Steel Times International March 2016

FURNACES

CONTINUOUS CASTING

TECHNOLOGY

PERSPECTIVES Q&A

Articles from Otto Juncker, Primetals Technologies and ArcelorMittal

Steel Authority of India Ltd discuss continuous casting at Burnpur

Scrutinising every aspect of steel production is crucial, says ABB

The Inteco Group is very active in Mexico, South Korea, India and China

www.steeltimesint.com March 2016 - Vol.40 No.2

STEEL TIMES INTERNATIONAL –March 2016 – Vol.40 No.2

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3/15/16 12:33 PM

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MARCH 2016

FURNACES

CONTINUOUS CASTING

TECHNOLOGY

PERSPECTIVES Q&A

Articles from Otto Juncker, Primetals Technologies and ArcelorMittal

Steel Authority of India Ltd discuss continuous casting at Burnpur

Scrutinising every aspect of steel production is crucial, says ABB

The Inteco Group is very active in Mexico, South Korea, India and China

www.steeltimesint.com March 2016 - Vol.40 No.2

STEEL TIMES INTERNATIONAL –March 2016 – Vol.40 No.2

COMPANY PROFILE: FIVES STI Tenaris image.indd 1

3/15/16 12:33 PM

EDITORIAL

Picture courtesy of Eredi Scabini Tundish cover made with Flextrong® HT, a preformed ceramic matrix composite reinforced with heat-resistant steel by Eredi Scabini.

Eredi Scabini specialises in advanced refractory solutions based on both monolithics and preformed shapes up to 15 tons, designed and manufactured in its factories.

The company is renowned for its ability to offer customised solutions for specific needs, ensuring in all cases a ‘turnkey’ service.

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

2 Leader Senseless rules might prompt a full English Brexit 4 News The latest steel industry news from around the world 10 Latin America update Latin America’s rail import market

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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

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15 Fives – exclusive interview Stéphane Mehrain, vp, sales and marketing, steel division, Fives

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Chief Executive Officer Paul Michael SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com

Furnaces 21 Coreless induction in micro mills 28 Fixing blast furnace number two 33 Blast furnace cooling stave design

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44 Continuing casting Starting up Burnpur’s billet caster

www.steeltimesint.com Steel Times International (USPS No: 020-958) is published monthly except Feb, May, July, Dec by Quartz Business Media Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER send address changes to Steel Times International c/o PO Box 437, Emigsville, PA 17318-0437.

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50 Perspectives: Inteco Steel – the material of choice 52 History Iron magnetism and civilisation

ISSN0143-7798

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Contents.indd 1

March 2016

3/17/16 9:42 AM

2

LEADER

Senseless rules might prompt a full English Brexit

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

There are not many things in life that can beat a full English breakfast and a mug of builder’s tea. Sausage, bacon, fried egg, a slice of black pudding, baked beans and a few mushrooms – pull up a chair!

That said, there’s a growing appetite in the UK for a Full English ‘Brexit’ from the European Union (EU) and while I haven’t made up my mind, there are some niggly aspects of the direction in which the EU is heading that worry me. Issues surrounding ‘ever greater union’, open borders, the Eurozone and a loss of sovereignity, not to mention excessive regulation, are at the heart of my concerns.

Even the Europeans are frustrated with the EU and some of its rules. Take the Lesser Duty Rule (LDR). While the Americans are hammering the Chinese with preliminary anti-dumping duty of up to 265.79% in response to uncontrolled dumping of cold-rolled coil, the ‘soft touch’ EU has settled for just 13-16% for cold-rolled flat products and this has proved too much for EUROFER. “No other major trading partner applies the LDR as judiciously as the EU, and its use is not a WTO obligation.”

There are so many questions, and most of them are simply why? Why does the

EU have so many silly rules that blatantly disadvantage its own industries? Why does the EU’s ‘state aid rule’ exist if it means that the British government is forbidden from supporting its own steel industry when it falls victim to Chinese imports?

EUROFER’s Axel Eggert is understandably angry. Tariffs as low as 13%, he argues, do not sufficiently capture the injury suffered by the European steel industry.

Why is the EU incapable of defending its strategic sectors? Eggert believes that many EU governments are neglecting the impact LDR is having on jobs and industry in their own countries.

Perhaps now is not the time to discuss the Transatlantic Trade & Industry Partnership (TTIP) – which is being quietly agreed behind closed doors by unelected officials, despite massive opposition from EU citizens and without proper consultation with European governments.

Cecilia Malmström, the EU’s unelected trade commissioner in charge of TTIP negotiations has commented: “I do not take my mandate from the European people.” It turns out she takes her orders from corporate lobbyists.

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March 2016

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www.steeltimesint.com

3/14/16 3:41 PM

INDUSTRY NEWS

US finished steel imports down The USA imported a total of 2.3Mt of steel during the month of December 2015, according to figures released by the American Iron and Steel Institute (AISI).

The figures, based on US Census Bureau data include 2.0Mt (net tons) of finished steel (down 5.3% and up 3.2% respectively when compared with November 2015 final data.

Full year total and finished steel imports were 38.7Mt and 31.4Mt respectively (net tons) and this was down 13% and 7% respectively when compared to 2014.

Finished steel import market share was an estimated 26% in December and is estimated at 29% for the full year.

Key finished steel products with a significant import increase in December compared to November are: wire rod (up 77%); tin plate (up 71%); cut length plates (up 65%); heavy structural shapes (up 46%); hot rolled bar (up 20%); and cold rolled sheet (up 19%).

Major products with significant import increases in 2015 versus 2014 include rebar (up 38%) and standard pipe (up 13%).

The largest volumes of finished steel imports into the USA in December 2015 (net tons) came from South Korea (235kt – down 25%); Turkey (167kt – up 8%); Japan (144kt – down 13%); China (135kt – up 111%) and Germany (122kt – up 42%).

The figures for the whole year (net tons) were: South Korea (4.8Mt – down 11%); Turkey 2.8Mt – up 28%); China (2.3Mt – down 25%); Japan (2.2Mt – up 7%); and Germany (1.5Mt – up 19%).

Source: AISI.

Mill 2000 sets all-time record OJSC Magnitogorsk’s (MMK) Mill 2000 set an all-time record for annual output of hot-rolled steel in 2015.

Last year’s record-breaking 5.935Mt was up 50kt on the previous record set by the Russian steelmaker in 2014.

In January 2015, the same mill set a monthly output record when it produced 526kt of metal.

MMK claims that its Mill 2000 is one of the most impressive and state-of-the-art facilities in Russia.

Its equipment makes it possible to produce a full range of steel grades. Sheet width varies from 760mm to 1,830mm and the mill produces the broadest range of products of any MMK plant.

Mill 2000 produces steel for various industries including pipes, construction and machinery manufacturing. Shipbuilding, structural and transformer steel are also rolled at the plant, and it produces rolled products used in automotive sheet production.

Last June, Mill 2000 produced its 100 millionth tonne of steel since it was commissioned in 1994.

www.steeltimesint.com

Industry news new file.indd 1

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NEWS IN BRIEF

Nucor annouces Q4 losses American steelmaker Nucor has announced that hefty impairment charges and lower earnings have contributed towards the company’s Q4 2015 loss. According to a report by Zacks, revenues tumbled ‘year over year’ on lower pricing and shipments as well as missed expectations.

Modest improvements are expected in Nucor’s steel mills and raw materials units during Q1 2016.

US anti-dumping probe The US Department of Commerce plans to launch an anti-dumping investigation into imported stainless steel sheet and strip products from China. China’s Ministry of Commerce is said to be ‘gravely concerned’ about the USA’s plans to push China to reduce its excess steelmaking.

Michael Froman, a US trade representative, believes that improving conditions for the US steel industry will require negotiations with other countries to eliminate subsidies for stateowned steel enterprises in addition to ‘vigilant trade enforcement efforts’.

Tata’s ethical accolade Romanian company TMK-ARTROM has ordered a heat treatment line for tubes from the German SMS Group. The company’s 160kt/yr Slatina plant produces seamless tubes, OCTG pipes and high strength tubes for mechanical applications.

The reason for the new equipment is that TMK-ARTROM wants to strengthen its presence on the market with tubes for mechanical applications and for oil and gas exploration. According to SMS Group, the Slatina plant is scheduled to commence operation during the second quarter of 2017.

Execution halts steel exports An escalation in tensions between the United Arab Emirates (UAE) and Kuwait have halted exports of Iranian steel to both countries, according to an online media report.

The row concerns the execution, in Saudi Arabia, of a prominent Shia cleric.

According a member of the Association of Iranian Steel Producers, Iran exports around 3Mt/ yr of steel to the UAE and Kuwait, which represents less than 10% of total exports from Iran.

Iraq and Afghanistan receive most of Iran’s steel output and, therefore, the cutting of trade ties with the UAE and Kuwait will have little impact on Iranian steel exports, according to Reza Shahrestani of the Association of Iranian Steel Producers.

The execution of Nimr al-Nimr took place on 2 January 2016 and ever since then relations between Iran and Saudi Arabia have worsened. Saudi Arabia counts the UAE and Kuwait (along with Sudan, Djibouti and Bahrain) as allies.

During the first 11 months of 2015, Iran produced 14.8Mt of crude steel and is the world’s 14th biggest steel producer – and the biggest Middle Eastern producer of steel.

Source: AzerNews

The Ethisphere Institute has recognised Tata Steel as the World’s Most Ethical Company for 2016.

Ethisphere, global leader in defining and advancing standards of ethical business practices celebrates its 10th anniversary this year.

Tata has won the award four times.

New CEO for ThyssenKrupp Ravi Kirpalani takes up the role of CEO at ThyssenKrupp India this month (14 March). Mr Kirpalani was previously managing director of Castrol India and prior to that worked for 16 years at BP, holding a number of roles in India and the UK.

Arcelor appoints de Klerk Willem de Klerk has been appointed CEO and executive director to the board. Mr de Klerk takes up his new role in September and, according to the world’s largest steelmaker, has the ‘necessary experience and understanding’ to do the job.

Mr de Klerk was previously finance director of Exxaro Resources.

March 2016

3/14/16 4:00 PM

4 NEWS IN BRIEF SAIL expansion likely Expansion is on the cards for Steel Authority of India Ltd (SAIL) following discussions between the company’s newly appointed chairman, PK Singh, and Chief Minister Raghubar Das. The two men met to discuss SAIL’s expansion plans for its Bokaro plant on available vacant land.

Singh wants to open a new medical college and develop a special work plan for slums, according to an India Times online report.

US anti-dumping frenzy The USA has imposed antidumping duties on Russian coldrolled steel as well as products from China, Brazil, India, Japan, South Korea and the UK, according to a Bloomberg report.

In the USA, the Chinese took the brunt of the duties with a rate of 265.79% followed by Japan (71.35%). Russian companies fared a little better with duty on Severstal being just 12.62%.

In Europe, however, the Russians were hit with higher rates.

Novolipetsk Steel will pay 26.2% and Severstal 25.4%. The Chinese will pay 13.8%.

POSCO steel mill in Iran South Korean steelmaker POSCO is to set up a US$1.6 billion steel mill in south eastern Iran.

POSCO claims it will take an 8% share in the 1.6Mt/year plant, which it is building in collaboration with the Iranian Pars Kohan Diarparsian Steel (PKP).

The plant will be located in the port city of Chabahar in the province of Sistan-Baluchestan.

Mexican workers strike Job cuts in a Mexican steel plant owned by ArcelorMittal have forced workers to go on strike.

Operations have stopped and over 3,000 workers have gone on strike at the plant in Lazaro Cardenas in the state of Michoacan.

ArcelorMittal has described the action as an illegal ‘blockade.’

Tata Steel coke ovens close Tata Steel UK has finally closed its Dawes Lane coke ovens in Scunthorpe, United Kingdom.

The coke ovens ceased production on 8 March after 40 years of operation and follow hot on the heels of a plate mill that was recently mothballed.

March 2016

Industry news new file.indd 2

INDUSTRY NEWS

Steel industry’s MES protest European steelworkers took to the streets of Brussels recently in protest against the likely bestowal of ‘market economy status’ on China – a move guaranteed to open the floodgates to cheap Chinese steel being dumped on Western European markets.

The protests aimed to raise awareness of the current plight of the European steel industry and persuade political leaders of the European Union and MEPs to think long and hard before granting China MES status in December.

It is argued that China is not a market economy and that to pretend it is could be catastrophic for the European steel industry.

The march was supported by EUROFER (the European Steel As-

sociation) and AEGIS Europe, an alliance representing about 30 industry sectors. In addition to the steel industry, representatives of other sectors – aluminium,

non-ferrous metals, solar panels, fibreglass and the ceramic industries (among others) – took part in the protest.

Newly appointed EUROFER

president Geert Van Poelvoorde said: “Since the financial crisis, 85,000 jobs have been lost in the European steel industry; in the past six months alone 7,000 more jobs have gone.

Without utilising the TDIs available to us in a timely manner there is a substantial risk that we will see more plant closures and job losses.”

According to Mr Van Poelvoorde, the situation will worsen if China is granted MES as it would give them ‘a licence to dump’.

“A decision to grant China MES is illogical; China is not a market economy and only fulfills one of the five criteria set out by the EU for countries to be deemed as such,” he said.

ThyssenKrupp to build auto components plant in Hungary ThyssenKrupp is building a new 100 million Euro automotive plant in Hungary where it plans to produce engine components and steering systems.

Construction begins in the spring and by 2018 production of electronic power-assisted steering systems and cylinder head covers with integrated camshafts will commence. The site is 70 km east of Budapest at Jászfényszaru and, once open, will create 500 new jobs.

ThyssenKrupp’s components division has recently acquired major orders from International OEMs, which, it claims, will enable the

company to continue the division’s profitable growth and regionalisation strategy for its components business.

“This investment follows our strategy towards standardisation and cost optimisation in the automotive components business,” said Dr. Karsten Kroos, CEO of ThyssenKrupp’s components business.

He explained how the company was localising production of two different technologies at one site.

“We have already enjoyed success with this strategy in China and will also be employing it in other growth markets,” he said.

Danieli signs Iranian steel contracts worth 5.7bn Euros Following the lifting of sanctions on Iran, the Italian Danieli Group has signed agreements worth approximately 5.7 billion euros.

The agreements, signed in Rome by the company’s chairman and CEO, Mr. Gianpietro Benedetti, relate to a joint venture and orders for the supply of machinery and plants to be installed in Iran.

“Persian Metallics” is the name of a joint venture worth an estimated 2 billion Euros, which will involve a group of international and Iranian investors.

The Persian Metallics project will use iron ore and energy to produce around 6Mt/yr million of pellets to feed direct reduced iron (DRI) for steelmaking using electric arc furnaces – the most environmentally friendly and often more competitive way to make steel today.

According to the Italian technology giant, other agreements relating to the supply of machines and plants to produce steel and aluminium will be signed with several Iranian companies and worth an estimated 3.7 billion Euros.

Primetals Technologies has received an order from Acciaierie Valbruna S.p.a to modernise its three-strand continuous billet caster located at the steelmaker’s Bolzano site. On completion of the project, the plant will be able to produce stainless steel and special alloy bars with larger cross-sections up to 180 mm. The machine radius of the plant will be increased from seven to nine metres.

Accolade for Arcelor ArcelorMittal has been ranked ninth in the Benchmark of Circular Business Practices, a comparative study of Netherlands-listed companies. The Dutch Association of Investors for Sustainable Development (VBDO) produced the study and ArcelorMittal’s ranking is in recognition of the company’s alignment with the concept of a circular economy. It was also singled out for its good practice in steel recycling. www.steeltimesint.com

3/14/16 4:00 PM

6

INDUSTRY NEWS

Blast furnace commissioned

by MMK Russian steelmaker OJSC Magnitogorsk Iron and Steel Works (MMK) has completed an overhaul of blast furnace number nine in Magnitogorsk.

The works, which included a technical overhaul of the cast houses, was launched in December last year. Blast furnace number nine is the most powerful blast furnace at MMK. It was the largest blast furnace in Europe when it was built in 1964.

During more than 50 years of operation blast furnace number nine has produced approximately 80Mt of pig iron. In 2008, it underwent upgrade work including the installation of a Paul Wurth bell-less top.

New pair of Hans for Tata Steel Europe Karl Koehler, a director of Tata Steel and CEO and managing director of Tata Steel Europe, has resigned.

