MPT International 4/2013 (Sep)

Metallurgical Plant and Technology

G 25074

ISSN 0935-7254

September 2013

Quality assurance: Topographic surface inspection system for slabs and heavy plate

Plug & Work: Automation pretested by Simulation

Tried and tested long before installation “Plug and Work” is the established product from our automation specialists. Forget time-consuming test phases at your works – our automation system is connected to a simulation model that reﬂects the entire process. That’s how we carefully test and optimize work routines and technological functions even before commissioning.

The result: Only proven and perfectly reliable automation systems are installed, connected and … run without a hitch. What you gain: steep run-up curves for new installations and plant revamps. Short assembly times that optimize your return on investment. What your customers gain: dependable production and guaranteed delivery dates.

SMS SIEMAG AG

Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany

Phone: +49 211 881-0 Fax: +49 211 881-4902

E-mail: communications@sms-siemag.com Internet: www.sms-siemag.com

Editorial

Shaping tomorrow‘s process automation Industry automation is so commonplace that it has become an integral part of production plants, processes and routines. We take it for granted that automation is permanently being further developed. Computers are omnipresent in any factory. Production is programmed and implemented by means of automation systems. All processes are monitored and analyzed. Products are documented along the complete process chain. As a result of all these processes, automation generates huge volumes of data (“big data”), much too big to be handled by classical databases and conventional data management tools. Traditional forms of data handling have reached their limits. Therefore, experts are already discussing the vision of a new, fourth industrial revolution, which will bring about networked factories: “Industry 4.0”. The development of automation may lead to the “intelligent factory”. Outstanding features of such a smart factory could be new forms of adaptability, resource efficiency and ergonomics as well as the integration of customers and business partners into business and value processes. To the same extent as the automation of processes is becoming increasingly complex, HMI and interactive systems are expected to become increasingly efficient. Intelligent systems shall be there to assist the human operator in controlling and organizing processes. New about this would be the fact that it would no longer be necessary for the operator to have full control of all details and the entire complexity of these processes. This trend towards Industry 4.0 is about to reach the steel industry. In this issue, renowned providers of industry automation solutions explain how they are responding to the new challenges. Siemens, for example, describes a new approach to process transparency as well as an analysis of production and processes which recently has been adapted to meet the needs of the metals business. Schneider Electric has positioned itself with a new process expert system that optimizes production and energy efficiency and is being rolled out right now for various industries. And ABB has developed a process optimization tool for rolling mills. It remains to be seen whether we are really on the verge of a new industrial revolution. At least, we are about to be presented with a new development stage of automation.

Dipl.-Ing. Arnt Hannewald

MPT International 4/2013

Contents

Volume 36

No. 4 – September 2013

Topical themes R. Fackert, C. Mittag

52 Topographic surface inspection for slabs and heavy plate Surface defects originating from the continuous casting process often persist throughout the entire process chain of strip and plate production. Therefore it is vital for the quality of the final product that the product surface be inspected throughout the complete process route from continuous casting through to the finished coil or plate. X-3Dvision can inspect slabs also immediately after the continuous casting process.

Cover photo: Slab surface inspection and edge contour detection at once at the continuous casting plant Surcon GmbH, Heiligenhaus, Germany Contact: www.ims-gmbh.de E-mail : info@ims-gmbh.de

Ironmaking 30 ArcelorMittal Kryvyi Rih repairs blast furnace in record time The largest producer of rolled steel in Ukraine has finished the overhaul of its blast furnace number seven after just 26 days. Similar overhauls have taken up to eight months in the past.

33 IronArc to revolutionize hot metal production

Editorial A. Hannewald

3 Shaping tomorrow´s process automation

Columns 8 International industry news 72 Technical innovations 77 Cartoon 78 Literature service 80 In the next issue 80 Imprint

Steelmaking 38 Liquid steel production at Outokumpu Stainless in Calvert, Alabama, USA For the new greenfield stainless steel works Siemens supplied an EAF, an AOD converter, secondary metallurgical facilities, and a continuous slab caster. The plant is designed to produce annually one million t of AISI 200, 300 and 400 grades of stainless steel.

A new method for producing hot metal has been developed in collaboration with the Swedish steel group Ovako at the Hofors steel plant. The method, called IronArc, lowers CO2 emissions significantly compared with blast furnace production.

P. Duarte, T. Scarnati, A. Martinis

34 Higher DRI quality and higher EAF yields by optimized DRI making The Energiron technology eliminates the need for an external gas reformer by carrying out the reforming, reduction and carburization reactions within the same furnace. The resulting DRI product is highly metallized and with comfortable carbon levels in the range of 3 – 5%. Due to this carbon and application of modern oxygen practices, the yield of the subsequent EAF meltshop is significantly higher than usual.

AOD converter plant at Outokumpu, Calvert, USA

R. Bruckhaus, R. Fandrich

40 Current technology trends in steelmaking Under the roof of German Steel Institute VDEh the Steelmaking Committee and the associated subcommittees have identified current trends and developments in steelmaking processes from a European point of view.

Metallurgical Plant and Technology Advertisers’ index Interview

28 Lower order intake but higher sales for SMS group During the financial year 2012, SMS group faced a down in order intake but an increase in revenues due to the completion of major plant building projects. After integration of Paul Wurth company, SMS group has continued its investments in its locations in Germany and abroad. For potential further expansion the group identifies electrics and automation, service, energy, and green technologies as growth fields.

Hot rolling

Automation

M. Guagnelli, P. Bobig

62 IT toolbox to analyze processes and to reveal potential in the metals industries

48 Thermo-mechanical rolling technology for the production of API 5L steel strip from thin slabs The requirements on ductile to brittle transition temperature are the most important limiting factors for API 5L strip grades produced by the thin slab technology because of the difficulties in achieving a refined and homogeneous microstructure. The results obtained at the new OMK Vyksa minimill are very promising.

Automation N. Ash

56 Process optimization for long product rolling mills ProfileOpt has been developed to simulate and optimize the rolling process of bar mills or wire rod mills in the steel industry, and generate set points for these optimized rolling conditions.

U. Lettau

58 Analytical monitoring of production data A Russian producer of longitudinally welded large-diameter steel tubes commissioned a new tube plant at its Chelyabinsk works. A data acquisition system from Iba AG was implemented for smooth process analysis.

Siemens Metals Technologies integrates its knowledge of metallurgy and plant design into the modular IT platform Simatic IT. The result is a new approach for transparency as well as for analysis of production and processes.

ABB AB

Andritz Sundwig GmbH

Aumund Fördertechnik GmbH

Automazioni Industriali Capitano srl

Braun Maschinenfabrik Gesellschaft m.b.H.

!?QRCJJGLG -DjAGLC Meccaniche S.p.A.

Combilift Ltd Co

Danieli S.P.A.

6,7

GLAMA Maschinenbau GmbH

Guild International Inc.

hpl-Neugnadenfelder Maschinenfabrik GmbH

IMS Messsysteme GmbH

31, 32

INTECO special melting technologies GmbH

JP Steel Plantech Co.

64 New process expert system optimizes production and GPGTI[ GHƂEKGPE[ PlantStruxure PES from Schneider Electric allows industrial companies to meet automation needs while optimizing operations and energy management by connecting the field, process, and enterprise levels within a business.

Heat treatment F. Brühl, T. Sagermann

66 Heat treatment technology as an integrated part of investment projects It used to be standard practice for investors to split orders for new plants into three different packages, namely mechanical equipment, electrical equipment and heat treatment. However, the investing companies in the steel and aluminium industries are more and more interested in solutions integrating the overall plant, including the process know-how.

I.B.C.

Amandus Kahl GmbH & Co.KG

Maschinenfabrik Köppern GmbH & Co.KG

KSK Kuhlmann-SystemKühltechnik GmbH

LAP GmbH

Lechler GmbH

MICRO-EPSILON MESSTECHNIK GmbH & Co. KG

Pert srl

QuinLogic GmbH

Saar-Metallwerke GmbH

SGL CARBON GmbH SMS Siemag AG

O.B.C. I.F.C.

Stein Industrie-Anlagen

TML Technik GmbH

PAUL WURTH S.A. Verlag Stahleisen GmbH Z & J Technologies GmbH Zumbach Electronic AG

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International industry news

News in brief Dongbu Special Steel, South Korea, has recently completed the commissioning of an integrated peeling line supplied by Mair Research.

Outotec F?Q MNCLCB ?L MDjAC GL Jakarta to strengthen its presence in Indonesia. RHI, Germany, will adjust the production capacity in Europe to the growth rates, which are expected to stay low in the future. For this reason, the Duisburg plant will be closed this year. Bahru Stainless, Malaysia, has successfully put into operation the new 20-roll millstand supplied by SMS Siemag. Tata Steel, the Netherlands, has commissioned a metal plate conveyor, which conveys iron sinter to the ring cooler at Tata Steel’s IJmuiden plant. The deep-drawn pan conveyor was supplied by Aumund.

The Americas

USA

AK Steel JV to start construction of pellet plant. MagnetaBrazil

Klöckner commissions new service centre equipment. Kloeckner Metals, a subsidiary of Klöckner & Co, has taken a modern cut-to-length line and downstream prefabrication capacity into operation at its service centre in Piracicaba in the metropolitan region of São Paulo. The production line with a total length of some 65 m has an annual capacity of 60,000 t. The investment supplements Klöckner & Co’s product portfolio in Brazil with custom prefabricated high-quality steel sheet and plate in widths of up to 2,100 mm, while the sheet products are mainly bought by customers from the electrical and household appliances industry. The thicker plate goes to applications such as crane and commercial vehicle construction.

tion LLC, the joint venture of AK Steel with Magnetation, Inc., has successfully completed financing for the construction of a new plant in Reynolds, Indiana, to produce high-quality iron ore pellets. Production from the pellet plant will supply AK Steel’s blast furnaces located in Ohio and Kentucky. AK Steel’s strategic investment in Magnetation will provide the company with about 50% of its annual iron ore requirements beginning in 2015. By becoming more vertically integrated, AK Steel will gain greater control over its cost structure and enhance its raw materials self-sufficiency. Construction of the pellet plant is underway and should be completed in about 18 months. Initial pellet production is anticipated during the fourth quarter of 2014. When fully operational, the Magnetation plant will produce about 3 million t of iron ore pellets annually.

