famous for its Ironbridge, is the village of Leighton. Most English villages have a public house where people meet to drink and eat – but the Kynnersley Arms in Leighton has something more – the remains of a blast furnace in its cellar. By Tim Smith* SIR Richard Newport built the Kynnersley Arms’ blast furnace in 1630.

Iron ore was mined locally and the furnace was fuelled with charcoal from local coppices. A series of pen ponds provided water to the main pond located on the opposite side of the road to the public house – and now a housing development.

Substantial remains of the blast furnace and corn mill survive in the cellars of the Kynnersley Arms. Surviving features of the furnace are the blowing arch and the housing for the bellows.

Television stars ‘Time Team’, a popular TV archaeology programme, explored the site in 2001. The site was excavated and interpreted in ‘just three days’.

Geophysical techniques and trenches were used to examine the car park and adjacent meadow. Of the geophysical surveys (Fluxgate Gradimeter, Electromagnetic, Ground penetrating radar, resistivity and magnetic) only magnetic showed evidence of the furnace beyond the existing cellar indicating a linear feature thought to be a water channel and a spread of anomalies arising from building debris.

Trenches in the car park adjacent to the remaining wall revealed the furnace structure. Beneath the car park on the

southern side of the building, by the cellar entrance, the casting beds were found indicating the position of the casting arch at 90° to the blowing arch.

In the cellar, excavation of the arch revealed the socket for the tuyere.

History of the site On 20 December 1630, Sir Richard Newport of High Ercall, Shropshire, leased the Leighton corn mill for a period of 99 years, with the intention of converting it into a blast furnace producing ‘sow metal’ (pig iron). The venture was so successful that on 10 May 1633, an agreement was made between Richard Newport and Roger Parre, to build a road from the Leighton furnace to the river Severn for pig iron exports.

A shot foundry was established at Leighton between 1642 and 1644 and during the English Civil War the furnace produced cannon balls for the Royalists.

A new lease was granted in 1655, and for most of the later 17th century the furnace was one of several within the extensive iron making partnership headed by Philip Foley of Staffordshire. In 1717 the furnace was recorded with an output of 400 tons.

Why not coke?

The furnace is largely contemporary with the famous Darby Furnace in Coalbrookdale

in which Abraham Darby, around 1709, first used coke as an alternative to charcoal as fuel and reducing agent. It took over 50 years for coke to become the predominant fuel in the blast furnace. Analysis of slag found at the Leighton furnace showed that it had not been converted to coke firing, despite Shropshire coal having good coking properties and being low in sulphur (0.50-0.55%) – an element that causes hot shortness in the iron. While sulphur can be removed by creating a highly basic slag by lime addition, a hot blast and high blowing rate are necessary. These techniques were not achieved until 1760 when steam-powered blowing cylinders are first recorded.

The charcoal source for the blast furnace would have been from across a very wide area – perhaps 20 miles square; the blast furnace at Ironbridge is known to have used charcoal produced in the Lake District. The majority of woodland in the country would have been managed in the 17th century to support the industrial expansion.

Today, as well as the remains of the casting arch evident in the cellar there is also a large water wheel in the position suitable to drive bellows via a cam shaft, but this most probably dates from the reconversion of the site to a corn mill in the 19th century. �

*Editorial consultant and member of the Historical Metallurgy Society Digital Edition - November 2016

History.indd 1

www.steeltimesint.com

01/12/2016 12:08:12

Nobody has more dilatometer technology than TA Instruments.

BUY a DIL 801, 821, or 831 and get a FREE upgrade to a DIL 802, 822, or 832 with patented True Differential technology.*

promo.tainstruments.com/bogo

Steel Times DIL B1G1 ad.indd 1

*Offer valid until December 23rd, 2016

11/9/16 11:54 AM

WE MAKE YOUR PRODUCT GOLD Since 1946 the brand KOCKS has stood for technological innovations that go beyond the usual standards in the steel industry.

Within the core technology of the manufacturing process of high-quality steel bars and seamless tubes – the 3-roll technology – KOCKS has been for 70 years the clear innovation thinker, setting decisive benchmarks again and again.

The 3-roll products offered by KOCKS enable our customers to improve their competitive­ness and productivity in the production of special quality long products: Steel which is KOCKS rolled® stands for an extraordinary quality of the finished product made consistently day in and day out.

KOCKS customers say: “This is where we make the quality!”

®

KOCKS rolled is a German trademark registered by KOCKS.

KOCKS ad_anniversary_print200616.indd 1

14.10.2016 16:42:23