Mr Koehler plans to take up a ‘senior leadership position’ within a large, privately owned industrial company in Germany, but will remain available to Tata Steel for a short period as an advisor.

Koushik Chatterjee, currently group executive director and a member of the boards of both Tata Steel and Tata Steel Europe, will also become Tata Steel’s executive director for Europe with effect from 1 March.

Hans Fischer, currently chief technical officer for Tata Steel Europe, will take over from Karl Koehler as CEO of Tata Steel Europe and will join the company’s board.

Fischer’s chief responsibilities will cover operational and business performance.

March 2016

Industry news new file.indd 3

Gerdau signs JVs with Japanese hannpeter. He added that the technical agreement will enable Gerdau to quickly and effectively supply the market with high-quality products.

Flat steel production commenced at Ouro Branco in Brazil in 2013 when the annual installed capacity was 800kt. In January 2016, the mill reached the 1Mt mark of goods produced since start-up.

Gerdau has also formed a joint venture with The Japan Steel Works (JSW) with the intention of manufacturing components from special steels for the wind power industry.

The plant for the project will be based in Sao Paulo.

Steelmakers Gerdau and the Japanese JFE Steel Corporation have signed a technical co-operation agreement for the production of heavy plate in Brazil.

According to Gerdau, the agreement will optimise the learning curve of the heavy plate rolling mill in Minas Gerais that is scheduled to commence operations in July.

The 1.1Mt/yr Ouro Branco Mill was originally scheduled to start operations later in the year, but the start-up date has been brought forward, according to Gerdau.

The agreement will optimise the learning curve of the heavy plate rolling mill, claims Gerdau, adding that JFE’s technical consultants

will help the company improve its technological mastery of heavy plate production, which should accelerate advances in production processes.

The new deal encompasses rolling and melt shop operations.

“This means that the Japanese will provide complete support for the development of new products,” Gerdau said, adding that by July the rolling mill should be producing ‘a complete array of gauges’.

“We selected JFE Steel Corporation because it is a world reference in technology for the production of heavy plates, as well as a leading global producer of the steel good,” said André B. Gerdau Jo-

Outokumpo’s logistics plan

Tata India to restructure in order to save costs

Quintiq, a Dassault Systèmes company and a global leader in supply chain planning and optimisation (SCP&O), will provide global stainless steel producer Outokumpu with a fully integrated supply chain planning system.

The stainless steel producer has expanded its use of Quintiq’s planning software to optimise various elements of its operations.

A new implementation from Quintiq will fully integrate and provide visibility of workflows in over 40 production facilities.

The software is designed to optimise planning for inbound and outbound logistics, steelmaking and rolling. The latest implementation will help Outokumpu accelerate improvements in productivity, efficiency and customer fulfillment.

In an effort to reduce costs and increase productivity, India’s oldest steelmaker, Tata Steel, is to restructure its domestic business, claims a report by The Economic Times.

Imported steel from China and poor demand are the chief reasons behind Tata’s decision to restructure the business and it will take place across all sectors and business functions including human resources, production, transportation and marketing.

Companies such as EY, KPMG, PwC and Deloitte are likely to be

involved in Tata’s restructuring, it is claimed.

In India Tata Steel has the capacity to produce 10Mt of steel annually. It has a workforce of 36,957. Arch rival JSW Steel produces 14.3Mt/yr and employs just 12,271.

Whether Tata’s plans include job losses is not certain. It is believed that the company will be looking at increasing the productivity of its assets.

The Indian steel industry is being badly hit by cheap imports, not just from China but from Japan and South Korea. While profitability is being hit across the board, Tata’s position is a little worse as the company’s UK business is already loss-making despite ‘continuous restructuring’.

Source: The Economic Times.

Chinese crude output down 2% China’s crude steel output for 2015 is likely to stand at around 806Mt (metric tonnes), down 2% year-on-year, according to Chinese media reports. This is being reported in China as the first negative growth since 1981.

The news is being seen in China as positive as China’s domestic steel industry has been directed to accelerate ‘de-capacity’.

During the first 11 months of 2015 China yielded 739Mt of

crude steel, down 2.2% year-onyear. A survey my Mysteel towards the end of December last year points to the operating rate of the blast furnaces being 74.03% – down 1.11% week-on-week; and the capacity utilisation rate being 80.02% – down 0.58% week-onweek.

According to Mysteel, China's crude steel output will drop further in January 2016. The company estimates that daily average

crude steel output between 1-10 January will be 1.9Mt (metric tonnes) down 0.36% from the period 21-31 December 2015.

While prices rebounded towards the end of 2015, steel mills didn't increase production.

The climate for Chinese steel will remain low throughout 2016. It is thought that crude steel output this year will be around 786Mt, down 3.1% year-on-year.

Source: China Metals. www.steeltimesint.com

3/14/16 4:00 PM

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8 DIARY OF EVENTS April 2016 04-08 Wire & Tube 2016, Fairground, Dusseldorf, Germany Two leading trade fairs in one location – the International Wire & Cable Fair and the International Tube Fair.

For further information, log on to www.wire-tradefair.com

10-12 Steel Orbis and IREPAS Conference, Sheraton Lisboa Hotel & Spa, Lisbon, Portugal Billed as the world’s number one event for the long products industry, this conference will attract over 300 steel executives and will offer delegates a better understanding of the global market situation and insight into the plans of major producers and traders.

For further information, log on to www.steelorbis.com/steelevents/

19-22 Paint Expo, Karlsruhe, Germany Described as the world’s leading trade fair for coating technology and billed as ‘bigger than ever’ in 2016, Paint Expo has already attracted over 430 exhibitors and one fourth of them come from outside of Germany.

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

25-27 EuroCoke 2016, Novotel Barcelona City, Spain Organised by Smithers Apex, the annual EuroCoke conference is always well-received by delegates.

The programme will tackle the technical advances and market drivers affecting the industry.

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

May 2016 16-19 AISTech 2016, Pittsburgh, USA A premier steel industry event that takes place annually in the USA. There is both a conference and an exhibition as well as various official events and plant tours.

For further information, www.aist.org For more steel industry news and features, visit www.steeltimesint.com March 2016

Industry news new file.indd 4

INDUSTRY NEWS

Crude production down 7.1% World crude steel production for January 2016 was 128Mt – down 7.1% on January 2015 – based on figures submitted by the 66 countries reporting to the World Steel Association (worldsteel).

In China the crude steel production figure for January was 63.2Mt, down 7.8% on 2015 figures. Japan produced 8.8Mt,down 2.8%, and India’s production was 7.4Mt, down 1.2%. In South Korea 5.7Mt of crude steel was produced, down 4.5%.

In Europe, Germany produced 3.6Mt of crude steel, down 2%

when compared with January 2015. Italian crude production was down 5.3% at 1.8Mt while the Spanish produced 1.2Mt,

down 9.5% on January 2015.

The Russians produced 5.6Mt of crude steel, down 10.6% over January 2015 while the Ukrainian figure of 1.9Mt was up 3.6%.

In the USA, 6.6Mt of crude steel was produced, down 8.8%, while in South America, Brazil produced 2.5Mt, down a staggering 17.9%.

The crude steel capacity utilisation ratio of the 66 countries was 66%, which was 5.8 percentage points lower than the January 2015 figure. When compared with December 2015 it was 0.8 percentage points higher.

For a full country-by-country listing visit: www.worldsteel.org/statistics/crude-steel-production.html

NLMK boosts Lipetsk HDG steel capacity Russian steelmaker NLMK has boosted the capacity of its continuous hot-dip galvanising line at Lipetsk. The line is expected to reach full capacity of 500kt/yr by April.

Productivity was boosted 30% on HDG-1 and the line’s hot-dip galvanised steel production for construction, automotive and white goods has been expanded by 11% to 1.25Mt. The company claims that it can now solidify its position in the high value-added steel market where, it claims, demand exceeds

the capacity of Russian manufacturers and is covered by imports.

Russia currently imports 1Mt of coated steels, claims NLMK. It took 90 days to install a new automated control system, upgrade the furnace section and assemble new process equipment.

The reconstructed line will reduce natural gas consumption by 25%, electric energy usage by 15% and air emissions by 30%. This is due to installing furnace control and modernisation systems; optimising equipment configuration

and optimising the natural gas afterburning system respectively.

NLMK holds 21% of the hot-dip galvanised steel market in Russia.

US steel imports up, says the AISI The USA imported a total of 2.5Mt (net tons) of steel during January 2016, including 2.2Mt (net tons) of finished steel – up 10% and 8.8% on December figures.

Year-to-date and finished steel imports were 2.5Mt and 2.2Mt (net tons) respectively, down 41%

and 38% respectively versus 2015.

The market share of imported finished steel in January this year was 26%. Oil country tubular goods imports were up 107%, standard pipe 68%, hot-rolled sheet 53%, line pipe 47% and structural pipe and tubing 43%. Plates in coils

were up 25% and wire drawn 12%. Turkey exported the largest volume of finished steel to the USA (244kt – up 34%) followed

by South Korea (241kt – up 2%); Japan (188kt – up 31%); Brazil (154kt – up 124%) and Germany (12Kt – down 1%).

Villares Metals processes first heat Villares Metals in Brazil has processed its first heat using a new electric arc furnace developed by Danieli Centro Met. The Final Acceptance Certificate was signed on 20 January – ahead of schedule.

Villares is a ‘reference producer for speciality alloyed steel and long products in Latin America.

The plant in Sumare San Paolo

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scrap charging; keeping nominal tap weight of 25 tonnes, with a liquid steel capacity of 28 tonnes; operational safety; easy-to-maintain equipment; applying a split shell design that allows a complete exchange or split exchange with an overhead crane; and optimising shell design with regard to overall weight. www.steeltimesint.com

3/14/16 4:00 PM

10

LATIN AMERICA UPDATE

Latin America’s rail import market The Latin American steel industry has developed a comprehensive supply structure. In fact, rail is the only relevant product category that it is not currently fabricated in the region, although Brazil, Mexico and Argentina have done it in the past. This article looks at the regional rail import market in general.

By Germano Mendes de Paula* THE first steel rails were made in England around 1857. In the USA, production started in 1865 and by 1867 was responsible for some 85% of the steel production. This ratio was reduced to 79% in 1880, 50% in 1890, 35% in 1990 and 0.7% in 2000, but recovered partially to 1.3% in 2013. Rail, therefore, was transformed into a niche market.

Various nations were engaged in rail fabrication in the past. However, a lot of outdated equipment was shut down and this explains why it is estimated that there are only 32 rail rolling mills in operation today globally. They are located in 19 countries. Such a geographical concentration results in a relatively high import flow.

International trade figures were obtained from the United Nations Comtrade Database and refer to the Harmonised System Code 7302, described as “railway and tramway track material of iron or steel”. In other words, it consists of rails and accessories.

Fig. 1 shows that the world import market diminished from 3.7Mt in 2010 to 3.4Mt in 2014, which is the latest available information. In the interim, according to worldsteel, global rail output reached 12Mt and 11.7Mt, respectively. Therefore, it can be concluded that the rail import ratio has been equivalent to roughly 30%. In 2014, rail’s participation in worldwide steel 3,8

international trade reached only 0.8%.

The value of global imports amplified from $4.15bn in 2010 to $4.65bn in 2013, reverting partially to $4.33bn in 2014 (Fig. 2). Thus, the average unit price varied from $1,110 per ton in 2010 to $1,284 in 2013 and $1,263 in 2014 (Fig. 3).

Global rail imports originating from China was equivalent to 400kt in 2010. After some variations between 436kt in 2011 and 386kt in 2013, it climbed to 473kt in 2014.

Chinese participation in the worldwide import market, therefore, improved from 10.7% in 2010 to 12.5% in 2011 (Fig. 4).

It contracted temporarily to 10.7% in 2013, but more than offset to 13.8% in 2014.

Latin American figures The same database was employed to calculate the rail import market in Latin America. The region’s imports reduced from 632kt in 2010 to 327kt a year later (Fig. 5). It recovered to 421kt in 2012 and has hovered around this plateau ever since.

It can be argued that 2010 was an outlier that can be explained, to a large extent, by the Brazilian experience. The country imported 501kt in 2010, when it was the largest importer in the world, beating Germany, the USA, Canada, and China.

Brazil was positioned in 5th place in 2011 and 2012, 6th in 2013 and 4th in 2014.

Fig. 6 demonstrates that Latin American rail imports reached $594M in 2010, but 4,7 4,6

3,7

3,4

4,4 4,3 4,2

3,3

4,1

3,5

3,2

1.400 1.300

4,5

3,6

1200 1.100 1.000 900 800

4,0 2010

2011

2012

2013

Fig 1. World’s rail imports, 2010-2014 (Mt).

2014

dropped to $446Mt in 2013, with a partial regaining to $477M in 2014. The average unit price rose from $939 per ton in 2010 to $1,250 in 2011 and then declined to $1,084 in 2014 (Fig. 3).

Latin America’s participation in global rail imports (in tonnage terms) was 16.9% in 2010, but equivalent to something like 11.8% between 2012 and 2014. The respective figures, in financial terms, were 14.3% and 10.7%.

The region’s rails from China diminished from 143kt in 2000 to 69kt in 2013, but partially reverted to 86kt in 2014.

Meanwhile, the Chinese stake on Latin American imports reached a 23% plateau between 2010 and 2011, 17% between 2012 and 2013 and 20% in 2014 (Fig. 7).

These ratios were considerably higher than those observed for China’s stake in the worldwide import market.

Over the 2010-2014 period, Latin American rail imports were, on average, the equivalent to 443kt annually. Brazil’s share reached 55.5%, followed by Mexico (24.3%) and Argentina (8.8%). The other countries have less than 3% each.

Venezuelan participation (1%) is remarkably low, even considering that data for 2014 is missing. The disaggregated data for the country in each year is shown in Table 1.

Looking at annual performance, Brazil’s share reached 79.2% in 2010 and 43.3% in 2012. t

2010

2011

2012

2013

Fig 2. World’s rail imports, 2010-2014 ($bn)

2014

2010

2011 World

2012 2013 Latin America

2014

Fig 3. Average unit price, 2010-2014 ($/t)

* Professor in economics, Federal University of Uberlândia, Brazil. E-mail: germano@ufu.br March 2016

LA new.indd 1

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3/15/16 9:14 AM

11

LATIN AMERICA UPDATE

16 14 10 8 6 4 2 0

2010

2011

2012

2013

2014

Fig 4. Chinese participation in the global rail import mar-

700 600

700 600

500

500

400 300 200

400 300 200

100

100 0

0 2010

2011

2012

2013

2014

Fig 5. Latin America’s rail imports, 2010-2014 (kt)

2010

2011

2012

2013

2014

Fig 6. Latin America’s rail imports, 2010-2014 ($M)

ket, 2010-2014 (% related to tonnage) 25 20

2010

2011

2012

2013

2014

Average

Brazil

501

161

182

169

216

246

15

Mexico

76

82

132

138

110

108

10

Argentina

22

22

51

42

57

39

5

Peru

11

12

11

16

13

12

Colombia

4

8

13

5

21

10

Chile

10

10

12

7

9

9

Ecuador

1

18

4

5

7

7

Venezuela

4

4

8

3

-

5

0

2010

2011

2012

2013

2014

Fig 7. Chinese participation in the Latin American rail import market, 2010-2014 (% related to tonnage)

Dominicap Rep.

2

8

3

1

1

3

Others

3

3

5

4

5

4

Total

632

327

421

389

440

443

Table 1. Latin America rail imports, 2010-2014 (kt).

Source: Own elaboration based on UN Comtrade Database

Due to its prominence concerning the region’s imports, the next article will examine the Brazilian situation.

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USA UPDATE

Calls

13

to ban Chinese imports The US Department of Commerce has slapped a hefty 256% duty on imports of corrosion-resistant steel from China; these products, were “unfairly traded at below market prices”. The move was welcomed by the domestic steel industry, which attributes the downturn to rising cheap imports. By Manik Mehta*

THIS action is considered to be the first in a series of trade cases filed in mid-2015 by US Steel, AK Steel Holding Corp., Nucor and Steel Dynamics Inc., charging that Chinese and other competitors were receiving subsidies from their governments and were thus able to sell their products at prices far below those of American steel companies.

The Commerce Department’s decision was also applauded by Leo Gerard, president of the United Steelworkers (USW).

He said that the union was ‘gratified’ by this move, which should serve China another ‘needed lesson for their jobstealing violations’. Gerard said that several steel-producing countries had captured more than a third of the US market when American steelworkers should be sharing in an improved economy but, instead, faced unemployment.