Cananda Starcore, Thailand, is producing high-grade strips on the new combined reversing and skin-passing mill installed and commissioned by Esmech Equipment, an Indian joint venture partner of SMS Siemag.

Acroni, Slovenia, has commissioned a new 2.6 m X-Roll® heavy-plate mill stand from SMS Innse, and a new roller-type quench supplied by Drever International. The two companies are subsidiaries of SMS Siemag. ArcelorMittal (Dofasco), Canada, F?Q MPBCPCB ? 1F?NCJGLC $JCV k?Rness measurement system for the continuous hot-dip galvanizing line at its Hamilton facility.

Nippon Steel Pipe Mexico has commenced commercial operation of its automotive steel pipe/tube business in Mexico. TMK Seversky Tube Works, Russia, has placed an order with SMS Meer for the supply of two threading machines, including transport facilities.

MPT International 4/2013

Evraz North America orders heat treatment system. Evraz

USA

North America, based in Chicago, has ordered an Elotherm TemperLine™ heat treatment system for its tubular products plant in Calgary, Alberta, Canada. With this unit, Evraz is increasing its capacity for heat-treated pipe by over 150%. The line will be designed for the heat treatment of up to 30 t/h of OCTG (oil country tubular goods). Due to the high flexibility of Elotherm’s heating systems, with very short downtimes for changing the pipe size or final grade, this 12 MW TemperLine™ will be capable of heat-treating more than 200,000 t/year of pipes. The heating unit is scheduled to go into operation in the fourth quarter of 2014.

Former RG Steel assets on sale.

Mexico

Casa Sommer orders levelling equipment. Herr-Voss Stamco received an order from Casa Sommer, located in Naucalpan, for a Precision Leveler®. The leveller is an addition to an existing Stamco cut-to-length line and will process stainless steel material up to 3.43 mm thick by 1,524 mm wide.

Casey Equipment has reached an exclusive agreement to sell the assets of the former RG Steel facility in Martins Ferry, OH. These assets include two Wean galvanizing lines complete with Herr-Voss tension levellers. Additionally, a 300,000 t/year Bliss 2-high temper mill has been made available for sale. The mill features 1,676 mm wide work rolls and can roll material of a gauge from 0.35 to 4.27 mm thick.

USA

Voestalpine has ordered Midrex DRI plant. Siemens Industry Inc., USA, and consortium partner Midrex Technologies, Inc. received an order from the Voestalpine group to build a direct reduction plant near the city of Corpus Christi, Texas. The Midrex plant will be designed to produce 2 million t/ year of hot briquetted iron (HBI), making it the largest single module of this type world-wide. The plant is due to begin operations in late 2015. Investments by Voestalpine will also include comprehensive infrastructure improvements

Have an eye on ... ... 40 years of INTECO .FMUJOH 3FæOJOH $BTUJOH Remelting 4ZNQPTJVN

40 years

The speakers

On the occasion of INTECO‘s 40th anniversary and TBR ĐĂƐƟŶŐ ƚĞĐŚŶŽůŽŐŝĞƐ͚ Ϯϱth anniversary both companies ǁŝůů ŚŽƐƚ ĂŶŽƚŚĞƌ ŐĞƚͲƚŽŐĞƚŚĞƌ ĨŽƌ ƚŚĞ ǁŽƌůĚǁŝĚĞ ƚŽƉ ĐůĂƐƐ ŽĨ ƐƚĞĞůͲ ĂŶĚ ƐƉĞĐŝĂů ŵĞƚĂůůƵƌŐǇ ŝŶĚƵƐƚƌǇ ŝŶ ^ĞƉͲ ƚĞŵďĞƌ ϮϬϭϯ͘ EĞǁ ĚĞǀĞůŽƉŵĞŶƚƐ͕ ƉƌŽŐƌĞƐƐ ĂŶĚ ƌĞƐƵůƚƐ ŝŶ ƚĞƌŵƐ ŽĨ ŵĞůƟŶŐ ĂŶĚ ĐĂƐƟŶŐ ƚĞĐŚŶŽůŽŐǇ ǁŝůů ďĞ ƉƌĞͲ ƐĞŶƚĞĚ ĂŶĚ ĚŝƐĐƵƐƐĞĚ ŝŶ ƚǁŽ ƉĂƌĂůůĞů ůĞĐƚƵƌĞ ƐĞƐƐŝŽŶƐ͘

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Friday, 20 of September Ͳ WůĂŶƚ ĞǆĐƵƌƐŝŽŶƐ

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tŝĞŶĞƌƐƚƌĂƘĞ Ϯϱ ϴϲϬϬ ƌƵĐŬ Ă͘Ě͘ DƵƌ ƵƐƚƌŝĂ ƵƌŽƉĞ dĞů͗͘ нϰϯ ;ϬͿ ϯϴϲϮ ϱϯϭϭϬͲϬ &Ăǆ͗ нϰϯ ;ϬͿ ϯϴϲϮ ϱϯϴϰϰ ǁǁǁ͘ŝŶƚĞĐŽ͘Ăƚ

International industry news

News in brief ArcelorMittal, Germany, has contracted SMS Mevac to modernize the steam ejector pump system for the existing RH facility at its works in Duisburg-Ruhrort.

Sahaviriya Steel Industries (SSI), United Kingdom, have put into production the MES and scheduling modules supplied by Broner Metals.

Tata Steel, the Netherlands, has placed an order for a new laser scanner inspection system for their RMPNCBM J?BJC kCCR ?R GRQ 'HKSGBCL plant. The system will be supplied by Minteq International, Ferrotron Division. Pro-Tec Coating Company, USA, successfully started hot commissioning of the continuous annealing line supplied by SMS Siemag and installed at the works in Leipsic, OH. The line will produce advanced highstrength steels (AHSS) and ultrahigh-strength steels (UHSS) from 590 MPa. Mechel, Russia, has started hot testing of rail rolling at its Chelyabinsk metallurgical plant. As part of hot testing, R-65 100-m-long rails were successfully rolled. Outokumpu Stainless, Sweden, has rolled out the Quintiq supply chain optimization platform at its Avesta plant. Yonggang, China, has successfully commissioned two high-speed bar and wire rod rolling lines. For these lines, ABB supplied the motor and drive systems, the automatic control system and other systems. Tata Steel, South Wales, has completed the upgrade of its process line for corrosion-resistant coatings at Llanwern. Modernization measures included increasing the size of the radiant tube section in the line’s annealing furnace and adding a second roll size to the temper mill.

Baosteel, China, has placed an order DMP ? 1F?NCJGLC k?RLCQQ KC?QSPCment system to be installed at the high-strength steel plate mill in Shanghai.

MPT International 4/2013

for the project location, particularly the necessary port facilities. The direct reduction plant will provide Voestalpine’s Austrian steel production sites in Linz and Donawitz with access to cost-effective and environmentally-friendly HBI. About half of the annual production will be shipped there. The remaining half will be sold to partners interested in longer-term contracts.

USA

AK Steel blast furnace experiences incident. AK Steel’s blast furnace at its Middletown, OH works facility experienced a mechanical failure in the charging apparatus last June. The blast furnace was taken offline to prevent any damage to the furnace and to position the furnace for the start-up once the repairs are completed. Prior to the completion of the repairs, the company will utilize its Butler, PA works electric arc furnace and its Ashland, KY works blast furnace and, to the extent necessary, purchase merchant carbon slabs to service its customers.

USA

V&M Star to install cross-roll piercing mill. SMS Meer has received an order from Vallourec & Mannesmann Star for the delivery of a crossroll piercing mill for the multistand pipe mill (MPM) at its Youngstown site in Ohio. In addition to a cross-roll piercer, the scope of the order also includes electrical equipment and basic automation plus transportation and handling equipment and a billet end centering unit. SMS Meer will supervise erection and commissioning as well as training of the operating personnel. The Youngstown plant is Vallourec’s main production facility in the USA for hot-rolled seamless tubes, used mainly for oil and gas exploration. Installation of the new equipment is scheduled for the fourth quarter of 2014.

Asia China

Hebei Puyang orders slab caster. Hebei Puyang Iron and Steel has

awarded SMS Siemag Technology (Beijing) a contract for the supply of a medium slab caster to be installed at the works in Wuan City, Hebei province. Puyang Steel is expanding its product mix mainly to include pipe grades, pressure vessel grades, high-strength shipbuilding plates and high-quality carbon steel slabs. The single-strand caster will be designed for slabs of 150 to 180 mm thickness and 1,000 to 2,300 mm width for a production capacity of 1.2 million t/year. Provision will be made for a future extension to twin casting for simultaneous production of two narrow slabs in one strand. SMS Siemag Technology (Beijing) will handle the project for Hebei Puyang completely in China. The scope of supply covers the entire plant and process engineering and the X-Pact® electrical and automation systems including the technological process models (level 2).

China

Shasteel signs coking coal supply agreement. According to an agreement signed with the Shasteel group, Mechel Carbon (Singapore), trading subsidiary of Mechel’s mining division, will directly supply Shasteel with 40,000 to 80,000 t/month of coking coal from Russian Far East ports, starting in summer 2013. Coking coal prices will be determined on a monthly basis.

China

Benxi to install cold rolling and strip processing lines. In April 2013, Bengang Steel Plates (Benxi) placed an order with SMS Siemag for the supply of a pickling line/tandem cold mill and two continuous annealing lines. In addition, MET/Con is providing technical support and know-how for the production of high-quality automotive grades on these lines. With these grades, Benxi will be entering the market for premium interior and exposed automotive parts. As of summer 2015, the new facilities will produce more than 2 million t of high-grade pickled, cold-rolled and annealed steel strip, including high-strength grades such as DP and TRIP. Besides the design of the mechanical equipment and the fabrica-

International industry news tion of sophisticated core components, SMS Siemag’s supply scope includes the supervision of the local fabrication as well as of the equipment installation and commissioning. The pickling line/tandem cold mill will come with a highly efficient turbulence-tank pickling system and a five-stand six-high tandem cold mill, equipped with the new combined CVC plus®/ESS technology. The line will be designed for 1,000 to 2,150-mm-wide strips with entry thicknesses between 1.2 and 6.0 mm, which will be rolled down to gauges between 0.3 and 2.5 mm. The two continuous annealing lines will feature annealing furnaces from Drever and inline skinpass mills for perfect strip surfaces. Except for the strip widths they can handle, the lines will be more or less identical. While one line will be able to process strips up to the record width of 2,150 mm, the maximum strip width of the other line will be 1,630 mm.