With the steel industry facing a sharp decline in orders, a number of steel companies have suspended production or completely closed down. US Steel announced that it was suspending indefinitely a plan to build an electric arc furnace to replace a blast furnace at its Fairfield Works in Alabama, much of which had already been idled since August 2015, causing some 1,100 workers to be laid off.

US Steel reportedly lost some $510 million in the first three quarters of the year as a result of weak prices, which company executives said were caused by imports and falling demand from the oil and gas sector.

Meanwhile, US steel company stocks have fallen to low levels. Some companies have been forced to idle their plants and eliminate thousands of jobs as a result of sluggish business and rising financial

losses. US Steel, Allegheny Technologies, ArcelorMittal and others cited the harsh business environment while seeking concessions in negotiations with the steelworkers’ union on healthcare and other workers’ benefits.

James Wainscott, chief executive at AK Steel, speaking after duties were slapped on Chinese imports, said that duties on imports of corrosion-resistant steel from India, Italy and South Korea were not high enough.

“We are disappointed that the preliminary dumping margins for India, Italy, South Korea and Taiwan were not higher, as they do not appear to adequately address the dumping that we believe is occurring in the US market,” Wainscott said.

While Chinese cold-rolled products have attracted a hefty 227% duty in order to, as one Commerce Department official put it, offset the high government subsidies Chinese companies receive, duties of 7.42% will be imposed on Brazilian steelmakers, and 4.45% and 6.35% on Indian and Russian steel suppliers respectively.

Those rates are meant to offset – or “countervail”, to use the local term – subsidies that governments in those countries give to their steelmakers. Foreign steelmakers can appeal against this decision at a hearing prior to the Commerce Department reaching its final decision.

According to US steel industry groups, imports in recent months have captured a record 30% market share of US steel consumption.

While sentiments run high against foreign steel suppliers, a US Congressman has gone one step further and called for a complete ban on steel imports. Congressman

Rick Nolan, a Democrat who represents Minnesota’s Iron Range – from where the bulk of iron ore for the steel industry is sourced – has called for sweeping measures, like imposing a five-year ban on foreign steel imports. The United States currently imposes 157 anti-dumping and countervailing tariffs against foreign-made steel, but Nolan has criticised these tariffs, claiming with trade agreements offering loopholes, they are too low to really matter.

There is outrage felt in Minnesota because that state has lost some 1,750 mining and steelworker jobs in its Iron Range as a result of rising cheap imports.

Another Congressman, Pete Visclosky, a Democrat from Merrillville, called for continuing “to do all that we can to stop the influx of illegal steel imports”, although he didn’t explicitly call for a ban. Many politicians are urging President Obama to take “firm and immediate action” against the steel import influx. After all, they recall, President George W. Bush took similar action when steelmakers, such as Bethlehem Steel and LTV Steel, went bankrupt in the early 2000s, even though imports then were not as high as they are now.

But imports have, finally, begun to decline. Steel imports, according to tentative figures, plunged 23% in November, according to the American Iron and Steel Institute (AISI).

The United States imported 2.3Mt (net tons) in November, a 22.7% decline over October. Finished steel imports fell 15.6% in November to 1.9Mt (net tons). This has also brought down the share of foreign steel in the overall market to 25% in November.

* USA correspondent www.steeltimesint.com

USA new.indd 1

March 2016

3/14/16 4:08 PM

14

USA UPDATE

Last year’s average market share by foreign steel was 28%.

The US steel industry is nervously watching developments in regard to the formation of the US-driven Trans-Pacific Partnership, a trade alliance of 12 AsiaPacific countries, which will wipe out existing tariffs and other barriers in trade between them. Many in the steel industry fear that the TPP would unleash an “avalanche of unfettered steel imports” into the country. This is, of course, a one-sided view of the new animal that will make its appearance in the global trade jungle. The TPP will also facilitate US exports to the remaining 11 member countries, making US steel cheaper thanks to the dismantling of trade barriers and creating a level-playing field for US companies, as some analysts are saying. The TPP agreement still needs to be ratified by the US and the remaining 11 member countries.

Meanwhile, Nucor Corp’s announcement to temporarily halt production at its St. James steel plant has generated considerable concern among its workers, though company officials were saying that none of the workers would be laid off; Nucor has a reputation for retaining its workers even during critical times.

Nucor invested $750 million in the St. James mill, a direct reduced iron (DRI) plant that uses natural gas to make high-purity steel pellets from iron ore.

Nucor mixes the pellets with scrap metal to make steel. Some analysts see the logic behind the plant closure because it would be cheaper to import pig iron from Russia and Brazil than Nucor producing the material at its plant.

But some pundits predict that if scrap prices stabilise this year, Nucor’s rawmaterial business should also improve considerably.

Another sign of the harsh business environment comes in the form of US Steel shelving plans to build an electric arc furnace (EAF) in Alabama, which would have enabled the integrated steelmaker to diversify into the mini-mill business.

The Pittsburgh-based steelmaker, which recently reported a loss of $173 million, blamed challenging market conditions in the oil and steel industries for postponing the construction of the electric arc furnace at its Fairfield Works in Birmingham, Alabama.

“The company continues to feel the effect of these energy market conditions, along with low steel prices and continued high levels of imports,” US Steel said in a statement.

US Steel has been looking at electric arc furnaces instead of blast furnaces as a way of cutting costs and being more responsive to varying market conditions.

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3/14/16 4:08 PM

COMPANY PROFILE: FIVES

15

Fives as Solution Provider : Strip processing lines at Baosteel, China

The solution provider Fives is keen to boost creativity and develop a culture of ‘open innovation’. It believes that the supply of ‘robust’ processing equipment is only part of the solution steelmakers are looking for and that ‘operational excellence’ takes precedence. Matthew Moggridge* travelled to Paris to meet Stéphane Mehrain, vice president, sales and marketing, at Fives’ steel division

OVER the past decade Fives has doubled in size. With a turnover (in 2014) of 1.6 billion Euros and a headcount of 8,000 employees worldwide (in 30 countries) the company operates across five key market sectors: aerospace and high-precision machining; automotive and logistics; cement; energy and, of course, metals and glass, where it offers processes and equipment for steel, aluminium and glass production.

For Stéphane Mehrain, vice president, sales and marketing at Fives, the group’s ‘multi-sectorial’ approach gives a global

vision of the industry and a continuous source of innovation. “In steel, we are not ‘an A-Z supplier’ of steel plants, our target is to bring added value to our customers to enhance their performance,” he explained.

Amidst the current doom and gloom afflicting the global steel industry – dogged as it is with overcapacity and pricing issues – there are a few glimmers of hope and, paradoxically, when current geo-political strife is taken into consideration, the good news emanates from – of all places – the Middle East.

Iran’s steel industry With sanctions lifted, Iran is shaping up to become a new market for big industrial engineering groups eager to supply the very latest production technology to expanding Iranian manufacturers harbouring global ambitions.

Mehrain describes Iran as a market with ‘big potential’ and certainly one in need of new capacity.

Iran is positioned to ride the new wave of automotive steel manufacturing and Mehrain believes there will be huge

* Editor, Steel Times International www.steeltimesint.com

FIVES interview.indd 1

March 2016

3/16/16 2:52 PM

16

COMPANY PROFILE: FIVES Stéphane Mehrain, vice president, sales and marketing, steel division, Fives (France)

domestic demand for automotive sheet. “It is here where we could be a player in the market,” he said.

Competition for new business in Iran will be fierce. As Steel Times International recently reported, multi-million dollar deals have already been struck by leading European production technology companies.

As for China, Mehrain stresses that growth has been technology-driven.

Exploding the myth “China has not bought cheap, low-end technologies. It has chosen to buy the best technologies available,” he said, adding that it is sometimes more difficult to be qualified to participate in a Chinese project because ‘they are counting a lot on innovation’.

“Over the last 15 years, China has bought ‘best-in-class’ technology,” according to Mehrain. He was keen to stress that the Chinese are not manufacturing low quality steel products or using inferior equipment. He said that Fives’ long-term success with Baosteel was down to convincing them that Fives was the right partner and then proving it over a 12-year period till now.

“They [the Chinese] want to get the best technologies at the best conditions.

They developed competitive and quality steel in order to be successful in the export market,” he said.

2015 was a very challenging year for steelmakers and the big hope for 2016 is that it could be a transition period.

As China steps up capacity cuts and European and North American antidumping and countervailing duties kick in, it is hoped that the impact of Chinese overcapacity on the rest-of-the-world steel industry will be lessened – and that steelmakers will be better able to balance the books.

The big questions, however, are how long will it take and will the steel industry be capable of stepping back from the abyss and re-inventing itself?

“Over the years we have taken a big portion of the market in China. From 2003 to 2014 – and even last year – we secured a number of orders in China.

Over the past decade we have put into operation 32 complete strip processing lines and vertical furnaces, and we have currently 11 other projects under execution, mostly in China,” said Mehrain.

March 2016

FIVES interview.indd 2

India And while, thanks to the China effect, the rest-of-the-world steel industry has slowed considerably in terms of new business opportunities, there are some regions that are full of promise – like India – where, last year, Fives received orders for four re-heat furnaces from Steel Authority of India Ltd (SAIL) and another major Indian steelmaker.

“We believe there will be a number of processing lines built in India,” Mehrain explained, as the country aims to reduce its reliance upon imported high value steel.

Fives is not a new kid on the block. The company dates back 200 years and has a strong steel heritage dating back 150 years. “The DNA of Fives is the pioneering experience. There are lots of fields where we have been the first to introduce a new technology solution on to the market,” he said.

Mehrain says that Fives is more than just a technology provider. “We want to provide our customers with a solution to their needs – needs that, of course, advance key proprietary technologies,” he said.

A key strategic objective of the company is to offer proprietary technologies that impact product quality, OPEX, CAPEX and customer performance. “On top of that we would like to bring them high added value expertise and technical assistance to make sure that our equipment is delivering the kind of performance they expect,” Mehrain said.

Operational experience In 2012 Fives acquired KEODS, a company with extensive operational and metallurgical experience, enabling Fives to communicate with its customers not only about the equipment, but how they need to produce their products. KEODS offers upstream and downstream expertise, metallurgical and product quality technical support as well as surface inspection solutions.

A recent contract signed with the Chinese steelmaker Baotou in Inner Mongolia set out to increase the steelmaker’s range of automotive products. Fives and Baotou signed a 10-year co-operation contract, which included high-end technological and process expertise covering from upstream to downstream production processes, steelmaking, hot-rolling, pickling, cold rolling, annealing and galvanising.

“With KEODS we are bringing a complete solution in the sense that we can accompany and assist our customers in getting their product to the level of quality they are targeting and helping them to introduce and market their products into the automotive arena,” Mehrain said.

KEODS is a part of Fives global offer for steelmakers, according to Mehrain, as it engenders teamwork by adding production, product and operational expertise to the mix. It is no longer a case of simply supplying robust equipment. “Our target is to improve the competitiveness of our customers, reduce their capital expenditure www.steeltimesint.com

3/16/16 2:52 PM

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18

COMPANY PROFILE: FIVES

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and bring them ‘opex’ advantage. We hope the market will continue to value both of these,” he said.

Fives wants to sell industrial and economic performance. “We’re offering performance contracts whereby one part of the prize could be paid upon performance of the installation,” he said.

Ultimately, the aim is to develop longterm relationships. Where POSCO is concerned, Fives had already built two automotive galvanising line vertical furnaces at its Gwangyang plant. Another one is currently under construction and the steel maker insisted upon the very latest furnace technology for their new automotive CGL 7. “These lines are where some of the best quality automotive products are produced,” said Mehrain.

Fives completed four full strip processing lines and nine vertical furnaces for Baosteel, having received regular orders from the Chinese steelmaker for the past 12 years.

It has also developed partnerships with WISCO, TISCO, Baotou and Shougang also in China.

The emergence of competitive materials in automotive manufacturing, such as carbon fibre and aluminium, are putting pressure on steelmakers to innovate.

Mehrain argues that while aluminium will always have a role to play in automotive manufacturing, it will never largely replace steel. “It is not easy for industry to radically change the material because it affects the entire fabrication and maintenance chain. While there is pressure on car manufacturers to reduce weight – and aluminium is a lighter metal – steelmakers have been forced to up their game and are now working on new and advanced highstrength steel products,” Mehrain said.

Quality of products is the main axis of Fives’ strategy. “When we talk about March 2016

FIVES interview.indd 3

advanced high strength steels (AHSS) and new steels, this sector is really dynamic in terms of both steel and technology development,” he added.

Rapid cooling A crucial process in the development of high strength steels is rapid cooling within vertical furnaces, an area of production technology that Fives has been developing for over 15 years.

In 1999 Fives installed a new rapid cooling technology at British Steel (now Tata Steel) in Port Talbot, South Wales, operating with 50% hydrogen, thereby increasing the cooling capacity. For three of POSCO’s latest automotive CGLs, Fives implemented its FlashCooling technology with 75% hydrogen and cooling rates of 200 degrees per second. Other suppliers are increasing the hydrogen rate by up to 30%.

The company also offers a complete range of ‘wet flash cooling technology’.

“Instead of a dry atmosphere we blow nitrogen with water mist, which offers flexibility in operation in terms of cooling rate control, temperature cycle control and uniformity of cooling.”

Wet flash cooling has replaced a more conventional technology involving

water quenching of the strip. The newer technology was introduced on an existing POSCO continuous annealing line at Gwangyang Steelworks.

With modern installations now capable of producing more than 40 different grades of steel, it is fair to say that many steelmakers simply cannot afford to scrap existing production lines and build new ones.

Flexibility of operation Low prices and reduced profitability brought about by an abundance of low-cost imported steels from China, have forced the hand of steelmakers in this respect and this means that flexibility of operation has become crucial.

“One of the key challenges is how to adapt existing facilities in terms of production to meet rapidly changing market demands in terms of grades, processing yield and flexibility in terms of fuel usage,” said Mehrain.

“We have vast experience in this field, mainly in Asia and China where integrated plants use site-generated fuels to power reheat furnaces and process lines. Through this experience we have developed a complete range of AdvanTek combustion systems. Mastering combustion and having our own range of combustion products has been a core strategy of Fives. We believe that mastering combustion and furnace design optimise the performance of the whole process section,” said Mehrain.

Fives’ AdvanTek Radiant Tube combustion systems are said to offer 20% better efficiency than other solutions on the market.

“We even have combustion systems that can be switched over automatically, meaning they can use more than one type of fuel,” he said.

“It is important that our core strategy revolves around delivering the best performance possible to our customers,” he said.

Reheating furnaces in Turkey

www.steeltimesint.com

3/16/16 2:52 PM

COMPANY PROFILE: FIVES

19

Environmental considerations The environmental performance of steel plants is another important axis for Fives. Twenty five per cent of the company’s research and development programme is devoted to environmental issues; meaning emissions reduction and improved energy consumption are constantly being addressed.

Mehrain cited the installation of two reheat furnaces at a hot strip mill owned by the US-based Allegheny Technologies. The company manufactures speciality steels for different markets where process flexibility is crucial. Fives supplied the company with two furnaces employing on/off pulse firing control – meaning all burners are individually pulse-fired controlled. “And you’ll ask why is this better? The answer is because the flame is fully developed for the best performance in terms of energy consumption and NOx emissions,” he explained, adding that the furnaces offered uniformity of heating, best quality products and flexible operation.

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Innovation According to Mehrain, the fact that Fives straddles so many industries makes for a more creative environment in terms of technological development.

An annual innovation award is open to all Fives employees. “It’s very important because we can benefit from individual creativity as well as from developments in one market or the other and it opens our eyes to other industries. We work to have a reactive R&D programme,” he said.

Changing strategy Mehrain described Fives as an agile, business-driven organisation.

“We decide what is necessary, prioritise one over the other in order to be close to what the market demands; and we try to have a good mix between programmes that are practical and shorter-term, and programmes which aim at developing breakthrough solutions, to be able to respond to the challenges of the market and be ready on time, and most of the time, we are even ahead of the market, In many ways, the current crisis affecting the global steel industry has prompted forward-thinking technology suppliers to change their strategic direction. In Fives’ case there has been a distinct change of tack where research and development is concerned.

Whereas prior to the crisis, the focus was purely technical, the company is now concentrating on helping steelmakers to improve their operational performance. It means that future research and development work will no longer hone in entirely on the technical panache of the equipment, but will look at achieving the same performance levels at lower costs.

“The target with Fives is having better performance at lower costs and the beauty of this is that most of the time we succeed in reaching the two targets at the same time,” Mehrain said.

Operational excellence In other words, it’s not only about competitiveness in costs and capital expenditure, it’s also about operating expenditure – or ‘operational excellence.’

Looking ahead, Mehrain is optimistic for the steel industry. “I’m very optimistic about steel and Fives because of the way we position ourselves. Through its 200 years history, Fives has always reinvented its business to adapt to industrial development and market needs.

Today, it’s all about providing high added value solutions and offering industrial and economic performance to the market.”

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11.02.16 17:47 3/16/16 2:52 PM

FURNACES

21

Fig 1. Typical arrangement of a medium-frequency coreless induction furnace plant

Coreless induction in micro mills Growing demand for micromills with an annual capacity of between 50kt and 400kt has prompted a growth in use of coreless induction furnaces in countries where there is a high scrap availability, such as India, Iran, South Africa and the Middle East. By R Bode, W Schmitz and D Trauzeddel*

ELECTRIC steelmaking using primarily scrap and some sponge iron, now accounts for almost 50% of the world’s steel production, not including China. In some countries, such as India or the Middle East, such mills provide as much as 60% and 80%, respectively, of output in 2011[1].

As a primary melting source, the electric arc furnace (EAF) has proven its merits in this context for many years; however, the induction furnace poses a serious alternative today if one takes into account specific application conditions. In line with the trend in local scrap markets, the demand for electric micro mills with an annual capacity of 50kt to 400kt is growing. It is here that coreless induction furnaces have become increasingly widespread in recent years, especially in countries with high scrap availability such as, India, Iran, South Africa and the Middle East. A combination of an electric arc furnace with a coreless induction furnace also presents an interesting solution, for instance, when it comes to efficiently upgrading the capacity of an existing EAF

steelmaking plant[2].

The required metallurgical treatment in an EAF steel mill depends on the quality of the feedstock – scrap or sponge iron – and on the grade of steel to be produced.

It should be noted that melt decarburisation and the reduction of sulphur and phosphorus levels can be efficiently performed in an EAF furnace; the same applies to de-slagging operations. A coreless induction furnace can sustain these operations to a limited extent only, but it offers benefits when it comes to alloying because of the bath movement and low melting loss it can provide. In all, the EAF – which, in process engineering terms, must be classified as a hearth furnace – is indisputably preferable for metallurgical tasks. However, for economic reasons, it has become standard practice to carry out such tasks with the aid of separate equipment such as ladle furnaces and converters while using the EAF as a melting furnace only. For structural steels and associated scrap grades, such treatments will be unnecessary, so the need for a

secondary metallurgical furnace is often eliminated altogether.

The coreless medium-frequency induction furnace Design and operation Induction melting has become an increasingly widespread process in the foundry and semi-finished products industries given its technical and economic performance potential. Its basic advantages derive from the direct input of heat into the metal with almost no temperature overshoot and from the fact that the bath movement can be selectively controlled.

These properties provide an accurate temperature and process control capability, low melting loss, reduced environmental and workplace pollution, and highly stable and precise analyses, all with high energy efficiency. The step to digitally controlled medium-frequency furnaces based on advanced frequency converter systems has brought a significant increase in power density and process engineering capabilities.

* Dr. Ing. Wilfried Schmitz, head of R&D, Otto Junker GmbH, Simmerath. Ralf Bode, sales & service, Dörentrup Feuerfestprodukte GmbH & Co. KG, Doerentrup. Dr. Ing. Dietmar Trauzeddel, freelancer, Otto Junker GmbH, Simmerath. www.steeltimesint.com

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An advanced high-power induction melting system as shown in Fig. 1 is essentially made up of: • the melting unit with furnace body and cradle, • the electric power supply system with transformer, frequency converter and capacitor rack, • the process control system with weigher, operator cabinet and melt processor as well as • the peripheral equipment including water re-cooler, charger and dust collection system.

State-of-the-art furnaces with advanced frequency converter systems can be operated with a selectable frequency usually in the range between 60 and 1,000 Hz. In new coreless furnace projects, they have completely supplanted mains frequency installations due to their numerous advantages.

A major benefit, thanks to higher frequency, is that the furnace can be started on solid charge material without any losses and it can be reliably operated with a power density which is a multiple of that of mains-frequency furnaces.

One key feature of the coreless induction furnace, distinguishing it fundamentally from all other melting sources, is the movement of the metal bath created by electromagnetic forces (Fig. 2). The electromagnetic forces generate a flow pattern resembling two rotational toroids in the melt. In a high-power furnace, the local flow velocity may amount to as much as 1 - 2 m/s. Moreover, a so-called bath meniscus will form at the surface of the melt. The intensity of this bath movement firstly depends on the furnace power; the higher the power input, the more vigorous the bath movement will be. But the flow intensity also depends on the frequency of the alternating current fed to the coil: The lower the frequency, the stronger the bath movement. This implies first of all that for a given fixed frequency, the heat input Melting at 250Hz

Electromagnetic force density

Inductor current

Current density induced into the bath

Bath movement

Magnetic field

Fig 2. Bath movement and meniscus

into the melt and the intensity of the bath movement are always correlated. Moreover, for a given specified furnace power, the intensity of the bath movement can be selectively controlled by choosing a suitable operating frequency.

This bath movement is very important from a technological viewpoint since it facilitates optimum melt homogenisation and stir-down of constituents and thus ensures a uniform melt composition and high temperature accuracy at the same time.

Special circuitry From a metallurgical perspective, the ideal induction melting process is one in which both the input of thermal power and the melt flow can be controlled to match given technological needs. In addition, the power input and bath movement should be mutually decoupled, i.e., the desired melt movement in the furnace should be adjustable independently of the respective power input. While it is no problem technologically to control the electric power and hence, the input of thermal energy into the melt, it takes very special circuit engineering to achieve control of the bath movement independently of this energy input. Moreover, when discussing intense bath movement, it is necessary to distinguish between deep intermixing of the entire melt and mere surface flows, as shall be explained later.

Based on R&D advances achieved

over the last few years, Otto Junker has established its Power-Focus and MultiFrequency technologies – two special circuit systems meeting the above requirements which have by now proven their merits in numerous installed furnace systems.

Power-Focus technology permits an automatic or freely selectable concentration of power in that coil section (top or bottom) in which it is needed most.

Multi-Frequency technology enables switching between different operating frequencies during the melting process. For melting cast iron, for example, the system will choose the right frequency of 250 Hz in this case. For the input of carburising agents and alloying additives, the system automatically switches to a lower frequency, such as 125 Hz. Practice has shown that the changeover to a reduced frequency can greatly accelerate the carbon pick-up in cast iron analysis adjustment (Fig. 3).

These options are substantially expanded further by the latest developments utilising the technical advantages of IGBT converter technology.

Apart from proven thyristor-based frequency converters, the successful development of special IGBT converters has come to play an increasingly important role in electrothermal processes. These systems involve the use of Insulated Gate Bipolar Transistors (IGBTs) instead of thyristors in the inverter.

Technical progress has yielded processoriented IGBT converter systems for manifold applications, which are explained for an example[3]: Provision of an IGBT converter with two separate inverters and a system ensuring a phase-shifted operation of the furnace coil sections form the technical basis for controlling the bath movement within wide limits. In the charge melt-down phase, the furnace can thus be run at an appropriate nominal frequency of, say, 250 Hz and to increase the bath agitation at low power the frequency can be controlled steplessly below 100 Hz. The amount of phase offset

Alloying at 125Hz

Fig 3. Multi-frequency technology

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between the two coil sections is likewise adjustable to provide a selective control of the flow pattern (i.e., direction of rotation and velocity) in the central coil area of the furnace. This way, the region of maximum flow velocity can be moved to the centre of the molten metal bath to obtain more effective intermixing of the entire melt. The technical options available for influencing bath movement in a coreless induction furnace can be implemented and combined in manifold ways to address specific metallurgical tasks.

Steel metallurgy in a coreless induction furnace Factors in favour of the coreless induction furnace as a metallurgical treatment resource include its exceptional ability to provide selective control of the bath movement, as mentioned earlier, and its substantial flow velocities achieved. On the downside, its unfavourable surfacearea-to-volume ratio and the rather thin and sensitive refractory lining need to be mentioned.

In today’s steelmaking practice it is not at all unusual for certain metallurgical operations to be performed in a coreless induction furnace. Thus, refining is carried out via the addition of iron oxide (ore or scale), which provides a certain degree of decarburisation and intense bath mixing.

Inert gas purging, typically with argon, via bubbling plugs in the furnace bottom is known to reduce the hydrogen, nitrogen and oxygen content of the melt.

On the other hand, such operations can provide only minor corrections to melt composition and are not always cost-

• De-oxidation of high-grade steel melts • Carbon reduction of molten steel • Melt adjustment to minimum gas content • Production of high-purity metals including pouring under vacuum • Production of super-alloys

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Sintered layer Fritted layer

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Of the special circuit features embodied on coreless induction furnaces, as mentioned above, Multi-Frequency technology is one that has found its way into steel melting applications. The options opened up by the process-oriented frequency converter technology have proven effective in melting fine-grained ferro alloys.

Fig 4. Layer formation in the crucible wall

efficient.

For adding alloying elements, the coreless induction furnace with its good melt stirring capability is well-suited to deliver high yields and an accurate and homogeneous control of the target melt analysis.

In melting down very rusty scrap and sponge iron, it should be noted that a particular approach is needed because of the intense slag formation. From the experience gathered in electric steelmaking practice, up to 85% iron sponge are assumed to be feasible in a coreless induction melting furnace if a liquid heel regime and repeated de-slagging (approximately three times) are used.

It should also be mentioned that vacuum-type coreless induction furnaces are successfully employed in producing high-purity steel alloys. Typical applications include the following:

Comparing EAF and coreless induction From the figures available in the literature,[4, 2] which all relate to specific application cases and hence do not represent average values, it emerges that the coreless induction furnace has a 3% to 4% cost efficiency advantage in terms of operating cost per tonne of steel. In particular, the coreless induction furnace avoids the cost of electrodes, and the slightly higher cost of its refractory lining does not wipe out this benefit. Another major advantage is the low melting loss of only 1% to 2 % versus 3% to 7 % for the EAF, which translates into clear savings of costly alloying elements.

The slightly higher energy demand of the coreless induction furnace amounts to approximately 5% to 8 %, depending on the literature source consulted.

In the overall economic performance assessment, advantages such as lower capital investment, smaller equipment Converter

MFT 1

MFT 2

e.g. 30%

e.g. 70%

100% total power variability

Fig 5. The sintered layer is removed

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Fig 6. DUOMELT technology

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footprint, lower demands on the power supply system, and lower environmental and labour safety requirements speak in favour of the coreless induction furnace.

The process technology drawbacks of the coreless induction furnace as a metallurgical treatment device are of no consequence if the furnace is used as a melting source only and is backed by appropriate secondary metallurgical processes and equipment.

The disadvantages of the EAF can be stated thus: • higher loads on the electrical power supply mains; • increased cost of dust collection and noise protection; • higher melting loss (approximately 3% to 7 %); • cost of graphite electrodes; • higher equipment cost compared to a coreless induction furnace system of comparable output On the other hand, it provides these advantages: • ability to load very bulky scrap; • support of metallurgical slag work; • thick-walled refractory lining; • comparatively long lining life The coreless induction furnace has the following drawbacks: • very restricted usefulness for metallurgical slag work; • thin refractory lining, calling for frequent relining and involving a higher risk of mechanical damage; • limitation of maximum scrap dimensions by the much smaller melting vessel (compared to an EAF).

Its advantages include the following: • lower capital investment; • smaller footprint; • easier to operate; • minimum metal loss; • high alloying efficiency: • low dust collection requirements, no noise problem; • multiple units provide more redundancy; • low load on power supply system Practical experience Refractory lining Coreless induction furnaces in micro mills are generally lined with so-called dry ramming mixes based on SiO2 (acidic compounds) and Al2O3-MgO (spinelwww.steeltimesint.com

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Fig 7. Layout of a coreless induction furnace plant comprising two 25-tonne furnaces

forming compounds). The SiO2-based lining provides only a very short service life (8 to 15 heats), meaning that the furnace must be relined every day. Accordingly, at least two coreless induction furnaces are necessary for a continuous operating regime. In some countries, acidic masses are still used for cost and availability reasons.

The spinel-forming compounds predominantly employed in coreless induction furnaces today are aluminamagnesia mixes which, when heat is applied, will form the so-called genuine spinel (MgOxAl2O3=MA) via a solid diffusion process.

MA spinel has the following characteristic properties: • good thermal shock resistance; • good chemical resistance; • high refractory performance; • good strength at high temperatures The lining of a coreless induction furnace is made with the aid of a lost former using vibratory compacting. The lining material is then heated either by induction or by pre-heating the furnace interior with a gas burner and subsequent introduction of a 1600 – 1700 °C hot melt.

The foregoing is followed by rapid induction heating to the required sintering temperature (at least 1700°C, or 50°C above the operating temperature).

Experience has shown that the sintering temperature should be held for at least one to two hours.

This will produce enough MA spinel to

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impart sufficient strength and density to the hot-face lining to make it resistant against attack of the liquid melt.

In the course of furnace operation, three zones will form in the lining made of dry ramming mix: the sintered layer, the fritted layer, and the loose layer (Fig. 4).

This layer structure makes it possible to conduct up to 10 or more intermediate repairs on the lining. Here, a distinction is made between two methods commonly referred to as ‘black relining’ or ‘white relining’.

The term relining’ or ‘patching’ refers to a renovation of the original hot-face lining.

A common rule states that for such relining to be performed, the wall thickness must be down to a residual 60% at least and the gap size should be 70 mm minimum. In the white relining process, the sintered layer (20 to 25 mm) is mechanically removed by means of a pneumatically operated chisel (Fig. 5).

Next, the top layer is removed all the way to the topmost cooling coil. After that a 10 mm to 20 mm thick layer is applied to the bottom of the coreless induction furnace.

Then the lost former is inserted, aligned and fixed in place, and finally the normal lining procedure is carried out.

A ‘black relining’ is understood to be one in which the hot-face lining is not removed, except for the topmost layer. It is performed at a residual wall thickness of approximately 50%. The last charge is superheated by roughly 50% so that any accretions will come off more easily and the hot-face lining itself will become virtually slag-free.

The interior of the furnace must be ironfree in this process.

Next, a 10 mm to 20 mm thick bottom packing bed is placed in the coreless induction furnace. The rest of the process is the same as in white relining.

A comparison of the various methods in terms of the consumption of refractories is presented below: Without relining = ~ 5.0 kg/t With 5 relinings = ~ 4.0 kg/t With 10 relinings = ~ 3.0 kg/t Accordingly, an average consumption of 2 kg/t – 4 kg/t can be expected with this relining and repair technology; best values range around 1.75 kg/t[5].

Furnace systems used It is evident from the available data that, contrary to what might be expected, coreless induction technology does not March 2016

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target very large furnaces holding 50 tonnes of liquid steel or more. Instead, units in the 25- to 30-tonne capacity range dominate this application. This is also the size range of coreless induction furnaces supplied by Otto Junker for electric steel mills.

In order to achieve the required melt output with high availability rates, it is frequent practice to run two, three or four furnaces on one or two switchgear systems.

The converter output can thus be put to use continuously by feeding two furnaces, or else it is possible to feed three or four furnaces alternately from two converter systems. Fig. 6 illustrates the principle of such a solution (DUOMELT technology).

Two furnaces are necessary for continuous melting because the service life of the crucible can be very short, especially with an acidic-type furnace lining. In terms of power density in kW/t (i.e., connected load per tonne of furnace capacity) these furnaces are in the moderate range of less than 700 kW/t.

While peak power densities of 1000 kW/t are achievable on smaller furnace systems, they are not (yet) feasible

in this size class for process or equipment engineering reasons.

Operating frequency and nominal power rating influence bath movement. Most systems are run on 250 Hz, but 500 Hz are also used.

A powerful coreless induction furnace plant might be characterised by the following characteristic data: Four coreless induction furnaces with a capacity of 25 tonnes each, running on two switchgear systems with an output of 15 MW each and an energy consumption of 540 kWh/t, can deliver approximately 1000 tonnes per day so that an annual output of over 300kt of steel becomes achievable.