China

Tangshan places order for cold rolling complex. Siemens Metals Technologies has won an order from Tangshan Iron and Steel Group to supply a complete cold rolling complex. The plant will be built at the Tangshan location in the Hebei province. It includes a coupled pickling line-tandem cold mill, a continuous annealing line and a galvanizing line. The cold strip mill to be supplied by Siemens will be designed for an annual production of 1.6 million t of high-strength, highquality steels for the Chinese automotive industry. Siemens is engineering and supplying the mechanical, electrical and process control equipment for the cold strip mill. The coupled pickling line-tandem cold mill and the annealing and galvanizing lines are to share an integrated automation system that consists of basic (level 1) and process automation (level 2) and of process models developed specially for cold rolling mills. The tandem mill will consist of five six-high rolling stands. Andritz will supply furnaces and process equipment for a hot-dip galvanizing plant (annual capacity: 415,000 t) and a continuous annealing line (annual capacity: 770,000 t). The scope of supply also includes automation equipment and key process components, such as the zinc stripping jet and the shears. All lines will handle strip of fi-

nal thicknesses ranging from 0.2 to 2.5 mm and widths from 700 to 1,600 mm. The first pickled and cold rolled strip is to be produced by December 2014 and production will be launched in 2015.

China

Nanshan Aluminium to build wide plate mill. The rolling mill project at Nanshan Aluminum, implemented by ABB and SMS Siemag, is expected to be put into operation by the end of 2014. The mill will make aluminium products with a maximum width of 2,650 mm. ABB mainly supplies equipment and systems, including distribution systems, MCC, primary and secondary automatic control systems, motors and transmission systems, special instruments and field sensors, and is responsible for the design, debugging of the electrical and automation systems and the follow-up services. All core components of the millstands will be manufactured at the SMS Siemag workshop in Germany.

MORE PRECISION STRIP THICKNESS & PROFILE laser-optical measurement with thicknessCONTROL

China

Anshan to receive slitting line. Siemens Metals Technologies has signed an order with Anshan Iron and Steel Group to equip a new slitting line. The scope of the supply for this project includes process technology, mechanical equipment, automation engineering as well as all equipment used in this production line. Siemens will also be responsible for supervising installation and commissioning. The line will be designed for processing automotive inner and outer panels with surface quality A (O3) and B (O5). The maximum strip width will be 1,850 mm, thickness 0.3 mm to 2 mm and tensile strength up to 800 MPa. The maximum number of slits will be 30. A special belt unit provides the back tension required for scratch-free operation. The slitting line is scheduled to be commissioned in the second quarter of 2014.

China

Drive and automation system for Chengde Nickel’s CAPL. ABB China has won an order to supply drives and automation systems to the ongoing MPT International 4/2013

SPEED & LENGTH optical sensor with ASCOspeed

SPS/IPC/DRIVES / Nuremberg 26.11.2013 - 28.11.2013 Hall 7A / Stand 7A-138

www.micro-epsilon.com MICRO-EPSILON | 94496 Ortenburg / Germany Tel. +49 85 42/168-0 | info@micro-epsilon.com

International industry news cold-rolling stainless steel CAPL (continuous annealing production line) project of Seihai Chengde Nickel Co. The line will have a capacity of 700,000 t/a. ABB will also deliver management, operation and maintenance training.

China

Chinese steel producer orders Arvedi ESP lines. A Chinese steel producer placed an order with Siemens Metals Technologies for the supply of two Arvedi ESP (endless strip production) lines. The new plants will be designed for an annual production capacity of 2 x 2.6 million t of high-quality, ultra-thin, hot-rolled strip products with widths of up to 1,600 mm and thicknesses down to 0.8 mm. Carbon steels, high-strength low alloyed (HSLA) grades and dual-phase steels will be produced. The steel producer will receive technical support and assistance for plant start-up and operations by personnel from the existing ESP plant at Acciaieria Arvedi SpA, Italy. The new casting-rolling facilities will be part of a new steelmaking facility currently under construction in China. The plant is scheduled to go into operation in 2015.

China

Zhongyuan orders new bloom caster. Zhongyuan

We agglomerate your valuable dusts and fines

Special Steel has placed an order with Siemens Metals Technologies for a two-strand vertical continuous caster to produce heavy blooms with a round cross-section. The caster will have a capacity of up to 370,000 t/a. A newly designed multi-roller drive unit will ensure optimum support of the 120 t strand during casting. With the new caster, Zhongyuan will in future be able to produce blanks for construction steel, tool and bearing steels as well as heat-resistant stainless steels. Commissioning is scheduled for the end of 2014.

China In the metallurgical industry we briquette e. g. steel mill residues, sponge iron (hot and cold), chrome ore, nickel powder, copper concentrate, and other ďŹ nes. Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units. KĂśppern â&#x20AC;&#x201C; Quality made in Germany. - & & ! & $& & ! ! * - $! %% & ! ! * !) !) - " & ( &* - ' $! $ $ " &

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MPT International 4/2013

Beihai Chengde to install stainless steel tandem cold mill. Siemens Metals Technologies has received an order from Beihai Chengde Stainless Steel to supply a Power X-HI type, five-stand, continuous tandem cold rolling mill and a heavy laser welding machine for the Beihai plant in the Guangxi province. The rolling mill will have an annual capacity of 600,000 t of cold strip and will be designed to produce series 200 and 300 AISI grades. It will handle hot-rolled, annealed and pickled stainless steel and produce exit thicknesses from 0.3 to 3.0 mm from entry thicknesses between 1.0 and 5.0 mm. Strip width will vary between 800 and 1,300 mm. The rolling speed will be 400 m/min. The rolling stands will be designed for a flying roll change, so production will not have to be interrupted to change the work rolls. The Siemens welding machine will be of the heavy laser type (LW21H) and include strip centering and strip cutting facilities as well as diagnostic systems. The new rolling mill is scheduled to be commissioned in the middle of 2014.

International industry news China

Fujian Fuxin to build VOD facility. SMS Mevac has received an order for the supply of a 150 t X-eed Duplex VOD facility from Zhangzhou-based Fujian Fuxin Special Steel, which is part of Formosa Plastics Corporation. The aim of the project is to enable the production of austenitic and ferritic stainless steels. The VOD facility will be equipped with two tanks and two vacuum covers, a joint four-stage vacuum pump system with automatic vacuum pressure control (VOD-SC) and a common alloy storage and addition system. To protect the environment, the VOD unit’s vacuum pump system will include a gas cooler and integrated bag filter system. The scope of supply covers the entire mechanical process equipment as well as the complete electrical and automation systems. Fujian Fuxin plans to commence production of stainless steel at the Zhangzhou plant by the end of 2014.

China

Angang Steel to install new motors in grinding mill. GE Power Conversion will be installing motors in the Angang Steel grinding mill facility operated by CITIC Heavy Industries Company. The supply will include two 4,200 Quadramatic™ motors as well as the controls. GE will supervise installation and commissioning. GE’s Quadramatic™ motor system has very high efficiency levels for dual-pinion, fixed-speed mill applications.

China

Jiangsu Yonggang to build BF-gas fuelled cogeneration plant. Jiangsu Yonggang will install four of GE’s Jenbacher cogeneration systems that will be fuelled with blast furnace gas. The project in China is the world’s first gas engine cogeneration plant that will use blast furnace gas to generate cleaner power and heat for a steel mill. Powered by four of GE’s 1.97 MW J620 Jenbacher cogeneration units, the 7.88 MW combined heat and power plant will offer a total efficiency of up to 83.5% to minimize the energy costs of the Jiangsu Yonggang steel mill. The project will also reduce 63,000 t of CO2 emissions per year at the mill.

China

VAMA places order for production management system. PSI China has signed a contract with Valin ArcelorMittal Automotive Steel to implement the production management solution PSImetals. VAMA is a joint venture between ArcelorMittal and Hunan Valin Iron and Steel. The company is setting up a new cold rolling complex in Loudi in the Hunan province in order to produce and market products for the automotive industry. Start of production is planned for June 2014. In the first phase, PSImetals will cover the whole cold rolling mill area offering functions for order dressing, integrated planning, production configuration, production execution, quality management and logistics. MPT International 4/2013

International industry news

China

India

Baosteel to build new hot strip mill. Baosteel Zhanjiang

Essar signs mill services contract. Harsco Corporation has con-

Iron & Steel has placed an order with SMS Siemag for the supply of a new 2,250 mm hot strip mill. The mill is to be built at the new steelworks location in Zhanjiang in the south of China. The high-performance hot strip mill will be designed for an annual capacity of 5.5 million t of hot strip with final gauges of 1.2 mm to 25.4 mm and strip widths between 800 mm and 2,100 mm. The range of products extends from mild deep-drawing grades and highstrength structural steels through to tube and pipe grades. On the basis of an optimized layout, the new hot strip mill will comprise a slab sizing press, one two-high and one four-high reversing roughing stand, each with flanged-on edging stand, seven CVC® plus four-high finishing stands, laminar strip cooling and two hydraulic coilers. Commissioning of the hot strip mill is scheduled for the end of 2015.

cluded a new 15-year contract with Essar Steel India. This contract is for slag management and metal recovery services at Essar’s Hazira facility. Harsco’s work is expected to begin in the third quarter of 2014.

India

Jindal to build new converter shop. Jindal Steel and Power Ltd. (JSPL) has contracted SMS Siemag for the delivery of an X-Melt® BOF converter shop including a secondary metallurgy centre and comprehensive environmental technology. In Angul, in the Indian state of Odisha, JSPL is building an integrated steel plant. In phase I, with two BOF units, the annual production will amount to 3.8 million t of high-quality steel. SMS Siemag’s scope of supply for the first phase will comprise two 250 t BOF converters, each equipped with a gas

cleaning and recovery plant, and three ladle furnaces and the entire X-Pact® electrical and automation systems. SMS ELEX will supply the primary gas cleaning system, which will include a gas conditioning system and a drytype electrostatic precipitator. SMS Mevac UK will supply a twin hot metal desulfurization plant and an RH vacuum degasser. In phase II, the converter shop is to be equipped with a third BOF converter complete with a gas cleaning plant and further secondary metallurgy equipment. The steel plant will cover a broad range of products – from high-grade ULC (ultra-low carbon) steel, API grades (X70) through to nongrain-oriented electrical grades.

India

Vandana Global orders dephosphorization facility. The Indian steel manufacturer Vandana Global has ordered a treatment stand for steel dephosphorization from Siemens Metals Technologies. The plant ensures compliance with new specifications mandated by the Bureau of Indian Standards (BIS)

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MPT International 4/2013

International industry news with regard to the maximum permitted phosphorus and sulphur content. It was developed specially for small and medium steel producers who obtain liquid steel from scrap and sponge iron via the induction furnace route and is being put to use for the first time ever in the world at Vandana. The plant will enable the company to offer higher-grade structural steels in future. Commissioning is scheduled for the beginning of 2014.

plant and auxiliaries. Inteco can build on experience from the implementation of the secondary metallurgy project No. 3 in 2005/2006.

Finland

Outokumpu starts up new ferrochrome works. Outokumpu inaugurated and started the ramp-up phase of its new ferrochrome works in Tornio. With the worldâ&#x20AC;&#x2122;s biggest ferrochrome furnace Outokumpu plans to double its ferrochrome production to 530,000 t by 2015. Outokumpuâ&#x20AC;&#x2122;s integrated stainless steel mill in Tornio includes a ferrochrome works, melt shop, hot rolling mill and cold rolling mill at the same site. The chrome mine in the neighbouring city of Kemi boasts the largest known chromite reserves in Europe. An integrated process from the mine to the stainless steel mills allows Outokumpu to improve energy efficiency of the mill, use molten ferrochrome and utilize carbon monoxide in the production. Outokumpu completed the investment ahead of schedule and below budget by the end of 2012.

Europe Austria

Voestalpine Stahl to build new secondary metallurgy equipment. Inteco has received an engineering contract from Voestalpine Stahl Linz for the secondary metallurgy project No. 4 to be implemented at the No. 3 LD steel plant. The Inteco project team will do the engineering activities mainly at the site of Voestalpine Stahl Linz. The project includes an RH vacuum system, a ladle furnace, an alloy

Germany

HKM to modernize continuous caster. Siemens Metals Technologies has received an order from HĂźttenwerke Krupp Mannesmann (HKM) to modernize continuous slab caster 1 in the Duisburg-Huckingen plant. The aim is to increase the production capacity of the plant from around one million to 1.1 million t/year of slabs and to improve the quality of the products still further. The plant will be fitted with a hydraulic mould divider for the production of twin slabs. Siemens will also design a new segment 1 and a new run-out area, both of which will be implemented in the second stage. The start-up of the casting plant is scheduled for the end of 2013. The entire conversion of the casting plant will take place during a scheduled ten-day plant standstill.

Germany

Alunorf to modernize hot rolling mill. Siemens Metals Technologies will supply the drive technology and the connection to the existing au-

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International industry news tomation system for the modernization of hot rolling mill No. 1 of Aluminium Norf GmbH (Alunorf), Neuss. The revamp will involve equipping the horizontal roughing stand with new screwdown systems and a new edger. Target of the measure is to increase production capacity. A roller table group in the rolling stand section will also be renewed. Siemens will supply the motors and drives, and connect them to the existing automation system, and will handle the entire installation and commissioning of the electrical components. The installation work is scheduled to be completed by January 2015.

Greece

Corinth Pipeworks orders largediameter pipe mill. Corinth Pipeworks in Athens has signed a contract with SMS Meer for the supply of a JCOE® large-diameter pipe mill for longitudinally welded pipes. With this investment, Corinth Pipeworks is expanding its product range in order to meet the growing worldwide demand

for high-strength pipes for oil and gas extraction and transit. The new mill will be able to produce longitudinal submerged-arc welded pipes with outside diameters from 18” to 56”, wall thicknesses up to 40 mm and pipe lengths up to 18.3 m in high-strength steel grades up to X100. The annual capacity will be 400,000 t. The new mill is scheduled for commissioning in the first quarter of 2015.

Romania

ArcelorMittal Galati launches GPGTI[ GHƂEKGPE[ RTQLGEV ArcelorMittal Galati in Romania has launched “Energize”, a project to increase energy efficiency and reduce associated costs. The first step of this project – which is already 90% complete – involves identifying the current levels of usage of electricity, fuel gases, steam, water, nitrogen, argon and other valuable resources. The second step is to identify solutions to increase energy efficiency. The resulting action plans cover a wide range of applications and

areas, from the energy-intensive steelmaking equipment and processes, to office activities. The plans involve all parts of the business: operations, maintenance, investment and purchasing.

Sweden

Ovako invests in new caster. Ovako has decided to invest in a new continuous casting machine at the steel mill in Smedjebacken. The existing continuous casting machine will be replaced over the next two years. The investment will provide the opportunity to continue to develop the product quality and size range. In addition, adjustments will be made in the rolling mills.

Turkey

Diler to modernize furnace dedusting system. Diler Demir Çelik has awarded Siemens Metals Technologies an order to modernize the dedusting plant at the company’s finger-shaft

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International industry news furnace in the Dilovası steelworks. With a diameter of 6.7 m, the fingershaft furnace in the electric steel plant has a tapping weight of 120 t. It was erected by Siemens and has been in operation since 2001. Depending on the operating mode of the furnace, the dedusting system will be able to clean between 1,400,000 and 1,500,000 m3 (stp) of gas after the modernization. In addition to cutting emissions, Siemens also aims to reduce the amount of volatile organic compounds in the exhaust gas by combining efficient postcombustion with rapid downstream cooling, thus avoiding the formation of new pollutants. The modernized dedusting plant is due to come on stream at the end of 2013.

Companies RHI’s Chapter 11 proceedings completed. In 2001, RHI divested all its U. S. companies due to soaring asbestos claims against its U. S. refrac-

tory companies. Now, after eleven years, the Chapter 11 proceedings of the companies deconsolidated in 2001 and the associated asbestos-related claims for damages have been definitively completed with full legal security. After expiry of the objection period and the fulfillment of conditions precedent, the reorganization plans of the U. S. companies have entered into force with effect from April 30, 2013. RHI will receive a payment of US$ 40 million from the former owner of one of the U. S. companies.

Vanitec launches improved website. Vanitec, a technical and scientific committee comprised of representatives of companies and organizations involved in the mining, processing, manufacture, research and use of vanadium and vanadium-containing products, has launched a new website (www.vanitec.org). The new website has been developed to provide those with a vested interest in vanadium – users, educators, students and producers – convenient access to in-

novative research, upcoming events, educational resources and technical publications regarding vanadium. Additionally, the site addresses and highlights the uses and benefits of vanadium across a range of applications, including steel, titanium and chemical. Currently the website is available in English and Chinese.

RHI acquires additional share in ORL. Following the acquisition of 43.6% of the share capital of Orient Refractories Ltd. (ORL) from the core shareholders in early March, RHI has completed the mandatory open offer for an additional 26% of the ORL shares. RHI now holds 69.6% of the voting rights in ORL.

Stainless steel centenary celebrations. The celebration of 100 years of stainless steel in the city of Sheffield, UK, which is the home of Harry Brearley, one of the key inventors of stainless steel in the 1910s, included a major international confer-

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International industry news ence and exhibition hosted by the Sheffield Metallurgical and Engineering Association (SMEA) and the British Stainless Steel Association. During the conference, Outokumpu CEO Mika Seitovirta addressed an audience of over 300 guests at Sheffield University on the theme of “Status of stainless steel in the world today”.

Siemens acquires Preactor. By acquiring the Preactor group headquartered in Chippenham, UK, Siemens will add new components to the Siemens Manufacturing Operations Management (MOM) portfolio. Preactor has been developing software solutions for efficient automated production planning processes for over 20 years. The company will be assigned to the Siemens Industry Automation Division. Preactor’s APS planning software is used to drive down production costs, boost productivity and improve adherence to delivery deadlines.

Timken establishes board strategy committee. The board of directors of The Timken Company has formed a strategy committee to evaluate a potential separation of the company’s steel business from its other businesses to review the company’s corporate governance and capital allocation strategy. The formation of the committee is in response to a nonbinding shareholder proposal. The committee has retained Goldman, Sachs & Co. to assist in its evaluation.

Schmolz+Bickenbach to implement strategic repositioning. As part of a strategy review supported by Roland Berger Strategy Consultants, the Schmolz+Bickenbach group has decided to focus its future business model more strongly on its production units in order to strengthen its leading position in the core tool steel, corrosion, acid and heat-resistant steels and engineering steel markets. The production units are DEW, Finkl, Sorel, Ugitech, Swiss Steel, Steeltec and Blankstahl. The group will in future be managed as an integrated entity by a management holding company in order to realize synergies between the units. The aim of the group’s repositioning is to bring 20

MPT International 4/2013

the company’s core production competencies further to the fore. This focus will also involve an evaluation of the group’s various activities.

will adopt the name Danieli Riverside Products.

German Steel Federation publishes study on ETS. The German ISSF presents 2013 sustainability award. The International Stainless Steel Forum (ISSF) presented this year’s sustainability award to Acerinox. Acerinox’ winning entry outlined how the company is recovering valuable raw materials from scale created during the stainless steel production process.