As regards the floorspace required for such a system, a surface area of two times 22 x 24 m would be sufficient as shown in the layout drawing in Fig. 7.

Apart from the four furnaces and two switchgear systems, and including the transformers in the basement, this surface area includes the charging chutes on the furnace platform. Needless to say, the requisite cooling equipment – i.e., air/ water or water/water heat exchangers – is

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With coreless induction furnaces firmly established as a melting source in the foundry and non-ferrous semi-finished products industries, new application fields are continuously opening up, including the equipment’s use as an alternative primary melting furnace in micromills.

Many successful applications are known to address specific process engineering and economic criteria. Specific metallurgical capabilities of induction furnace technology are still far from exhausted.

References [1] World Steel Association: Steel Statistical Yearbook 2011/2012 [2] Anthony B. Phillips: BSE Symposium, April 2009 [3] Trauzeddel, D.; Schmitz, W.: Giesserei 2012, Nr. 6, S. 26-30 [4] Dötsch, E.: Induktives Schmelzen und Warmhalten [Induction melting and holding], Vulkan-Verlag, 2nd ed.

[5] Bode, R.: Presentation 2015, Dörentrup Feuerfestprodukte GmbH & Co. KG

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Fixing blast furnace number two In September 2012 a break-out took place at tap hole #3 on blast furnace #2. As a consequence – and in addition to an unprepared technological stoppage and a very difficult restart – the reliability of the two remaining tap holes was limited. Once the break-out was stabilised towards the end of 2012, the decision was taken to prepare spot repairs to tap holes # 1 and 3 and return the blast furnace to a reliable condition. By Gabriel Gilis*

BLAST Furnace no. 2 within ArcelorMittal’s Poland operations, is a 12-metre hearth furnace equipped with four tap holes. On 23 September 2012 a break-out of tap hole #3 took place, forcing the blast furnace team to develop, in co-operation with experts from the steel company, a viable method of tap hole repair.

Cause of application As a result of the tap hole break-out shown in Fig. 1, one of the tap hole staves was completely damaged and the central tap hole block was disintegrated creating an opening directly to the hearth. As a result of this incident, the blast furnace team decided to remove the damaged part of the shell with the old stave, install new cooling elements and shell and finally inject carbon mass inside the tap hole to fill the space created by the missing central block as presented in Fig. 2. This tap hole was temporarily secured and idled. The entire operation took six days and as the blast furnace was not prepared for such a long stoppage, restart was rather difficult, particularly with a partially chilled hearth. Starting up a blast furnace with a limited number of tuyeres above the remaining tap holes in order to get a connection for liquid evacuation demanded the use of a high number of oxy-pipes.

This caused a predicted but extensive degradation of tap holes 1 and 3, which had already been idled. As a consequence, the nominal capacity of the furnace with a limited number of tuyeres was reduced from an initial 7.2kt/day to 5kt/day to sustain reliability of damaged elements.

Following the successful recovery of furnace operations, the next decision was to perform spot repairs to tap holes 1 and 3 and continue the campaign of the furnace, which had started in 2006.

Conceptual preparation of relining In December 2012 the project team received the following boundary condition of tap hole relining: • Time of relining less than 40 days • Preparation of relining less than five months. To be ready in mid-May 2013 for blow-down • Avoid wet quenching of hearth due to high alkaline penetration of microporous carbon blocks • Restore two damaged tap holes to full reliability Cooling plates

In co-operation with the technical office of ArcelorMittal, the project team approved a method of mixed carbon block installation. This consisted of the installation of dry-joined large blocks, tap hole and adjacent ones according to the original design and connection with the old lining side walls using Graftech UCAR mortar bricks. This application had been successfully used in several ArcelorMittal steelmaking locations. The main advantages of this method are: • Good propagation of forces from new lining to old side walls • Immobilisation of large blocks in stable mechanical condition • Keeping good gas tightness between dry joints • Possibility of lining spot repairs

Ceramic insulating mass

Cooling plates (300mm width)

Shell (70mm width) not seen at front view Carbon block

Taphole fi80

Probably way of HK leaking It is possible that lakelet of HM appeared...

FRONT VIEW

CROSS-SECTION

Fig 1. Damage of tap hole

* Blast furnace relining manager, ArcelorMittal Poland. Email: gabriel.gilis@arcelormittal.com, March 2016

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Fig 2. Missing central tap hole block

Based on visual inspection of carbon blocks from September 2012, a decision was taken to manufacture three rows by three blocks each including tap hole as indicated in Fig. 3 and Fig. 4.

The main issue, linked to the fact of having no clear picture regarding profile and shape of side walls in the surroundings of the tap hole, was to determine wall thickness with high accuracy in order to prepare the correct engineering. As we can observe in Fig. 5, the existing thickness of the old wall linings would determine the maximal length of tap hole blocks connected with UCAR bricks and good force propagation. Based on this assumption a set of core drilling surveys was undertaken.

What is significant in the achieved results is that in parallel to healthy cores as presented in Fig. 6, some empty spaces and discontinuity were found. At this stage in the research it was linked by the project team to the existence of a brittle layer in the surroundings of the tap holes. Based on the survey together with Pirson engineering of the tap holes, repair as presented in Fig. 7 was developed.

Preparation to relining As a result of the aforementioned boundary condition and taking into consideration the high level of health and safety requirements, the following order of works and events was planned: • Blow-down of the furnace • Salamander tapping • Flattening of dead-man on the level of tuyeres with removal of coke excess through jumbo cooler • Covering of dead-man with concrete layer to isolate hot coke in hearth www.steeltimesint.com

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Fig 3. Horizontal section of replaced blocks

VIII-1 1180

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UCAR carbon

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Fig 5. Small bricks connection with old lining

• Safety blast in stack • Installation of movable platform through top opening • Cleaning of the shaft from slag accumulation (H&S requirement) • Opening of technological entrance at hearth shell (tap hole #3) • Demolition of tap hole #3 lining • Hot burden removal • Demolition of tap hole #1 lining from inside of furnace • Closing of shell at tap hole #3 • Installation of lining on both tap holes • Reconstruction of tuyeres belt with castable high alumina material.

• Shotcreting of stack, bosh, belly and hearth • Gas tightness test of furnace • Drying of furnace • Restart of furnace Bearing in mind the above, 38 days were

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Fig 4. Vertical section of replaced blocks

allotted for planning, while the preparation phase was scheduled for five and a half months, starting from January 2013.

Course of relining Relining started with blow-down of the furnace on 11 May, without any disturbance. The whole process went smoothly and on 12 May salamander tapping released 360 tons of hot metal and slag. In the next step all tuyeres sets were opened and with the use of Pirson’s bobcat vehicles the surface of the deadman was flattened. After this operation the tuyeres section area was covered with a layer of concrete. Following isolation of the hearth where hot coke had been banked, a movable platform was installed through the main top opening. Over the next 48 hours the whole stack was cleaned and any massive particles that might have fallen down were removed. In the next step, with the use of heavy equipment, tap hole #3 was demolished and hot burden removal started, releasing 700m3 of coke along with some quantities of slag. Dumping the burning coke had been arranged with the use of a special ramp to reduce the cycles of vehicles moving between two points.

During hot burden removal no intensive oxidation on the carbon surface was observed. However, during the first days the temperature was around 200 ºC. The first inspection of the hearth as a whole and a detailed inspection of the side walls led to the following findings: • Below the lowest expected course of carbon block prepared for dismantling (level VII) layer VI also had significant damage from the hot phase and a reduction in thickness. (See Fig. 8).

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• There were empty spaces and gaps in the carbon blocks close to tap hole.

• Steam penetration of the level V top surface of carbon blocks. Visible roughness on carbon surface.

• Vertical cracks in carbon blocks.

As a result of a visual survey of both repaired tap holes the scope of relining was extended to an additional three blocks in level VI on both spots. Extra sidewalls were dismantled to remove blocks with discontinuities in structure. A decision was taken to shorten virgin blocks to avoid intensive projection in relation to the existing hearth profile and resultant mechanical stresses. Installation started with the cleaning of the top surface of the carbon block (layer V) and partial machining to improve the flatness of existing carbon blocks. This operation is visible in Fig. 9.

Following installation of first three blocks in relation to layer VI, parallel works involving the installation of mortar bricks were started. UCAR bricks have been glued with graphite mortar directly to the staves to achieve a good heat transfer to the cooling system. Cold phase layers have been built using NMD type bricks (~70W/m°K) and hot phase with NMA bricks (~18W/m°K) which have higher wear resistance. In terms of quality parameters, it was important to secure proper thickness of mortar joints,

Fig 6. Sample of core drilling

Fig 7. Tap hole engineering done by Pirson

but not greater than 2mm. Second, tight insertion of each brick with connection to the old lining was performed using hydraulic pumps. This installation method was continued until the last level of large carbon blocks (level 9). Starting from the newly created flat surface the entire lining up to the tuyeres level was built with only UCAR material. On reaching the tuyeres level, however, the project team decided to cast parts of the protective ceramics with a high alumina material above both tap holes. This solution satisfied the requirements of short-time application and created good, solid protection by the time fresh slag made skull. All new tap hole blocks were equipped with thermocouples to establish continuous monitoring of the thermal state. Some spot grouting was necessary to stabilise blast furnace gas leakages. Currently, blast furnace no. 2 is operating under stable conditions.

Conclusion The relining took 37 days and 18 hours,

meeting the target and becoming a great planning and organisational success. Not a single lost time injury occurred, which is significant taking into account 300,000 working hours. Since the outlined method of tap hole relining took place, blast furnace number 2 has proved reliable. There have been no hot spots and no tap hole has shown any signs of failure or reduced reliability. Hot burden removal has proved that with a proper level of risk assessment it can be done in a safe way securing the remaining carbon lining and avoiding water quenching.

Acknowledgments The author wishes to thank all those who supported what was a difficult relining project.

He extends special thanks to Andrzej Chyzy, Yves de Langhe, Patrick Negro and the entire blast furnace and engineering department at ArcelorMittal and wishes to express his gratitude to Pirson Group, SGL Group, Graftech and HPR Centrex.

Layer X - 249mm IX - 577mm VII - 563mm VII - 510mm VI - 704mm

Virgin blocks

Average wear profile

Fig 8. Hearth survey prepared by SGL

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Fig 9. Levelling of layer VI

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Blast furnace cooling stave design Primetals has been involved in the early use of both cast iron staves – in the mid-1970s at British Steel’s Redcar plant – and with copper staves from the 1990s to the present day. This experience combined with the company’s process design base ensures that furnace lines and cooling systems, as well as the detail design of cooling panels, provide the right solution for steelmakers around the world. The combined solution offers long life, low maintenance and a high yield from the furnace.

By Martin P Smith*, Jeremy Fletcher*, Richard W Harvey*, Robert Horwood*

COOLING the steel shell of the blast furnace with water became an increasing design issue from the late 19th century and a variety of cooling boxes and external shell cooling and double skin cooling were developed to achieve this. By the mid-20th century cast iron stave cooling panels were in use in blast furnaces, firstly developed in the Soviet Union and then in Japan. By the 1970s cast iron stave cooling panels were the accepted and modern method for cooling a pressurised blast furnace shell. As furnaces were driven larger and pushed for maximum throughput it was evident that the cast iron staves were wearing in the hotter parts of the blast furnace. Copper stave cooling panels were developed in the late 1980s and early 1990s for use in these hot areas of the blast furnace – the bosh, belly and lower stack. By the turn of the last

century copper staves mixed with cast iron staves became the standard modern design of blast furnace cooling.

Blast furnace cooling system The use of copper staves in the high heat load areas of the blast furnace increased rapidly from the turn of the century as confidence in their durability grew. As more installations came into service, however, initial problems were reported at some plants with stave cooling circuit failures due to the effects of thermal expansion. More recently, failures have been reported due to premature wear of the staves themselves.

This has raised questions over the longterm design concept although many plants do still continue to operate without such concerns.

The incorporation of copper staves into

a blast furnace cooling system cannot be analysed simply as fitting individual items of unit equipment. At Primetals it is seen as forming part of a total solution for the blast furnace. The design starts with ensuring a suitable blast furnace profile which is achieved via a set of empirically established rules that have been developed and expanded through many years of experience with differing cooling concepts and operating philosophies. The continuing successful long-term operations at Primetals’ copper stave installations has shown that the developed rules are proven to provide an optimum furnace profile concept.

The copper stave solution provides advantages in rebuild situations where the thinner wall sections allow for a significant increase in the working volumes of the Gas separation tank

Secondary cooling water Secondary cooling water

Secondary cooling water

Auxiliary leak detection circuit

N2

N2

N2

Expansion tank with pressure and level control

Fig 1. Cooling circuit – closed type

Expansion tank with pressure and level control

Fig 2. Cooling circuit – optimised water flow

Expansion tank with pressure and level control Fig 3. Cooling circuit – closed type

* Primetals Technologies Ltd, 7 Fudan Way, Thornaby, Stockton-on-Tees, TS17 6ER, United Kingdom. Tel:+44(0)1642 662203 www.steeltimesint.com

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Fig 5. Standard Primetals Fig 4. Blast furnace cooling circuit design

blast furnace, especially if replacing plate coolers. This advantage, however, must be considered in combination with any negative effects that may be transferred to the furnace profile. Only once the furnace profile has been established as suitable for the desired production environment can the stave design be detailed. Once the profile is established then decisions on the cooling concept can be enhanced allowing for the size and number of staves to be fixed. Again, rebuild situations can have a significant bearing on these decisions, such as tailoring staves to enable maximum reuse of existing shell penetrations.

The use of copper staves also requires a reliable cooling system with sufficient monitoring to allow understanding of the day-to-day operational conditions ensuring the stability of furnace shell temperatures.

Again, Primetals considers the whole solution in determining the best cooling concept that can be applied and often tailor the requirements to suit existing constraints.

A typical solution in Fig.1 involves closed circuit cooling utilising soft water and thus ensuring that the quality of the water within the staves can be easily monitored and controlled. Demineralised water is also an option, but is considered more expensive and of no real advantage in terms of performance in practical terms.

An expansion tank allows for control of the internal circuit pressures to avoid boiling and gas leakage and is the key element in the approach to leak detection. Primetals favours an approach to the circuit design using a small vertical pressure vessel for the leak detection role where the vessel March 2016

Furnaces primetals.indd 2

Copper Stave

can be considered to sit on the circuit in order to be the pressure control point. A gas separation role is not considered part of the Primetals circuit design. The physical position of the pressure vessel is dependent on available nitrogen pressure, while the clear preference is to locate at ground level local to the circulating pumps.

There are, however, many variations on these concepts, which can be adjusted to suit specific site conditions. Overall cooling system complexity can be increased by splitting the water circuit into areas, such as hearth, copper staves and cast iron staves. This breakdown offers advantages for monitoring and leak detection, but increases capital cost.

Fig. 2 shows one such example successfully implemented to suit available water quantities where a double pass circuit in the copper stave zone of the water system was created. The idea reduces water consumption in this area to half of that required with the basic design requirement of the copper stave design. The option has the added advantage of reducing pipework around the tuyere area, which can be useful in rebuild scenarios when multiple work fronts can become a bottleneck to progress.

In all designs, heat flux monitoring and leak detection are of paramount importance. Heat flux monitoring in its most simple sense relates to flow and temperature measurement on a zonal basis. Again, the balance between cost and provision of an operating system needs to be considered. The needs of the zonal approach in terms of instruments must, of course, be matched with that of the piping arrangement. Vertical and horizontal

(circumferential) zones are the norm for Primetals, albeit with no hard or fast rule to be applied to any particular project, rather a clear desire to agree with the customer what is required.

While heat flux monitoring can be summarised as a combination of temperature and flow measurements, leak detection represents a far broader and interesting topic for discussion. The pressure vessel previously noted is the core to Primetals’ leak detection analysis. Any leak in the water circuit will result in a loss of water volume and, therefore, a loss of level in the vessel. The choice of a vertical vessel derives from a desire to maximise sensitivity to change in volume. Within the control system, alarms can be configured to notify the operator of a change in level beyond the norm most likely signifying a leakage.

This, of course, is the start of the process of finding the guilty party in terms of leakage.