Outokumpu conducts strategic review of VDM. Outokumpu has started a strategic review of its high performance alloys or VDM business unit. During this review, Outokumpu will evaluate strategic options for VDM and consider how best to drive continued growth and profitability for the business, within or outside of Outokumpu. Outokumpu acquired VDM as part of Inoxum in 2012. The review is expected to be finalized before the end of the year.

Outokumpu plans new pricing model for alloys. Outokumpu plans to introduce an additional stainless steel pricing model – the Daily Alloy Surcharge that would build on the traditional Monthly Alloy Surcharge mechanism. The new Daily Alloy Surcharge model is designed to address the weaknesses of the monthly model as it would react far quicker to changes in the volatile alloy costs and decrease volatility and speculation. Outokumpu plans to start piloting of the Daily Alloy Surcharge model with select distributor and tubular customers in Europe during the summer to gain experience with the planned model.

Danieli acquires Riverside Products. Danieli has added to its recycling product portfolio with the strategic share buy-out of Riverside Products, Inc. The deal will see Danieli take control of primary facilities in Bettendorf IA, USA, and satellite operations in the United Kingdom and China. The Riverside product line and business units will be merged into the Danieli Centro Recycling division. The ongoing business

and European steel industries will continue to face inconsistent international climate policy conditions in coming years, even if CO2 emission trading systems are introduced in countries or regions outside the European Union. This is the result of a study carried out by the Cologne Institute for Economic Research Consult (IW Consult), commissioned by the German Steel Federation and the Düsseldorf branch office of the Industrial Union of Metalworkers (IG Metall). The study examined the development of emission trading systems and their significance for the steel industry in important competitor nations. Together with the European Union, the countries looked at – China, India, Japan, Russia, Australia, South Korea, Brazil and the USA – account for 87% of world steel production. Only Australia and South Korea have plans for binding national emission trading systems. Allocation of the CO2 certificates will be free-of-charge for the steel industries in these countries. Regional initiatives in the USA foresee no participation by the steel industry. Participation in Japan is voluntary. In other countries, such as Russia, there are no developments towards emission trading systems. Pilot projects in China and Brazil have only just started.

-QEJ * - GZRCPFU QHƂEG CPF workshop facilities. Koch H&K Industrieanlagen has completed its move into a new building in Dillingen/Saar. The reason for constructing the new building was the substantial growth of the company and the resulting increase in workforce. After two years in the previous building in Rehlingen – which Koch H&K had moved into in 2011 – space had been becoming tight again. Next to the office building, the company now has an adjacent storage and assembling area in which the plant components can be pre-assembled and tested. Simultaneously, the company changed its name to Koch H&K Industrieanlagen GmbH. This emphasizes the roots from which the two companies Koch H&K evolved.

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www.LAP- LASER.com

Siemens acquires Service Guide. Siemens Industry, Inc. has completed the acquisition of Service Guide, Inc., an Ohio-based company that has provided services for steel and aluminium mills since 1964. The agreement includes three of the companyâ&#x20AC;&#x2122;s four local operating facilities in Warren and Cortland, Ohio. The fourth facility, Oakes Foundry, will continue to be owned by the Oakes Family Trust. The acquired facilities provide the steel industry with repair and refurbishing services, as well as the manufacture and sale of spare parts and components.

Tenova acquires Technometal. Tenova has completed the acquisition of Technometal GmbH, a German company based in Duisburg. Technometal is a plantmaker with the ability to cover the full set of plants and services in the secondary metallurgy market, e. g. project studies, plant design, engineering, supply, commissioning, training and consulting. Technometal supplies equipment with capacities ranging from less than five to more than 300 t. This know-how allows Tenova to integrate and expand its product portfolio in ladle furnace, VD and VOD processes by including the refining equipment (RH) for the blast furnace/converter route.

ThyssenKrupp Metallurgical Products acquires BenMet NY. ThyssenKrupp Metallurgical Products GmbH has acquired the business of metal commodity trading company BenMet NY, headquartered in New York. With the acquisition, ThyssenKrupp Metallurgical Products is significantly expanding its activities in North and South America and widening its product portfolio appreciably. BenMet trades nonferrous metals and has a similar business model to ThyssenKrupp Metallurgical Products. Its product range comprises nickel, cobalt, cobalt oxide and minor metals and will be supplemented by the product portfolio of ThyssenKrupp Metallurgical Products. The company primarily supplies customers in the super alloys sector and the alloying and foundry industries. The raw materials are held in warehouses in the USA, Mexico and Canada.

MEASURING SYSTEMS FOR THE STEEL INDUSTRY

[THICKNESS]

[DIAMETER]

Fives acquires OTO Mills. Fives has signed an agreement to acquire OTO Mills, subsidiary of the Marcegaglia group. The Italy-based company supplies high-performance mills for the production of welded tubes and automation systems for the steel industry.

Personalities New AIST president. Terry G. Fedor II, U.S. Iron Ore Operations, Cliffs Natural Resources, Bentleyville, Ohio, has been appointed president of the Association for Iron & Steel Technology (AIST) for 2013 â&#x20AC;&#x201C; 2014. He succeeds past president, Kent D. Peaslee, F. Kenneth Iverson Steelmaking

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International industry news Chair, Missouri University of Science & Technology, Rolla, Mo., USA.

Corporation of America. Sam Siegel worked alongside Ken Iverson to build the company. He retired in 1999 and left the board of directors in 2001.

New general manager of Metalscan. Bruno Lebrun is the new general manager of Metalscan in France. Metalscan is a company of the Tecnatom group.

Management appointments at Steel Dynamics. Robert A. Simon has been appointed to the position of vice president and general manager of Steel Dynamicâ&#x20AC;&#x2122;s Structural and Rail Division. The position became vacant following John Nolanâ&#x20AC;&#x2122;s assumption of the newly created position as vice president â&#x20AC;&#x201C; product development.

Nucor remembers former CFO, vice chairman and director Sam Siegel. Sam Siegel, a key figure in the history of Nucor Corporation, passed away Sunday, June 2. Siegel joined the company in 1961 as an accountant when it was still Nuclear

Management board changes at RHI. Management board members Giorgio Cappelli, chief sales officer steel division, and Manfred HĂśdl, chief sales officer industrial division and chief technical officer, have resigned from the management board of RHI by mutual consent.

U. S. Steel elects new president. The board of directors of United States Steel has elected Mario Longhi to the position of president. Longhi will retain his current role as chief operating officer and assume additional responsibilities for risk management and human resources.

0GY +55( QHĆ&#x201A;EG DGCTGTU GNGEVGF The International Stainless Steel Forum (ISSF) has elected Philippe Darmayan,

chief executive officer of Aperam, for a two-year term. Bernardo VelĂĄzquez of the Acerinox group and Sea-Suh Young of Posco have been elected as vice chairmen. Mika Seitovirta, president and CEO of Outokumpu, has been re-elected as ISSF treasurer for the coming year.

Executive changes at U. S. Steel. United States Steel has appointed Christine S. Breves to the position of vice president and chief procurement officer. Michael S. Williams has been appointed senior vice president â&#x20AC;&#x201C; strategic planning and business development, assuming the responsibilities of David H. Lohr who plans to retire later this year.

Changes on the board of Cliffs Natural Resources. Francis McAllister has elected to retire from Cliffs Natural Resourcesâ&#x20AC;&#x2122; board of directors effective immediately. McAllister has served on Cliffsâ&#x20AC;&#x2122; board since 1996, most recently as lead director. The board elected James F. Kirsch, former chairman, president and chief exec-

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MPT International 4/2013

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International industry news utive officer of Ferro Corporation, to be its new lead director.

Health and safety expert joins Fine Tubes. Fine Tubes has appointed David Richardson as health, safety and environmental manager. Fine Tubes is committed to providing and maintaining a safe and healthy working environment for all its employees and visitors.

Deutsche Edelstahlwerke with new board chairman. Johannes Nonn, CEO of Schmolz+Bickenbach, who has been holding the position of chairman of the board of management at Deutsche Edelstahlwerke on an interim basis since February 2013, will withdraw from this position in order to focus on leading the entire group. His position of chairman of the board of management will be filled by Dr. Martin LĂśwendick. He has been a member of the board since February 2013 and is the head of the sales department.

Changes to Aperamâ&#x20AC;&#x2122;s board of directors. The board of directors of Aperam has decided to co-opt Joseph Greenwell as director until Aperamâ&#x20AC;&#x2122;s next general meeting of shareholders, where Greenwellâ&#x20AC;&#x2122;s election will be submitted for confirmation to the shareholders. This decision follows the resignation of David Burritt from the board for personal considerations.

Outokumpu renews leadership team. Outokumpu has implemented changes in its leadership team in order to further accelerate production optimization and capacity reductions. Jarmo Tonteri will lead the business areas Stainless Coil EMEA and HighPerformance Stainless and Alloys. This will enable the company to tap into additional synergy opportunities between these business areas. Ulrich Albrecht-FrĂźh, the current head of business area Stainless Coil EMEA, will leave Outokumpu. As part of these changes Outokumpu will conduct a strategic review of its cold rolling and

precision strip operations in Nyby and Kloster, Sweden, and in DahlerbrĂźck, Germany, with the aim of reducing production capacity and achieving further cost savings through increased efficiencies. Decisions based on the strategic review are expected to be made by the end of 2013.

Broner Metals names global sales director. Broner Metals has named Mark Ferguson as its new global director of sales. Ferguson will be responsible for leading Bronerâ&#x20AC;&#x2122;s worldwide sales team.

New president of Nickel Institute. Tim Aiken is the new president of the Nickel Institute. He brings with him experience at Nickel Institute member company Anglo Platinum and as former chair of the board of the Nickel Institute.

ABB names new CEO. The board of ABB has unanimously appointed

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MPT International 4/2013

International industry news Ulrich Spiesshofer, the head of its Discrete Automation and Motion (DM) division, as chief executive officer. He will succeed Joe Hogan in this role in an orderly transition on September 15, 2013. Hogan will continue with ABB for some months as senior advisor to the board.

Outotec appoints new member to executive board. Outotec has appointed Olli Nastamo as senior vice president, operational excellence, and member of the executive board. His responsibilities will include enterprise architecture and operating model, business processes and organization structures, QEHS systems and practices, information management and some other global services. Olli Nastamo joins Outotec from Comptel Corporation.

Joseph Carrabba as chairman. Carrabba will continue to serve as president and CEO and a director of the company until a successor has been elected.

U. S. Steel names general manager – engineering projects. David E. Hathaway Jr. has been advanced to the position of general manager – engineering projects of United States Steel Corp. In this position, he oversees engineering projects at all North American U. S. Steel facilities.

U. S. Steel executive vice presiFGPV CPF EJKGH ƂPCPEKCN QHƂEGT to retire. Executive vice president and chief financial officer Gretchen R. Haggerty plans to retire in 2013 after 37 years with the company. U. S. Steel is undertaking a comprehensive search for a new chief financial officer.

Cliffs Natural Resources’ president and CEO to retire. Joseph Carrabba plans to retire as Cliffs Natural Resources’ president and chief executive officer by the end of 2013. James Kirsch, who currently serves on Cliff’s board as lead director, has been elected non-executive chairman of the board, effectively immediately, replacing

Executive retirement at AK Steel. Albert E. Ferrara, Jr. has retired from AK Steel. He served AK Steel for more than a decade, principally as senior vice president and chief financial officer and, most recently, as senior vice president of corporate strategy and

investor relations. Following Ferrara’s retirement, the company’s investor relations activities will be managed by Roger Newport, AK Steel’s vice president and chief financial officer, with assistance from Doug Mitterholzer, AK Steel’s assistant treasurer.

ThyssenKrupp to mourn for Berthold Beitz. The honorary chairman of the supervisory board of ThyssenKrupp AG and chairman of the board of trustees of the non-profit Alfried Krupp von Bohlen und Halbach Foundation died on July 30, 2013 at the age of 99. During World War 2, together with his wife, he saved hundreds of persecuted Jews from the Nazis, risking his own life in the process. Berthold Beitz was brought to Krupp in 1953 by Alfried Krupp von Bohlen und Halbach to be his personal chief executive. After Alfried Krupp died in 1967, Berthold Beitz was named executor of Krupp’s will and in 1968 became chairman of the board of trustees of the Alfried Krupp von Bohlen und Halbach Foundation, which todays owns 25.3 percent of ThyssenKrupp. His great acts of humanity also shaped the corporate culture and social relations at ThyssenKrupp.

STAHL 2013 28 November 2013 Düsseldorf, Germany Organizers: Steel Institute VDEh and German Steel Federation www.stahl-online.de 2013 has been an eventful year so far. Only in retrospective will it be possible to judge the purport of many of the developments we have been witnessing this year. Will the euro regain its strength despite the depth crisis? Will the economy continue to be faced with a volatile political environment? Will the structural change taking place in the European steel market also change the steel industry in Germany in the long run? Amidst the context of both, an increasingly volatile global economic

MPT International 4/2013

environment and shortening cycle times of technological innovations, “Steel in Motion”, the motto of this year’s STAHL conference, is a perfect summary of the present situation. This year, the number of sessions (“Talks about steel”) has been increased to eight. The speakers will address the following topics: - Energy turnaround and industrial competitiveness in an international context - The city of tomorrow – Challenges for steel - New plants and processes

- Protectionism in raw materials and steel trading - The industrial location of Germany in the European context - How steel contributes to a lowcarbon Europe - Brussels’ clean air objectives – Demands beyond feasibility? - New developments in forming technology The conference day will be closed with the traditional “Steel get-together”, where participants have the opportunity to socialize and exchange ideas in a casual atmosphere.

W E

Events 24 â&#x20AC;&#x201C; 26 September 2013 Qingdao, China Organizers: China Iron & Steel Ass.; MC-CCPIT www.ironoreconference.com

C O N V E Y

Q U A L I T Y

Hot Solutions for the Iron and Steel Industry

13th China International Steel & Raw Materials Conference. Topics covered by this conference include: status quo of Chinaâ&#x20AC;&#x2122;s steel industry, analysis of the global iron ore market, iron ore production in China, dry bulk shipping market outlook, Chinaâ&#x20AC;&#x2122;s port capacity expansion, etc.

26 â&#x20AC;&#x201C; 28 September 2013 Bangalore, India Organizers: Indian Institute of Metals; Koelnmesse www.metex-india.com

MetEx India 2013. The 3rd International Exhibition on Metal, Materials and Metallurgical Technology, Equipment and Supplies will showcase products and services for the metals and associated industries. The conference on â&#x20AC;&#x153;Emerging trends in materials and processing technologiesâ&#x20AC;? will be held concurrently with the fair.

16 â&#x20AC;&#x201C; 18 October 2013 Beijing, China Organizers: Beijing Hiven Exhibition www.bcime.com

CIMIE 2013. The 10th China International Metallurgical Industry Expo will run concurrently with exhibitions on heat treatment and furnaces, on foundry equipment and on refractory materials.

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10 â&#x20AC;&#x201C; 12 November 2013 Lima, Peru Organizers: Alacero www.alacero.org

Alacero-54. The 54th Annual Congress of the Latin American Steel Association will comprise four sessions: raw materials and energy, global economy, driving forces of steel consumption in Latin America, and the global steel market.

7 â&#x20AC;&#x201C; 9 May 2014 Milan, Italy Organizers: AIM www.aimnet.it

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ICRF 2014. The 2nd International Conference on Ingot Casting, Rolling and Forging will provide a forum for researchers and manufacturers involved in conventional ingot casting through to remelting processes for high steel cleanness and also rolling and forging technologies.

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MPT International 4/2013

Germany based SMS group â&#x20AC;&#x201C; a group of companies in metallurgical plant and machinery construction â&#x20AC;&#x201C; generated an order intake in business year 2012 of 2.835 billion euros (2011: 3.423 billion euros). Sales increased by 5% to 3.237 billion euros (2011: 3.070 billion euros). Acquiring a majority share in Luxembourg company Paul Wurth at the end of 2012 means that the group added roughly 500 million euros to the total order volume. That produced a net group result of 258 million euros (2011: 265 million euros), almost matching the previous yearâ&#x20AC;&#x2122;s level. Both business areas of the group, SMS Siemag and SMS Meer, clearly felt the impact of customersâ&#x20AC;&#x2122; restraint in placing orders. Specifically, order intake by SMS Siemag contracted by 24% to 1.519 billion euros (2011: 2.007 billion euros). SMS Meer experienced a decrease by 16% to 1.152 billion euros (2011: 1.365 billion euros). The Elexis group contributed an unchanged order intake of 180 million euros to the group. On average over 2012, the number of employees in the SMS group â&#x20AC;&#x201C; including apprentices â&#x20AC;&#x201C; was 11,822 (2011: 10,477). Due to the acquisition of the majority share in Paul Wurth, the number of employees in the SMS group increased to a total of 13,588 at the end of 2012. Paul Wurth will continue to operate as an independent company within the SMS group. Numbering more than 1,500 employees and 25 subsidiaries, it ranks among the worldâ&#x20AC;&#x2122;s leading producers of blast furnaces, coke oven plants, and green technology for metallurgical plants. The product ranges of Paul Wurth and especially SMS Siemag complement each other perfectly. That is why Paul Wurth is associated organizationally with the business area SMS Siemag. The merger creates a solid basis for future growth.

/CTMGVU Dr. Heinrich Weiss, who lead the SMS group for the last 45 years, stated: â&#x20AC;&#x153;Despite a persistent reluctance of our customers to invest, we expect a slight recovery on the market by the end of the year. Based on the continued high level of orders in hand, and taking into account the effects of the first full year of consolidation of the Paul Wurth group this year, we anticipate a modest increase in sales compared to 2012, but a decline in profit.â&#x20AC;? Characteristic of the market for metallurgical and rolling mill plants in 2012 was a cautious mood. Struggling with a difficult profit situation, many steel producers waited to see how the market would develop and postponed project activities. Furthermore, ongoing purchasing processes for existing metallurgical plants in North America and Brazil are blocking other investment decisions by some key accounts. Still unchanged, the main sales markets are the developing and threshold countries. +PXGUVOGPVU While continuing its dual strategy of globally networked manufacturing, SMS group remains committed to producing the most complex components of its machinery and plants in its own workshops in Germany. The company invested heavily over recent years in expanding and upgrading its facilities in Hilchenbach and MĂśnchengladbach. Yet, parallel to these measures, it expanded its production capacity in China. Here it is mainly about better customer service on the ground as well as special products designed for the Chinese market, both can be produced at a competitive price locally. Overall, SMS group is further improving productivity and cutting manufacturing costs by optimizing design engineering and manufacturing logistics.

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%QORCP[ RTQƂNG Equally important is intensifying onthe-job training and qualification of experienced core personnel as well as training new staff. “Carrying out these activities,” says Heinrich Weiss, “means we strengthen our ability to supply both high-tech and low-cost plant and machinery. That will enable our customers to produce even more competitively. We are also expanding our presence outside Europe by hiring qualified personnel as well as building production and service facilities in our key markets of China and India. This is how we will be able to meet demands

in China for a locally-produced share of supplies without increasingly losing these types of orders to local competitors.”

%JCPIGU KP VJG UWRGTXKUQT[ DQCTF CPF OCPCIKPI DQCTF With effect from July 1, 2013, Heinrich Weiss, who has been responsible for the development and leadership of the group of companies for the last 45 years, has resigned from his post on the managing board and hence will chair the

supervisory board of the family owned SMS group. Dr. Joachim Schönbeck, who was already a member of the managing board, was appointed to represent the company externally with effect from July 1, 2013. Jointly with Burkhard Dahmen and Eckhard Schulte, he continues to constitute the management of SMS GmbH. Dr. Joachim Schönbeck is still primarily responsible for SMS Meer as before, Burkhard Dahmen is responsible for SMS Siemag (including the Paul Wurth majority holding), and Eckhard Schulte is the CFO of the group. #

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MPT International 4/2013

Ironmaking

ArcelorMittal Kryvyi Rih repairs blast furnace in record time ArcelorMittal Kryvyi Rih, the largest producer of rolled steel GL 3IP?GLC F?Q jLGQFCB RFC overhaul of its blast furnace number seven after just 26 days. A total of 17 operations were performed on the blast furnace. Similar overhauls have taken up to eight months in the past. Blast furnaces have been recognized as an area that can NPMTGBC QGELGjA?LR AMQR Q?TGLEQ for ArcelorMittal’s new US$ 3 billion management gains plan.