From the old and established arrangement of open circuit cooling, a leak could be identified by a change in the characteristic of the return water to a tundish. This relied on the skill of an operator. Modern furnace systems from Primetals put more onus on the control system while relying on the experience of the operator in the background. Leak detection solutions can vary from simple manual intervention to progressively isolate parts of the circuit and check for pressure integrity through auxiliary circuit options, which can be used via manual or automatic valves to switch groups of elements or individual elements on and off the master water circuit (Fig. 3 and Fig. 4). Further levels of review can be applied with automatic pressure checks carried out on the circuit, all initiated from the main control room.

From the simple starting point of water volume required to cool the stave element based on a water velocity of 1.8 m/s in a channel of a certain size, the actual cooling system developed can be designed to suit customer requirements in terms of operational benefits and capital cost.

New blast furnace solution Primetals’ standard stave design has been developed over many years and has numerous key features that enable long service life and optimum performance. In a new blast furnace shell the standard stave is easily implemented. Standard design www.steeltimesint.com

3/15/16 9:29 AM

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FURNACES

Fig 6. Existing openings in the Redcar blast furnace shell

parameters along with the use of 3D CAD software make it possible to produce the ideal design even in short and demanding deadlines.

Fig. 5 shows a typical copper stave design in the stack area of the blast furnace. 3D models are produced for both design analysis and integration into a full blast furnace site model where erection methodologies are made clearer by the creation of 3D movies demonstrating how the staves are to be installed.

JSW BF NO.3 AND BF NO.4 Two of Primetals’ proud examples of copper staves that have been designed for a new blast furnace shell are at JSW, India.

These were two large blast furnaces that commenced operation in 2009 and 2011 respectively.

Their cooling systems are comprised of a combination of cast iron and copper staves throughout the full blast furnace from the hearth to the throat. Five rows of copper staves are installed in the high heat flux zones of the Bosh, Belly and Lower Stack and possess the key features found on a Primetals stave. Four inlet pipe connections at the base of the stave feed into four vertical cooling channels up to the top of the stave where four outlet pipe connections are located. Compensators are installed around the copper pipes to allow for movement of the stave during operation. Fixing bolts, which are initially used for the installation of the staves, are also positioned towards the corners of the stave to help alleviate the ‘banana’ effect that has been seen where the corners of the stave fold in to the furnace.

Both a guide and fixed pin are installed March 2016

Furnaces primetals.indd 3

Fig 7. First row of copper stave installation almost complete

to help control the movements of the stave when it sees higher temperatures and expands. The fixed pin is the only fixed point of the stave whereas the guide pin controls stave movement at the lower end to stop it from bowing in axially towards the centre of the blast furnace.

Working with a new blast furnace shell gave the designer much freedom in utilising a typical and standard stave design. As always, attention was given to blast furnace lines. As a new blast furnace designed by Primetals, focus was not lost on the criticality of this, as has been seen on other blast furnace designs across the world, which can have a detrimental effect to the performance and lifespan of the copper stave.

Re-line blast furnace solutions Primetals embraces the challenge of designing copper staves to be integrated into an existing shell. A blast furnace shell that was previously a plate-cooled furnace or an older cast iron stave-cooled furnace presents many problems and design constraints that need to be overcome.

Projects that involve such scope have shut downs, where time constraints are very much paramount. Minimising any re-work to the blast furnace shell is vital.

SSI Redcar blast furnace re-line In 2010 the blast furnace at Redcar in the UK was mothballed. This site is local to Primetals’ blast furnace design centre of competency and the impact to the area was seen at first hand. It was, therefore, of great joy when SSI purchased the blast furnace and announced that they were to restart it.

Replacement copper staves were required for four rows within the furnace. Being

a large furnace there was an existing arrangement of 48 staves per row, however, these staves had encountered problems with bending in the previous campaign and were very large in their width. Primetals proposed replacing each row of 48 staves with a row of 72 staves, therefore reducing the individual width, which would reduce any movements during operation. The holes in the shell were designed for old cast iron staves which made it a great challenge to design the copper staves not only to fit the shell and its openings, but also to re-use the existing holes as much as possible to minimise rework on the shell. The existing holes in the shell can be clearly seen in Fig 6.

Existing instrumentation locations were accommodated and further to this the addition of copper stave wear rods on each row was arranged. Utilising the fixed pin of the stave to accommodate additional instrumentation along with the copper wear rods eliminated the requirement for more holes in the furnace shell and hence saved time.

Proposing to plug all the existing holes in the shell and drill new ones to suit the standard design was not a practical solution as the importance of getting the blast furnace back online as quick as possible was of greater significance. These needs are realised with the final installation of the staves (Fig 7).

Ternium’s blast furnace number two Ternium Siderar was shutdown in 2012 to reline its blast furnace. The shutdown was required much earlier in the campaign than anticipated due to the performance of the staves, which had been installed a few years earlier. Extreme wear had occurred on a www.steeltimesint.com

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FURNACES

37

Silicon carbide

Anchor

Graphite

Gunning

Fig 8. Refractory inserts into the hot face of the copper stave

number of the copper staves over a short period of operation. In some cases the wear exposed the cooling channels leading to some innovative thinking by the operations team to keep the blast furnace running.

Since the blast furnace had incorporated copper staves in the last campaign, it made it relatively simple to introduce the Primetals standard design of stave into the blast furnace. Utilising existing bolt holes, pipe holes and fixed pin holes kept furnace shell modifications to a minimum. The addition of a guide pin on each stave meant that just one extra hole per stave was required in the furnace shell.

Due to the severe nature of wear that occurred in the previous campaign it was decided that extra protection of the hot face was required. This resulted in the addition of refractory inserts into the castellations of the staves. Silicon carbide inserts and graphite would be used in a complementary manner to achieve the best possible protection. Silicon Carbide’s high-strength, low-thermal expansion and excellent abrasive properties make it an ideal material for the rigours of the blast furnace environment. Using graphite alongside silicon carbide conducts the cooling of the stave to that of the silicon carbide, maintaining the excellent abrasive properties of the silicon carbide and supplying the stave with its protection. The arrangement can be seen in Fig 8.

In addition to the refractory lining it was also decided to install a system of wear monitoring devices that could indicate the condition of the lining in front of the copper staves. This consists of copper wear rods that are inserted at strategic positions on the stave rows accessible during furnace www.steeltimesint.com

Furnaces primetals.indd 4

Fig 9. Primetals pipe fixing design

operation and measurements taken of the length of the rod. If there is any abrasive wear present on the front face then this can be immediately picked up and fed back for suitable action.

SSAB Lulea blast furnace no.3 Primetals was awarded the contract to reline blast furnace number 3 at Lulea in Sweden in August 2014. The shut down in June 2015 involved a full replacement of cast iron and copper staves. Three rows of copper staves in the bosh belly and lower stack were replaced with full utilisation of the existing openings in the furnace shell.

In its previous campaign the ‘banana’ effect became apparent, causing a particular problem on row three of the copper staves.

Since the previous campaign’s blast furnace shell was designed for the use of copper staves, Primetals’ standard stave

was seen as the ideal solution. The main difference between the Primetals design and the previous stave design is that the fixing bolts, which were located lower than Primetals advises, did not prevent the stave from bending in at the corners. This presented a problem to the installation of the Primetals standard as the existing bolt holes needed to be re-used while stopping the corners bending in once more. The design experience at Primetals led to the use of a patented fixing detail at Lulea, which was previously designed and implemented on a blast furnace at VA Stahl.

The pipe fixing design (Fig. 9) prevents the stave from bending in at the corners while still allowing the stave to thermally expand and move during its operation.

Primetals accepts that during operation the copper stave will expand and move, this cannot be prevented, but it can be controlled so that failures do not occur.

The design implemented during the reline at Lulea further demonstrates the understanding and versatility of Primetals in reline and rebuilds. While understanding and supporting the requirement of a tight shut down period the design of the stave is never compromised.

Results and conclusion Primetals promotes its standard copper stave design as the optimum solution for blast furnace cooling. While this is the basis for all designs, the requirements and restrictions of the blast furnace, or the shutdown period, are always considered as a major part of the design. Primetals can adapt the standard design and its features to provide the optimum solution for individual blast furnaces. t March 2016

3/15/16 9:29 AM

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TECHNOLOGY

39

Production under scrutiny In an ultra-competitive, unforgiving market, steelmakers must ensure that they produce good quality output at a competitive cost. To achieve this, they need to scrutinise every aspect of production to optimise processes and lower operating costs. By Alex-Yuntao Zhong2, Hanyu Pan2, Nils Jacobsen1 and Martin Sedén1 TECHNOLOGY can be instrumental in unlocking profitability. Traditional aspects of steel production, such as slab casting, can benefit from improved quality across a broad throughput range using the latest generation of electromagnetic flow control (FC) technology to minimise the presence of contaminants in the final product.

By applying AC and DC fields simultaneously to the molten steel, third generation FC molds can, for example, decrease oxide inclusions in ultra-low carbon steel by 45% and final defects in cold-rolled coils by 79%. New mold sensor systems also give steelmakers the opportunity to improve quality further by optimising their electromagnetic (EM) device and through greater taper control and the reduction, if not elimination, of cracks, stickers and breakouts.

The challenges Steel production demands exceptional end-product quality and high productivity, both of which are influenced by process cleanliness. Achieving these goals simultaneously demands accurate control of fluid flow during continuous slab casting.

Non-metallic and gas inclusions trapped within the steel degrade its quality. Flaws such as these are costly for producers.

Quality is paramount in order to compete in challenging markets.

Continuous slab casting is at particular risk from impurities corrupting steel quality.

Contaminants, in the form of non-metallic inclusions in the steel, entrapped casting powder and even argon bubbles, arise during processing. When these float up to the meniscus these are neutralised easily when they reach the liquid mold powder.

FC MOLD G3 – Inside and out structure

Upper part coils – Positioned on each side, behind broad sides of the mold at meniscus level – Fed with DC and AC power

Lower part coils – Positioned on each side, behind broad sides of the mold at meniscus level – Fed with DC and AC power

Lower and upper coils forms magnetic dircuit through back yokes

Operating modes • DC • DC power to upper and lower coils • Used during high-speed casting • Static magnetic field is generated in air gap between lower coils • Lower intensity static magnetic field also generated in air gap between upper coils • By applying DC to upper coils, a second DC magnetic field is imposed on magnetic field generated by the lower coils • Lower DC field reduces downward penetration • Upper DC field reduces high flow speeds at meniscus, reducing turbulence • DC fields stabilise flow, avoiding transitions between single and double roll • AC • AC power to upper coils creates travelling magnetic field over each wide side • At low casting speed, it: • Accelerates meniscus flow speed • Increases washing over front of solidifying shell by means of upper level rotational AC magnetic field • Combi • AC power to upper coils and DC power to lower coils applied • AC and DC magnetic fields applied simultaneously to optimise molten steel’s flow speed • At lower level, below SEN jet spouts, DC field is applied for internal quality • At upper level, AC and DC magnetic fields are superimposed for improved surface/ sub-surface quality and meniscus stabilisation.

• Deep penetrating downward flow is reduced by lower positioned DC field features • Seamless transition between modes: no electrical connections to be modified • Smooth transition between modes as currents are gradually adjusted between AC and DC • Avoids quality deterioration due to turbulence caused by instantaneous field changes

*1. ABB AB, Metallurgy Products, Terminalvägen 24, 721 59 Västerås, SWEDEN 2. ABB Metallurgy, ABB (China) Limited, Beijing, China www.steeltimesint.com

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TECHNOLOGY

Steel grade

process

Number of coils

Number of coils

Percentage of coils

examined

with inclusions

with inclusions

2

0.14%

magnetic interaction number, numerical simulations and on-line mold monitoring.

Ultra Low Carbon

FC Mold

1446

- 1467

10 0.68%

Table 1. Effect of FC Mold on the amount of coils with inclusion defects

However, when the inclusions follow the steel flow, carried downward via the momentum generated from the submerged entry nozzle (SEN), they become trapped in the solidified shell causing significant internal defects. The higher the speed the more likely the problem generated by the deep penetrating flow.

Electromagnetic FC technology Inclusion minimisation is achieved through the proper interaction between mold powder and steel. FC devices assist with this as their principal objectives are to reduce downward penetrating flow, keep a constant meniscus flow velocity during any given condition while stabilising the overall flow pattern, and that of the meniscus in particular.

The second generation FC mold’s doublelevel direct current (DC) magnetic fields provide stabilising zones at the meniscus and in the lower mold. It is recommended that casters be operated to maintain meniscus flow velocity between 0.2 and 0.4 m/s to obtain the desired inclusion removal properties1. Faster meniscus flow may result in mold powder entrapments, whereas slower flow velocity reduces the ability to exclude other non-metallic inclusions from the solidified steel shell. An efficient washing of inclusions is critical to prevent surface/ sub-surface defects in the solidified shell2.

There are a number of flow patterns, depending on format, casting speed, SEN geometry and the amount of dispersed Argon3. FC Mold technology provides a stable flow that avoids fluctuations between patterns, thereby optimising process parameters and enhancing output.

Earlier research has confirmed the various steel quality improvements that electromagnetic FC technology delivers2,7.

The latest development of the FC Mold, which can be utilised for both mold stirring and braking, takes the slab’s surface and sub-surface quality to even higher standards.

Further enhancing internal, surface and sub-surface quality Third generation technology, as represented March 2016

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Meniscus flow speed, FC Mold G3 Combi Mode vs. reference case without EM device

[m/s]

0.5 0.4 0.3 0.2 0.1

Wide side flow speed, FC Mold G3 Combi Mode vs.

FC Mold G3 DC Mode

No EM Device

by the FC Mold G3, retains the two DC magnetic fields of its predecessor, yet adds a travelling alternating current (AC) one to stir in the upper part of the mold.

The DC fields ensure braking and stabilisation in high speed applications whereas the accelerating AC fields are well-suited for processes of low-to-medium casting throughputs.

Meniscus flow speed can be better controlled by simultaneously combining DC and AC magnetic fields in the mold’s upper region, or smoothly transitioning between these modes. The DC component suppresses fluctuations and stabilises flows whereas a travelling AC field stirs the molten steel, thus washing non-metallic inclusions from the solidification.

The flexibility of applying DC and/or AC currents enables steelmakers to improve their control flow behaviour for a broad range of casting conditions yielding improved slab cleanliness and surface quality.

The ability to make real-time adjustments to magnetic field strengths and configurations catering to specific casting conditions further optimises steel quality. The FC Mold G3’s control package automatically and seamlessly adapts casting operations to a wide variety of situations.

The control is based on the mold index, the

Test results The following tests were performed at customer sites in Asia.

• Mold level fluctuations Without an electromagnetic device, the standard deviation of the meniscus level fluctuations is 1.47 mm. However, after 20 minutes the FC Mold G3 is switched into Combi mode and the standard deviation of the fluctuations falls to 0.97 mm5. Even with stirring for improved surface and subsurface quality, there is increased stability of the meniscus level. This can be attributed to the DC magnetic flux density component.

This result is obtained even though AC stirring is applied in the upper part of the mold.

• Oxide inclusion suppression Using an ultra-low carbon slab sample, the effects of the DC mode on cleanliness was analysed in order to quantify oxide inclusions6.

The detection was performed in seven positions along the direction of the slab thickness and at quarter width of it.

The device reduced the total oxygen value in all seven positions by an average of 45%, demonstrating that the FC Mold will improve the internal quality by lowering the amount of inclusions in slabs.

• Final defects in cold-rolled coils In a comparison of casting with and without the electromagnetic device, the inclusion defect content of cold-rolled ultralow carbon steel coils was analysed by the plant’s quality control system6. The number of coils with inclusions were retrieved with and without the application of the DC fields of the FC Mold. The results are presented in Table. 1.

The number with inclusion defects is reduced from 0.68% to 0.14%. Yielding a 79% reduction of cold-rolled coils with inclusions, the device offers a significant improvement in surface quality6.

Further improvements on the way In an ideal world, steelmakers would find it useful to track shell thickness, flux thickness, flow patterns and speed as well as inclusion locations. While direct assessment of these features is not feasible, ABB has developed a solution which captures this www.steeltimesint.com

3/15/16 9:34 AM

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TECHNOLOGY

90 92

Mold level

DC current, lower FC mold level [%] AC current, upper FC mold level [%]

75

0.0016 0.0014 0.0012

50

0.0008

96 98 102 104 106

25

108 14:20

14:30

Time

14:40

Fig 2. Meniscus level fluctuations without and with FC mold G3

information indirectly by analysing heat flux and temperature measurements from a multitude of optical Fibre Bragg Gratings sensors.

Mold temperature distribution, measured by OptiMold Monitor.