“In April we accomplished a category two overhaul repair of our blast furnace No. 7. During this period, the furnace remained idle for four weeks (19 days of repairs and seven of commissioning operations). We were using only two blast furnaces in this period, but this did not affect our production performance in April,” said Paramjit Kahlon, ArcelorMittal Kryvyi Rih chief operating officer. He added that cold repairs to the two-bath steelmaking vessel in the open-hearth plant and repairs to the

- cooling plates on the blast furnace stack, - repairs and relining of hot-metal runners and scum gutters, - implementation of rust protection on high-line bunkers, - new metal structures on the bin trestle, - cleaning of blast furnace structures, - replacement of the water supply system, aspiration, ventilation, and water wash, - repair works on screens, replacement of skip hoists. Similar overhauls have taken up to eight months in the past. However, this overhaul, which was on a bigger scale, was completed in 20 days.

Improvement through training

Figure 1. Blast furnace No. 9 at ArcelorMittal Kryvyi Rih after repair

ArcelorMittal Kryvyi Rih, Kryvyi Rih, Ukraine Contact: www.arcelormittal.com/kryviyrih

MPT International 4/2013

return-stream apron conveyor number one in the sinter shop number one also started in April. The biggest part of the project came with the replacement of the charging equipment – this will prevent skull formation on the blast furnace in future. A double-bell distributor with a calibration device from Taratov was also installed in the blast furnace – a first for the plant. This will reduce coke consumption equivalent to around 25 kg per tonne of hot metal. Other repair processes also included: - replacement of the closing machine for the iron tapping holes,

ArcelorMittal Kryvyi Rih recently held training sessions on keeping temperatures stable in blast furnaces. Part of the course was dedicated to ‘chilled hearths’, one of the most serious disruptions that can happen in a blast furnace plant. The training sessions lasted for three days and gathered 18 blast furnace operators at Kryvyi Rih. “Training will help improve the efficiency of blast furnace management which in turn will reduce coke consumption in the blast furnace process, achieve stable and low silicon content in hot metal and reduce overall cost of hot metal production,” said Vincent Cholet, chief technology officer of ArcelorMittal Kryvyi Rih. Blast furnaces have been recognized as an area that can provide significant cost savings for ArcelorMittal’s new US$ 3 billion management gains plan. The plan was presented at the Investor Day 2013, on March 15, 2013 by group management board member Louis Schorsch. Blast furnaces have been made a priority for this plan with savings expected through reliability, end-of-campaign management, fuel rate, etc. In general, yield, productivity, and energy are recognized as the main drivers for cost savings in the gap analysis. #

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Dimension

Ironmaking

IronArc to revolutionize hot metal production A new method for producing hot metal has been developed in collaboration with the Swedish steel group Ovako at the Hofors steel plant. The method, called IronArc, lowers CO2 CKGQQGMLQ QGELGjA?LRJW compared with blast furnace production. The two-stage reduction process achieves high CLCPEW CDjAGCLAW RFPMSEF ? AMK@GL?RGML MD FC?R CLCPEW QSNNJW TG? NJ?QK? ECLCP?RMPQ and internal combustion of the NPMACQQ E?QCQ @W U?W MD ? LCUJW developed reactor concept.

Figure 1. IronArc pilot plant (Picture: Matej Imris)

“There is a good prospect that ‘IronArc’ will become a competitive alternative to the blast furnace, which at present is definitely the dominant iron production process,” says Gert Nilson, technical director at Jernkontoret, Sweden. “Apart from the decrease in CO2 emissions, the process provides the environmental benefit of removing the need for coking and sintering plants, with the coking plants having the highest environmental impact.” When the iron oxide material undergoes direct smelting, during the first stage of the process (figure 2), its physi-

cal properties during heating and reduction have no significance. This makes it possible to recover other metals from secondary products of the steel plants. This affords significant environmental benefits, since better recovery of byproducts implies reduced need for virgin raw materials. The IronArc method has been verified on pilot scale at ScanArc Plasma Technologies in Hofors, Sweden. The next planned stage in the development work is a demonstration plant for production on a scale of 40,000 t/year. The demonstration plant is primarily intended for reprocessing by-products such as oxide scales and grinding dust into new metallurgical raw material, but it will also be used for testing iron extraction from different ores. “This is an eagerly awaited technological breakthrough – production of hot metal with reduced emissions of greenhouse gases,” underlines Bo-Erik Pers, chief executive of Jernkontoret. “It is a welcome proof that the Swedish steel industry retains its position on the front line, with constantly optimized process technology, highly advanced products and the provision of specialist services.” #

ScanArc Plasma Technologies AB, Hofors, Sweden; Jernkontoret, Stockholm, Sweden Contact: www.scanarc.se E-mail: mail@scanarc.se

Figure 2. Schematic illustration of the plasma-powered reduction system MPT International 4/2013

Figure 1. 1.6 million t/year Energiron DR plant and adjacent steelmaking plant at Emirates Steel (picture by courtesy of Danieli)

Higher DRI quality and higher EAF yields by optimized DRI making The Energiron technology eliminates the need for an external gas reformer by carrying out the reforming, reduction and carburization reactions within the same furnace. The resulting DRI product is highly metallized and with comfortable carbon levels. Due to this carbon and application of modern oxygen practices, the yield of the subsequent EAF meltshop is QGELGjA?LRJW FGEFCP RF?L SQS?J

Pablo Duarte, Thomas Scarnati, Tenova HYL, Monterrey, Mexico; Alessandro Martinis, Danieli & C., Buttrio, Italy Contact: www.tenova.com E-mail: thomas.scarnati@tenova.com

MPT International 4/2013

Introduction For several decades, commercially available gas-based direct reduction technologies had been characterized as having a natural gas reforming unit and a reduction furnace for carrying out the removal of oxygen in iron ores to produce direct reduced iron (DRI). Since the late 1990s, Tenova HYL has been implementing an improved technology in which the natural gas reformer was eliminated and the combined reforming, reducing and carburization reactions are carried out in the reducing shaft furnace. This type of technology, known as in-situ reforming, is fast becoming the standard for advanced direct reduction technologies and is currently marketed worldwide as the Energiron ZR process. Energiron is the innovative HYL direct reduction technology developed jointly by Tenova and Danieli. The two major commercial DR technologies both have configurations using a natural gas reformer. To date, many DR plants worldwide have used this type of configuration. However, there are two key differences between the technologies. The

first one is that the Energiron process can use but does not require a gas reformer. If a gas reformer is used in an Energiron plant, it is independent of the reduction circuit and does not have spent reducing gas recycled back to the reformer. The other difference is that the Energiron process is a pressurized operation, while conventional processes operate at ambient pressure. This ability to produce DRI in a completely independent reduction circuit provides significant advantages in terms of efficiency, reliability and operating costs as well as increased product quality. This in turn leads to a better reduced iron product for making steel in an electric arc furnace meltshop or other steelmaking unit.

Pressurized operation A key aspect of the Energiron technology is that the process operates at high pressure. The reactor is a pressurized vessel in which the solids travel downward by gravity while getting into contact with the gases flowing in counter-

Ironmaking current. As a result of the reduction of the oxygen from the iron ore feedstock, DRI is produced. Usually, the reactor operates at a pressure of 6 – 8 bars. For this reason, the reactor has a series of mechanical seals allowing for the iron ore to be charged and DRI discharged. The reactor charge and discharge are carried out by interphase bins which operate alternately at the same pressure as the reactor or at atmospheric pressure depending on the stage of the charging/discharging sequence at a given time. This high-pressure operation results in major advantages, including smaller relative sizes for plant equipment (reactor size, compressors, piping, etc.) as well as lower gas velocities inside the reactor and consequently better yields (lower iron ore requirements, lower gas consumptwion, etc.). Specifically, the benefits of the high operating pressure of an Energiron plant can be summarized as follows:

cess requires only 60 – 75 kWh/t of product, power consumption for ambient processes start at 95 – 110 kWh/t.

Iron ore consumption All of these factors resulting from the pressurized operation have a positive economic effect on plant operating expenses. One significant item is reduced iron ore consumption. It was decided therefore to compare theoretical calculations for iron ore consumption in both pressurized and non-pressurized systems, and then compare the calculated values with actual operating results for validation.

plants, it is normal practice to feed iron ore screened at less than 6.3 mm. More fines inside the shaft have no impact because any additional pressure drop simply implies additional and marginal pressure increase through the recycling gas compressor. In contrast, it is not possible to routinely feed iron ore screened below 6.3mm to low-pressure processes, typically operating at 1.2 bar and with gas sealing systems. Having more fines inside the shaft will imply higher pressure, which, in order to prevent gas sealing disruptions, requires decreasing the gas flow to the shaft, thus reducing the productivity of the DR plant.