ABB’s new OptiMold Monitor, to be launched later this year, is a robust mold sensor system, providing quick monitoring and process evaluation to deliver full 2D maps of temperature in the copper plates of the mold.

The OptiMold Monitor’s easy-to-populate mold plates are densely filled with sensors for particularly accurate results. For example, a fully equipped wide face mold plate may have several thousand sensor points. The optical fibres are very small and lightweight which allows a negligible impact on strand cooling when installed in the mold copper plates. They are also immune to electromagnetic interference and are intrinsically safe due to the absence of electrical voltage.

With high resolution mold temperature monitoring and an analysis of the temperature gradients, OptiMold allows for early sticker detection as well as crack and break-out warnings. Taper control is improved, submerged entry nozzle (SEN) clogging can be detected and mold cooling monitored. Additionally, the system provides information on meniscus level and mold lubrication.

As well as monitoring overall process characteristics, OptiMold can, in real-time, if connected to a flow control device, control and adjust operational parameters for the electromagnetic equipment (currency, frequency etc.). This enables users to obtain a desirable flow pattern where meniscus speed, asymmetry and steel flow stability are managed on-line as required for optimal steel production. This control feature is March 2016

Technology ABB.indd 3

FC mold ON

0.001

100

110 14:10

0.002 0.0018

100

94 Meniscus level [mm]

125

14:50

0 15:00

FC mold OFF

0.0006 0.0004 0.0002 0 1

2

3

4

5

6

7

Position

Fig 3. The effects of FC Mold on the total oxygen value in ultra-low carbon steel

190 180 170 160 150 140 130 120 110 100

Mold temperature distribution, measured by OptiMold Monitor

based on high resolution temperature sensor data at the top of the mold to infer the meniscus level profile at any given moment, enabling the meniscus speed to be fine-tuned in a timely manner.

The technological improvements offered by OptiMold enhance both the casting process and steel quality. The high resolution measurements provide valuable information on mold and mold flux, generating important insights which, in turn, lead to fewer caster disturbances and improved quality. More specifically, stickers, cracks and break-outs can be limited or avoided entirely, surface defects reduced, and temperature distributions homogenised with better taper control.

In conjunction with the latest generation of flow control device, FC Mold G3, OptiMold can control and optimise molten steel flows and substantially reduce inclusion defects for all casting conditions.

applied simultaneously via third generation technology’s Combi mode. Use of this equipment can also significantly reduce the number of internal oxide inclusions and significantly improve the surface quality in final cold-rolled coils.

Even newer technology, in the form of advanced mold sensor systems, promises to perfect output even further. By providing the ability to infer shell thickness, flux thickness, flow patterns and speed, as well as inclusion locations, steelmakers will soon have the opportunity to tweak operational parameters to yield ever more defect-free steel. Improved production will yield higher profits and greater end-user satisfaction. t References [1] L. Hibbeler, B.G. Thomas, “Mold Slag Entrainment Mechanisms in Continuous Casting Molds”, Proceedings, AISTech Conference (2013), Pittsburgh, pp. 1215-1230 [2] S. Kittaka et al., “Nippon Steel in-Mold ElectroMagnetic Stirrer for Improving Slab Casting”, Proceedings, 5th ECCC, Birmingham (2005), pp.

476-481 [3] M. K. Singh et al., “Impact of Argon Flow Rate and FC-II on Flow Near Meniscus of Thick Slab Caster”, Proceedings, Science and Technology of Ironmaking and Steelmaking, Jamshedpur (2013), CAST, Paper 11 [4] H. Yamamura, T. Toh et al., “Optimum magnetic flux density in quality control of casts with level DC

Conclusion ABB’s third generation FC Mold overcomes the various challenges in a modern dynamic caster. The FC Mold G3 delivers a stirring (AC) function for all casting speeds as well as a braking (DC) function which is conventionally applied at higher casting speeds. In addition to the braking and stabilisation benefits offered by DC magnetic fields using well-established FC Mold technology, meniscus fluctuations are reduced when AC and DC power are

magnetic field in continuous casting mold”, ISIJ International (2001), Vol.41, No. 10, pp.1229-1235 [5] M. Sedén et al., “Control of Flow Behavior by FC Mold G3 in Slab Casting Process”, Proceedings , 8th ECCC, Graz (2014), pp. 558-569 [6]B. Jin, C. Zhang, J. Wang, H. Pan, L. Li, “The Effects of FC Mold on the Fluid Flow and the Qualities of Low Carbon Steel in a Slab Caster Mold”, Proceedings , 8th ECCC, Graz (2014), pp. 585-594 [7] K. Kariya et. al., “ Development of flow control mold for high speed casting using static magnetic fields”, AISE (1994), Chicago

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CONTINUOUS CASTING

Starting up Burnpur’s billet caster The problems experienced and their rectification during the start-up of billet caster No 1 at SAIL-ISP, Burnpur, India, are described at a time when new upstream and downstream plant were also being commissioned with a view to doubling output to 2.5Mt/yr. By A Gupta, R Kumar Singh, S Mondal, S Kumar and M Prasad THE former Indian Iron and Steel Company (IISCO), Burnpur, now IISCO Steel Plant (ISP), is the second oldest integrated steel plant in the country, established in 1939 with Open Hearth furnaces (OH).

The Duplex Process of steelmaking was adopted in 1948 when Bessemer converters were installed for initial refining of the pig iron followed by final refining in the OH furnaces. The plant reached its rated production capacity of 1.0Mt of ingot steel during 1963-64 with the operation of seven Open Hearth furnaces.

The IISCO Steel Plant (ISP), which had been a 100% subsidiary of Steel Authority of India Ltd (SAIL), was amalgamated into SAIL in 2005-06. Since then, an ambitious expansion plan has been undertaken with the replacement of the OH furnaces with modern, state-of-the-art and cost-effective technologies for production of quality steels.

This upgrade to modern technologies and processes expanded plant capacity to 2.5Mt/yr of crude steel, greatly improved environmental conditions and reduced specific energy consumption. With the closure of the old plant, an entirely new production stream comprising blast furnace, steel melting shop, continuous casting plant and rolling mills was planned within the existing complex of ISP, Burnpur.

The upgrade included two billet casting machines (each of six strands) for long products and one new Bloom/Beam Blank caster of four strands for heavy sections.

The billet casters will be able to produce around 1.688Mt of quality billets a year based on the envisaged product-mix and the feedstock requirement for the new long-product mills. Some billets will be fed

Fig 1. DIAMOLD curved caster mould from Primetals Technologies

Mold

Section I - I Top part of the mold tapered square section

Section II - II Bottom part of the mold tapered

Homogenous shell growth

View A

Fig 2. Parabolic taper shape of DIAMOLD for enhanced

Fig 3. Open corner areas in lower part of mould to reduce

heat transfer

friction

to a wire rod mill or bar mill depending on requirements and the balance sold as semis to outside parties.

Diamold Diamold provides high-speed casting for a higher production rate. For this, it is important to achieve optimum heat transfer so that a high casting speed is possible. A better lifetime of the copper tube mould is required so that downtime is minimised.

The performance of DIAMOLD[1] suited the requirement for this machine as it can be inserted into any existing mould housing.

The re-use of existing equipment lead to a reduction in capital costs. The key features of DIAMOLD[2] can be summarised as:

Features of billet caster The existing billet caster was modified by Primetals Technologies (formerly Siemens VAI) to introduce innovative techniques including: - DIAMOLD® mould tube; - DYNAFLEX® flat spring guided hydraulic oscillator; - Compact withdrawal units.

The authors are with the Research and Development Centre of Iron & Steel, Steel Authority of India Ltd, Ranchi, India March 2016

Continuous casting Gupta.indd 1

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3/16/16 12:11 PM

CONTINUOUS CASTING

Completion of mechanical erection

Completion of hydraulic pipeline

Completion of electrical erection

Commissioning of hydraulic systems

Charging of PLC

45

Completion of media pipelines (water+gas)

Commissioning of cooling water systems

Installation of software and readiness of HMI I/O checking

Casting speed Frequency

Individual trial run of equipment/ single function test

Stroke

Individual trial run of equipment with media

Fig 4. Frequency and stroke variation in DYNAFLEX oscillator with casting speed

Individual trial run of equipment/combined functional tests

Fig 5. Flowchart showing the process sequence of erection and start-up of caster

• Appropriate selection of the mouldtube length to ensure sufficient residence time of steel in the mould for the product mix and related casting speeds. (Fig. 1).

• Mould design with pronounced parabolic taper at the strand mid-face along the entire mould-tube length to assure rapid and homogeneous strand-shell growth (Fig. 2).

• Open corner areas in the lower part of the mould in order to prevent excessive frictional forces during strand withdrawal and to ensure homogeneous strand-shell growth (Fig. 3).

The rapid and homogenous strand shell growth is a feature of DIAMOLD and is highly beneficial in terms of production efficiency resulting in fewer strand breakouts and hence less machine downtime.

Dynaflex Hydraulic Oscillator To further improve production efficiency by reducing caster downtime, factors

Availability of gases

Cast simulations/readiness for first cast

to be improved were reduced wear of the guidance system, shorter time for adjustment of stroke, frequency and wave form of the mould and prevention of mechanical backlash in the mould oscillation system. Studies of the Dynaflex hydraulic oscillator system[3, 4] indicated that this provides such requirements.

The advantages of the modern actuator mechanism permit the ideal oscillation characteristics – waveform (sinusoidal, non-sinusoidal, saw-curve, and so on), stroke (amplitude) and frequency (strokes per minute), to be varied to optimise the positive and negative strip time as desired during casting. The basic principle involves a wear-free leaf spring guidance system and hydraulic drive derived from the Dynaflex oscillators successfully used first in slab casters.

Key features of the Dynaflex Oscillator system are summarised as: • Produces billets with the highest surface quality due to excellent guiding accuracy;

Machine type

Primetals Technologies caster with curved mould VP-BC9/2 x 6/R

Number of strands

6

Machine radius

9000 mm

Strand centre distance

1200mm

• No mechanical backlash of the drive and guidance mechanisms of the oscillator table; • Simple adjustment of stroke, frequency and wave form also during casting (by remote control); • Smooth running over the whole frequency range; • No servo-hydraulic components; • Highest flexibility in operating parameters and wear-free operation; • Nearly maintenance-free.

During start-up of casting, the oscillations operate with a higher frequency and shorter stroke which helps minimise the depth of the oscillation marks as shown in Fig. 4. As casting progresses the stroke is increased and the frequency reduced.

By doing this, positive strip time increases while keeping the negative strip time constant, which increases lubricant consumption and in turn reduces the chance of the shell sticking in the mould and rupturing.

Machine speed - Maximum restranding speed

approx. 6.0 m/min

- Maximum speed of run-out roller table

40 m/min

Metallurgical machine length

max. 27 m

Designed production capacity

approx. 215 t/h

Casting mode

– open stream casting with oil lubrication

– submerge nozzle casting with stopper rod

Ladle accommodation

Ladle turret (butterfly type)

Cutting device

torch cutting machine

Discharge equipment

roller table, billet lifting device, cross transfer car, turnover cooling bed

Section size

100x100 mm to 160x160 mm

Cut length

6, 9, 12 m

Level of casting platform

approx. +9800 mm

Level of roller table

approx. +800 mm

Table 1. Mechanical details of continuous casting machine No.1

www.steeltimesint.com

Continuous casting Gupta.indd 2

DYNAFLEX hydraulic oscillator

March 2016

3/16/16 12:11 PM

Pagine 2013 A3 esecutivi 2013_08_08_qxd8_A3 esecutivi 23/02/16 11:24 Pagina 12

QSP QUALITY STRIP PRODUCTION THE DANIELI WAY TO BE COST WINNER IN THIN SLAB CASTING-ROLLING

Danieli QSP technological layouts and process know-how fully satisfy the widest market demand in terms of product mix, high productivity and flexibility, tight geometrical tolerances.

> From 1.5 to 4 Mtpy capacity > From 0.8 to 25 mm strip thickness > Coil-to-coil, semi-endless, endless

Four latest references out of total 11 ESSAR ALGOMA CANADA 1998: QSP featuring the world’s first vertical curved flexible thin slab caster, for outstanding hot strip quality production, including Peritectic grades for the automotive American market.

Flat Products Rolling Mills and Strip Processing Lines

OMK RUSSIA The flexibility of the QSP layout allows the production of API X80 grades for Artic applications as well as 1.0 mm thin gauges. The only thin slab-based plant in the world conceived for “top notch” API grades production.

Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111

MMK METALURJI TURKEY With its QSP and downstream Danieli cold mill, it represents the most modern facility for flat products in the Mediterranean area, serving both commodity and quality market segments.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

NMDC INDIA QSP plant for the widest production range including API X80, HSLA, ULC steels and thin gauges. The first plant in India featuring vertical-curved casters and separation between roughing and finishing stands.

www.danieli.com

Pagine 2013 A3 esecutivi 2013_08_08_qxd8_A3 esecutivi 23/02/16 11:24 Pagina 12

QSP QUALITY STRIP PRODUCTION THE DANIELI WAY TO BE COST WINNER IN THIN SLAB CASTING-ROLLING

Danieli QSP technological layouts and process know-how fully satisfy the widest market demand in terms of product mix, high productivity and flexibility, tight geometrical tolerances.

> From 1.5 to 4 Mtpy capacity > From 0.8 to 25 mm strip thickness > Coil-to-coil, semi-endless, endless

Four latest references out of total 11 ESSAR ALGOMA CANADA 1998: QSP featuring the world’s first vertical curved flexible thin slab caster, for outstanding hot strip quality production, including Peritectic grades for the automotive American market.

Flat Products Rolling Mills and Strip Processing Lines

OMK RUSSIA The flexibility of the QSP layout allows the production of API X80 grades for Artic applications as well as 1.0 mm thin gauges. The only thin slab-based plant in the world conceived for “top notch” API grades production.

Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111

MMK METALURJI TURKEY With its QSP and downstream Danieli cold mill, it represents the most modern facility for flat products in the Mediterranean area, serving both commodity and quality market segments.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

NMDC INDIA QSP plant for the widest production range including API X80, HSLA, ULC steels and thin gauges. The first plant in India featuring vertical-curved casters and separation between roughing and finishing stands.

www.danieli.com

48

CONTINUOUS CASTING

Line along with premature separation was taking place inside cooling chamber Dummy bar storage and guide: location where rectification has been done to resolve the problem of premature separation

Fig 6. Location of premature separation of dummy bar

Fig 7. Point of rectification of alignment of dummy bars

Retainer plate

Slot for locking bolt

Fig 7a. Dummy bar starter piece

Compact Withdrawal Unit Along with a higher production rate it is necessary to maintain a good quality billet.

For high quality billets a minimum strain and strain rate is required during casting.

Also, less and simplified maintenance was a focus to increase machine availability and reduce downtime. This led to the selection of a compact withdrawal unit which provides: • Rigid frame, internally water-cooled; • Internally water-cooled rolls with highly wear-resistant surface ensuring long life; • Water-cooled tunnel through which the hot strand passes to avoid harmful heat radiation towards electrical and hydraulic components; • Arrangement of motors on top of the frame with connection of the gears via universal joint shafts, allowing optimum protection of motors and sensors and easy access from the top; • Withdrawal units fixed by four connecting rods from the top to the base frame, which, together with the arrangement of all electrical and fluid connections on top, allow a very rapid exchange of the withdrawal units for maintenance purposes.

Mechanical equipment Continuous casting Machine No1 is a 6-strand billet casting machine with an March 2016

Continuous casting Gupta.indd 3

Fig 7b. Locking bolt

annual production capacity of 833.4kt/yr.

Machine details are as listed in Table 1.

Commissioning and start-up The sequence of activities carried out for machine readiness, starting from erection of individual components and equipment, are summarised in Fig. 5.

During initial heats of CCM No1, just after start-up, strand failure was occurring because the end of a new strand often separated from the dummy bar inside the cooling chamber, after the final cooling zone. As the cast piece was not yet within the withdrawal unit, further pulling of the strand was impossible, hence casting in that strand had to be stopped.

This problem was causing maximum strand loss at the start of casting. After investigation it was found that at the location of premature separation there was a sudden jerk of the dummy bar which was causing separation (Fig. 6). The source of this sudden jerk was misalignment of the dummy bar. This was corrected, which resolved the issue (Fig. 7).

A converse problem was that of the dummy bar not detaching from the strand as it was withdrawn from the casting machine. The dummy bar, after pulling the new strand through the caster, must disconnect so that the straightened strand can be carried by the roller table to be cut into billets and discharged. Detachment

was failing on some strands and the cast material continued moving with the dummy bar following a curved path instead of resting on the roller table. This led to stoppage of the strand and production was lost on that strand.

The steps of dummy bar disconnection are (Figs. 7a and 7b): - Dummy bar starter piece is fixed with dummy bar head; - Dummy bar starter pin is fixed in dummy bar head to hold starter piece with dummy bar head from start of cast to dummy bar disconnection point; - Locking bolt is used to restrict the rotation of the dummy bar starter piece as it has a sliding fit into a slot on the starter piece; - As the downward disconnecting force is applied on the top face of the billet, the starter pin breaks allowing the locking bolt to slide out from the slot and disconnection is completed.

All these processes have to take place simultaneously.

Thorough investigation into the problem revealed that: - The starter pin used for connection was made of a ductile material; as a result when the disconnection force was applied the pin bent instead of breaking.

- The locking bolt was also made of a soft material leading to the formation of a groove on its cylindrical face restricting its free slide, which is essential for dummy bar disconnection.

- The Retainer plate of the starter piece was not fixed properly taking into account the curvature of the mould.

This misalignment led to the locking bolt undergoing mechanical stresses, further enhancing the biting of its cylindrical face.

This further increased the friction on the bolt, which prevented its easy withdrawal from the slot and so prevented detachment www.steeltimesint.com

3/16/16 12:11 PM

CONTINUOUS CASTING

No. of heats

98.00 96.00

250

94.00

End stops

Number of heats

200

92.00 90.00

150

88.00 100

86.00 84.00

50

Fig 8. Billets passing the end stop of the roller table

Yield (%)

Billet gone past the end stop while lifting

Yield %

300

Billets in normal discharge route

49

82.00 80.00

0 Dec ‘14

Jan’15

Feb’15

Mar’15

Apr/15

Fig 9. Production ramp-up of continuous casting machine No1

of the dummy bar.

- Over cooling due to zone V spray cooling and the cooling chamber water falling onto the billet led to thicker shell formation in the strand and excessive bending in the strand.

All these factors were suitably taken care of to resolve the issue of non-detachment of the dummy bar. The materials for the pins have been suitably changed to be more brittle, resulting in improved performance.

Another problem was that of billets overshooting the end-stop of the roller tables causing the billet to roll to the ground rather than being discharged on the designated travel path via a billet lifter and cross transfer [Fig. 8]. Those billets which fell to the ground were deformed as they were still hot and so rendered unfit for prime use.

It was observed that this was happening because of - Lack of synchronisation between the two arms of the billet lifter, and - Rollers on roller table still in motion when the billet lifter comes into action.

Lack of synchronisation between the two arms of the billet lifter led to the raising of the head end of the billet from the roller table while the tail end was still in contact with the driven rolls of the table. In such cases, the billet experienced a forward thrust pushing the raised head of the billet above the end-stop, causing it to slide over the arm of the billet lifter passing the end stop and causing the billet to fall to the ground.

An interlock between the roller motion and actuation of the billet lifter was set up to rectify this problem, preventing the billet lifter from lifting until the rolls on the roller table came to a halt. www.steeltimesint.com

Continuous casting Gupta.indd 4

Operating results Commissioning of the caster commenced on 10 September 2014 after all upstream facilities were completed, but still commissioning.

The upstream and downstream facilities consisted of the blast furnace, basic oxygen furnaces, mills etc. The caster was started casting billet sizes of 150x150mm by 12 metres in length.

Initially, fewer ladles of steel than were ultimately needed were available because upstream facilities were also being commissioned. The yield obtained was below what was ultimately intended due to various reasons including: • Tundish nozzle clogging; • Premature disconnection of dummy bar; • Non-disconnection of dummy bar; • Non-functioning of automatic mould level control; • Strand loss due to emergency closing of strand (sensors malfunction); • Malfunction of discharge area equipment due to hydraulic/automation/ mechanical issues; • Poor liquid steel quality due to BOF steelmaking facilities being commissioned; • Torch cutting machine malfunctioning due to cooling/automation issues.

These issues were taken care of as and when they occured. Modifications or rectifications of equipment, operating parameters and software logic, where required, were incorporated. Streamlining of equipment and process led to an increase in machine productivity.

All units of the integrated steel plant were under trial running and commissioning in parallel. Hence, commissioning and ramp up differs from that of a newly added single facility to an existing plant.

Fig. 9 shows the production ramp up of the continuous casting machine over a five month period from December 2014 as operating issues were resolved.

This saw the number of heats grow from below 50 to 250 by April 2015 with the yield improving from 86% to 97% over the period.

The erection, commissioning and stabilisation of continuous casting machine No1 proved to be a challenging undertaking due to the simultaneous commissioning of the upstream facilities of an integrated steel plant.

The commissioning of continuous casting machine No1 of ISP, Burnpur, has been an insightful experience in terms of the various important factors to be dealt with during such processes. t

Acknowledgement The authors would like to thank the management of RDCIS, SAIL and IISCO Steel Plant, Burnpur, for granting permission to publish this paper. Special thanks go to project group of IISCO Steel plant, Burnpur, for their involvement and help.

References [1] Al. G. Shalimov; Continuous Casting and Hot Rolling of Steel; Metallurgist, Vol. 48, Nos. 7–8, 2004 [2] https://www.industry.siemens.com/ datapool/industry/industrysolutions/metals/ simetal/en/SIMETAL-DiaMold-en.pdf [3] R. Kohl, K. Morwald, J. Poppl, H. Thone; The Dynaflex Oscillator for billet Casting- First Industrial Application at Lech Stahlwerke; Steel Times International, March 2001 [4] R Kohl, K Morwald, J. Poppl, H. Thone; The Dynaflex Oscillator, a technology breakthrough in billet casting; Metallurgical Research and Technology, Vol 98, Issue 1, January 2001 March 2016

3/16/16 12:12 PM

50

PERSPECTIVES: INTECO

Steel – the material of choice Inteco is busy working on the start-up of a new EAF-based mini-mill in South Korea and another similar project in Mexico. The company is also very active in India and China, according to Dr. Harald Holzgruber*, the company’s founder and CEO (pictured below) 1. How are things going at INTECO? One could say we are more than busy at the present time. Since the autumn of 2015 we have booked numerous orders, and because the market is tough, not only price and quality but short delivery time matters.

2. What is your view of the global steel industry?

It is undergoing a serious restructuring due to reduced production levels. Only companies with optimised production cycles and modern equipment will survive.

Companies with the financial wherewithal, are making selective improvements targeting overall better performances.

3. In which sector of the steel industry does INTECO mostly conduct its business?

The INTECO group is able to facilitate all production processes for the liquid treatment of steel, ferro-alloys and super alloys with its technology. It delivers tailormade equipment for melting (electric arc furnace, submerged arc furnace, vacuum induction melting), refining (ladle furnace, vacuum degassing plant, secondary converter) and casting (continuous casting and ingot casting ), as well as remelting (electroslag remelting and vacuum arc remelting).

4. Where in the world are you busiest at present?

Right now my sales managers and I travel a lot to Asia, especially India, Korea and China, where customers are seeking technologies for quality improvements, but Europe remains a challenging market.

5. Can you discuss any major contracts you are working on?

We are working on the start-up of a new mini mill in Korea based on a 150t EAF including full fledge secondary metallurgy and ingot casting up to 500t. Another big project is a second mini mill based on a 50t EAF also including secondary metallurgy and ingot casting in Mexico.

We have put into operation a major EAF revamping project for SBQ grade where we were able to operate with a closed slag door and no oxygen manipulator through the door. Decarburising and recarburising

is perfomed directly inside the EAF via special energy injection systems developed

by INTECO PTI. Robotised T&S has also decreased the direct work of operators on the EAF platform.

6. Where do you stand on the aluminium versus steel argument?

I am very confident that steel will remain the number one material in regards to quality and quantity to ensure and support our life style.

7. It has been claimed that aluminium is the ‘greener’ metal when compared to steel. What’s your view?

Steel is the ‘greener’ material considering the recycling ratios and overall energy consumption.

8. Where ‘green issues’ and emissions control are concerned, how is steel performing?

Over the last 10 years the steel industry has done a lot already. Today’s installations always consider ‘green’ issues and request the utmost emissions control, but there is always room for improvement, particularly at older sites that have been in operation for many years. Environmental control has become more relevant for us.

9. In your dealings with steel producers, are you finding that they are looking to companies like INTECO to offer them solutions in terms of energy efficiency and sustainability? If so, what can you offer them?

Energy efficiency and sustainability are requirements for all steel producers around the globe. INTECO is proud to offer a number of systems and technologies in particular when it comes to electric arc furnace operations.

10. How quickly has the steel industry responded to ‘green politics’ in terms of making the production process more environmentally friendly and are they succeeding or fighting a losing battle?

The steel industry has responded rather

* Founder and CEO, Inteco March 2016

perspectives.indd 1

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3/17/16 9:28 AM

PERSPECTIVES: INTECO

quickly to “green politics” and I am confident, particularly in Europe, that it is operating at the highest possible levels. I sometimes have my doubts as to whether the politicians understand what they can ask for and in which time period and if they are not – sometimes – jeopardising the steel industry and thousands of jobs.

11. Where does INTECO lead the field in terms of steel production technology?

INTECO is market leader in the field of quality steels and special metallurgy.

Customers who need to take the next step on the quality ladder contact us and today we are the only company worldwide which offers and has multiple references covering melting, refining, casting and re-melting of quality steels and super alloys.

12. How much importance does INTECO attach to Industry 4.0?

The production of steel grades with customer-specific requirements regarding steel chemistry has been day-to-day business for many years. In addition, the networking of office floor IT systems with production systems on the shop floor are state-of-the-art in modern steel plants.

We have developed process automation systems, which cover the different automation levels up to ERP systems. The Industry 4.0 demands such as on demand driven supply, smart planning and the consideration of transport and logistics is already, step-by-step, incorporated in INTECO’s smart automation solution.

INTECO has already developed discrete packages for the steel making processes.

13. How do you view INTECO’s development over the short-tomedium term?

We have put intensive work into important issues such as safety, robotised solutions, avoiding human risks and focusing on reducing electric energy consumption and CO2 emissions.

INTECO’s development over the last 40 years, of course, has always been linked to the global steel industry and thus we were able to grow the company over the last 10 years to become a global acting group employing approximately 400 highly educated engineers and offering all kinds of services and equipment to the steel www.steeltimesint.com

perspectives.indd 2

industry around the globe. At present the steel industry is facing some challenges and thus projects are rare, but I am more than confident that with the technologies developed and/or acquired INTECO is wellpositioned and that we will be able to make the next step towards sustainable growth.

14. How should the industry react to the Chinese situation?

China dominates global crude steel production in terms of quantity, but when it comes to high quality steels, the ‘older’ steel plants around the world remain unbeatable. It is, however, vital that steel producers and technology suppliers serving this market stay one step ahead and continuously invest in new developments.

51

to ensure our standard of living; and steel is the most versatile material by far. The challenges are the overcapacity situation at present and low raw material prices, which are deflationary, resulting in a halt of global investments. Nevertheless challenges in the steel industry have always been part of a steelmaker’s life and are an opportunity to develop new technologies and materials.

17. What exhibitions and conferences will INTECO be attending in 2016?

After a METEC year (2015) we try to keep a low profile the following year. We will be at AISTech in Pittsburgh, USA, the EEC in Venice and the annual STAHL conference in Dusseldorf, Germany, in November.

15. Where do you see most innovation in terms of production technologies – primary, secondary or more downstream?

INTECO in the last couple of years is heavily involved in the primary metallurgy

18. INTECO is based in Austria, but what’s happening steel-wise in the country?

Austria might be small but in my opinion, it plays a major role when it comes to high quality steel. On one hand, you have

and in particular in electric arc furnace technologies. Due to the requirement to globally reduce CO2 emissions I see a lot of innovation and strenuous efforts to optimise this particular technology.

Boehler and voestalpine, who are major and well-known steel producers, and on the other you have INTECO and other Austrian companies offering high tech steelmaking plants.

16. How optimistic are you for the global steel industry and what challenges face global producers in the short-to-medium term?

INTECO is clearly optimistic – steel is and will continue to be the material of choice

19. If you possessed a superpower, how would you use it to improve the global steel industry?

We would like to reduce the specific enthalpy of steel from 390 kWh/ton to one third, but this is only a dream. t March 2016

3/17/16 9:28 AM

52

HISTORY

Iron magnetism and civilisation Iron is the backbone of our society. The amount of iron produced in the world in one year equals that of all other metals combined over 10 years. If iron is the basis of the construction and transportation industries, then iron magnetism is the basis of our civilisation. By Fathi Habashi*

1

2

3

4

5

6

Fig 1. A museum sample of lodestone [magnetite, Fe3O4] - Fig 2. A magnetic needle - Fig 3. William Gilbert (1544-1603) - Fig 4. Hans Christian Ørsted (1777-1851) - Fig 5. Ørsted and assistant examining the effect of a wire carrying current from Volta’s pile on a magnetic needle in 1819 - Fig 6. André-Marie Ampère (1775-1836)

A lodestone (Fig. 1) in Middle English means 'leading stone' and is a naturally magnetised piece of the mineral magnetite that can attract iron. The property of magnetism was discovered in antiquity by the 6th century BC Greek philosopher Thales.

Pieces of lodestone, suspended so they could turn, were the first magnetic compasses, and their importance to early navigation is indicated by the word lodestone. The name ‘magnet’ may come from lodestones found in the village of Magnesia in Anatolia.

It was also known since ancient times that a piece of iron could be magnetised by rubbing it with a lodestone and as a result the magnetic needle (Fig. 2) was created that later became an important laboratory instrument for research. In the middle of the 15th century many advances were made in technology that would help sailors.

For example, improvements were made in the compass, in the astrolabe, in ship building, the availability of maps, and maritime and astronomical information. As a result, the invention of the printing press (1456) led to the Age of Exploration.

In 1600, an English physician William Gilbert (1544-1603) (Fig. 3) published his

De Magnete, Magneticisque Corporibus, et de Magno Magnete Tellure. In this work, which is the first on magnetism, he described many of his experiments with his model earth called the terrella. From his experiments, he concluded that the Earth was magnetic and that this was why compasses pointed north.

Electricity and magnetism In 1800 the Italian scientist Alessandro Volta (1745–1827) constructed the first ‘pile’ of metals from which he was able to generate electricity. Soon after, in 1819, the relationship between electricity and magnetism began with work by Hans Christian Ørsted (1777-1851) (Fig. 4) professor at the University of Copenhagen.

He noticed the turning of a compass needle next to a wire carrying current (Fig. 5).

This simple observation was so crucial that it was followed by a large number of observations and inventions by many scientists in many countries.

For example, in Paris in 1820 André-Marie Ampère (1775-1836) (Fig. 6) made the revolutionary discovery that a coil of wire carrying electric current acted as a magnet.

William Sturgeon (1783-1850) in London filled the centre of a solenoid with iron in

1825 and produced a powerful magnet. He also invented the galvanometer.

Michael Faraday (1791-1867) discovered electromagnetic induction in 1831 and the basis of the electric motor, i.e, converting mechanical energy into electrical energy, hence it was possible to generate electricity from waterfalls and vice versa generating mechanical energy from electrical energy.

Power plants were built on this principle.

Heinrich Hertz (1857-1894) then demonstrated the existence of electromagnetic waves (radio waves) leading many inventors and scientists to try to adapt them to commercial applications, such as Guglielmo Marconi (1874-1937) in 1895. However, magnetism is influenced by temperature and it was the French physicist Pierre Curie (1859-1906) who discovered in 1895 that magnetite loses its magnetism at about 570°C while iron loses its magnetic properties at 770oC. Magnetism remained a curious phenomenon until it was explained in the 20th century as a force generated in matter by the motion of electrons within its atoms. The orbital and the spin motion independently impart a magnetic moment on each electron causing them to behave as a tiny magnet. t

* Department of Mining, Metallurgical, and Materials Engineering, Laval University, Quebec City, Canada. Fathi.Habashi@arul.ulaval.ca March 2016

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3/14/16 4:34 PM

AS ONE We are stronger

Two powerful companies in the metals industry have forged together. Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies have united to become the new global force in metals technologies.

Creating the future of metals as one. primetals.com

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