Lower iron ore consumption per t of DRI. This is because the high operating pressure implies low gas velocities of 1.9 – 1.4 m/s, which in turn implies low fluidization and low dragging force. This results in less fines carry-over by top gas (1% losses in top gas), based on actual data from operating plants. On the contrary, for ambient pressure DR process plants, the gas velocities are typically 4.8 – 5.1 m/s, resulting in 2 – 2.5% of the fines being lost to the top gas. Figure 2. Iron ore consumption vs. DRI quality (no losses considered 68% Fetot)

Better use of iron ore fines. Feeding fines of less than 6.3 mm or using friable iron ore implies more fines inside the shaft, thus a higher pressure drop. The Energiron plant simply requires more compression with no other impact, whereas the ambient system requires either avoiding the use of this material or decreasing the gas flow to the furnace, thus reducing the production rate. Greater plant capacity/size ratio. With smaller equipment comes an overall smaller plant footprint, resulting in a more compact and efficient DR plant layout. For example, an Energiron ZR process plant can produce up to 2.5 million t/year of DRI in a reactor of just 6.5 meters inner diameter, whereas a process operating at ambient pressure requires a significantly larger reactor size – with 30% less production capacity. Lower power consumption is a further benefit. While the pressurized pro-

Iron ore consumption in DR processes is affected by: - material and dust losses during handling, - screening, - DR quality (metallization and carbon), - carry-over of dust into the DR shaft during reduction and cooling (for cold discharge). Iron ore loss occurring during handling and storage depends on the arrangement, transfer points, dust collection system, storage procedure, etc. and is independent of the DR technology. The other three factors (screening, DR quality and dust carry-over) depend on the DR process being used. Screening. The first process-related reduction in iron ore comes from the screening of the iron ore prior to its feeding into the furnace vessel. Due to the high operating pressure (6 – 8 bar) and the mechanical sealing in Energiron

DR quality. The next process-related aspect affecting iron ore yield is the DRI quality being produced, measured in terms of metallization and carbon. Iron ore consumption, as a result of DRI quality, is simply a function of mass balance. In general, higher Fetot requires more ore. For the same iron ore (Fetot), higher metallization requires more ore. Higher carbon content in DRI requires less iron ore, since part of the mass in the product comes from the carbon addition through the gas. Considering 1.35 as the standard “theoretical” value for the oxide/DRI ratio, this is based on a metallization of 94% and carbon share of 2.5%. It is certainly not an absolute limit since carbon can be – at least for Energiron technology – much higher. For the production of hot DRI, the carbon limit of a non-pressurized DR process is around 1.8%. When increasing to 2.4% C, the productivity is decreased to avoid lower metallization due to burden MPT International 4/2013

Ironmaking

Figure 3. Energiron ZR material balance from iron ore to liquid steel

cooling. For cold DRI, the limit is in the 2.6 to 2.8% range. However, in the Energiron ZR process, higher carbon (more than 4% C) for both cold and hot DRI can be easily achieved. Simply because of higher carbon DRI and the principle of conservation of mass, there is no possibility for the conventional, low-pressure process to achieve lower iron ore consumption. Figure 2 shows the mass (t) of iron ore required per t of DRI based on the DRI carbon content for both hot and cold DRI at different metallization levels. It is obvious that, for example, a DRI of 94% metallization and 2.5% carbon will require 1.35 t of iron oxide pellets to produce 1.0 t of DRI; however, as the metallization and/or carbon levels increase, the required amount of iron ore pellet decreases accordingly. Dust carry-over. In the DR shaft furnace dust carry-over by the top gas (and/or exit cooling gas) is due to dragging force, which is mainly a function of particle size and characteristics, as well as gas characteristics and velocity. Gas velocity depends on the operating pressure and determines the fluidization of the solids bed. The higher the operating pressure, the lower the gas velocity, the lower the dragging force, the less dust carry-over and thus the lower the iron ore consumption. Fluidization of the solids bed depends on gas conditions such as pres36

MPT International 4/2013

sure, temperature and molecular weight and limits the amount of gas that can be blown through the solids bed. If the gas velocity is too high, the gas will have enough energy to initially suspend the bed and prevent gravity flow, and if the gas velocity is further increased, it will have enough energy to fluidize the bed. The velocity that causes the suspension of the bed is called minimum fluidization velocity. It can be calculated. Fluidization is inversely proportional to the operating pressure. A fluidization factor f = 1 is the limit and upper values imply fluidization of the solid particles. For f = 1, the limit for the ambient-pressure technology are particles ~ 6 mm, while for Energiron the limit is ~ 2.5 mm. The iron ore particles which can be carried over by the top gas in the unpressurized reactor are twice the size of those of Energiron, which means that more than 2% of iron ore particles will be carried over in the other process shaft furnace. Based on the principle of conservation of momentum, there is no chance for the unpressurized process reactor having lower fines carry-over (higher iron ore consumption) than Energiron. Yield. Taking into consideration the factors of pressurization, product quality and fines losses, we see that both the theoretical and actual values for Energiron technology are the lowest avail-

able. These theoretical values are backed by actual plant operations data from the Ternium 4M plant (1.367 t per t DRI), Ternium 3M5 plants (1.363 t per t DRI), ESI1 plant in Abu Dhabi (1.379 t per t DRI) and the GSPI plant in Abu Dhabi (1.357 t per t DRI). These operational results have proven that this process requires less iron ore than the unpressurized process.

Higher yield during subsequent steelmaking The benefit of higher DRI production, at lower cost and with higher quality, means also a significant benefit to the EAF shop. The ability to provide highquality DRI with high levels of combined carbon in the form of iron carbide, combined with modern oxygen practice, provides significant chemical energy to the EAF. This makes steel production more efficient in terms of tap-to-tap times, and more economical in terms of electrical power and electrode consumptions. Figure 3 shows the overall material balance from iron ore to liquid steel for an Energiron ZR process plant, based on DRI production of 94% metallization and 3.7% carbon. Just in terms of the DRI plant output, there are savings of 0.05 t of iron ore per t of DRI (1.40 t for unpressurized process vs. 1.35 t for Energiron). In the EAF, the combination of highcarbon DRI at high temperature yields a

Ironmaking ESI-I plant, Abu Dhabi

Cold DRI practice

Hot DRI practice

Charge temperature

30Â°C

600Â°C

Productivity

148 t/h

196 t/h

El. energy consumption

550 kWh/tls

< 400 kWh/tls

Oxygen consumption (stp)

38 mÂł/tls

Electrodes consumption

1.6 kg/tls

1.4 kg/tls

Tap-to-tap time

61 min

< 46 min

Charge mix

95% cold DRI, 5% scrap

90% hot DRI, 10% cold DRI

Table 1. Comparison of hot DRI vs. cold DRI use at ESI-1 plant, Emirates Steel, Abu Dhabi

power decrease of more than 160 kWh/tls and a productivity increase of up to 22% for a practice of 90% hot + 10% cold DRI (as compared to cold, low-carbon DRI). As compared to scrap, melting DRI in the EAF normally demands more power because of DRI gangue content. However, the difference almost becomes zero when comparing the melting of 100% scrap vs. 100% high-carbon, hot DRI in the EAF. For both cases, the power consumption ranges from 360 â&#x20AC;&#x201C; 400 kWh/tls. Table 1 shows the production figures in case of Emirates Steel (ESI) in Abu Dhabi, comparing the savings and productivity increase using hot DRI instead of cold DRI. It is up to each steelmaking operation to calculate the value of such savings in kWh, electrodes and tap-totap times as well as the approximately 32% increase in productivity. However, it is obvious that the combined savings for Energiron DRI production and EAF melting of hot, high-carbon DRI are significant. In addition to the savings on the DR plant side, it is easy to see that the combination of the Energiron process at high pressure, producing DRI of the highest quality and carbon content, allows steelmakers to produce high-quality steel at significant cost advantages over any other option on the market today.

Figure 4 shows a comparison of the total costs for making 1 t of liquid steel starting from iron ore, using the Energiron process and an ambient pressure technology. Both DRI products considered have 94% metallization and are charged hot to the EAF at 600Â°C. The Energiron product has a carbon content of 3.7% vs. 2.0% for the ambientpressure process. When comparing processes, the Energiron ZR technology affords clear operating cost benefits for EAF steel production, basically due to: - less fines losses and less screening (less ore consumption), - overall lower energy consumption in terms of natural gas and power, - higher benefits in EAF operation due to high-carbon DRI.

Summary The benefits of the Energiron direct reduction technology have allowed for significant advantages not only in the production of DRI, but also in steelmaking. Theoretical calculations are backed by actual operational data to show important savings in iron ore consumption by using a high-pressure reduction system. By taking advantage of the pres-

Figure 4. Comparative DRI & steel production costs for hot DRI charged to the EAF

surized operation, resulting in smaller plant and equipment size as well as increased process dynamics, the Energiron process actually uses fewer raw materials per t of DRI produced. At the same time, the DRI is unique in that it contains the highest levels of carbon content in the form of iron carbide. This is a natural effect of the process because of the in-situ reforming and reduction reactions taking place, and it naturally produces the best DRI quality for EAF steelmaking. Results in operating steel mills reflect the achievable savings on consumptions and the increased productivity resulting from the use of hot, high-carbon DRI in steelmaking. #

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Steelmaking

Liquid steel production at Outokumpu Stainless in Calvert, Alabama, USA At the beginning of April 2013, Siemens Metals Technologies U?Q ?U?PBCB RFC jL?J ?AACNR?LAC ACPRGjA?RC DMP RFC stainless steel works owned by Outokumpu Stainless in the USA. The plant was constructed in Calvert, Alabama, and went into operation in November 2012. The scope of supply from Siemens included an electric arc furnace, an AOD converter, secondary metallurgical facilities, and a continuous slab caster.

Siemens AG, Industry Sector – Metals Technologies, Linz, Austria Contact: www.siemens.com/metals E-mail: rainer.schulze@siemens.com

The new stainless steel works was constructed on a “green field” site near the port of Mobile, Alabama. The plant is designed to produce one million tons of AISI 200, 300 and 400 grades of stainless steel per annum. In 2008 Siemens received the order from ThyssenKrupp Stainless to equip the plant. Initially the idea was to process the stainless steel slabs in the adjacent rolling mill of ThyssenKrupp Steel USA. Later, ThyssenKrupp transferred its stainless steel activities to Outokumpu in 2012. At the new Calvert stainless steel works, liquid steel is produced in an electric arc furnace (EAF) with a tapping weight of 160 tons (figure 1). The steel is then further processed in a 180 ton AOD converter (AOD: argon oxygen decarburization, figure 2) and a ladle treatment station. Integrated basic automation and a Level 2 process optimization system ensure that all components of the plant interact optimally. In order to minimize the environmental impact, Siemens installed an off-gas dedusting system with pulse-jet filters for the electric arc furnace and the AOD converter plants. Siemens also supplied the whole single-strand continuous slab caster for the casting section. The bow-type caster has a casting radius of 9 m and a straight mould. It is designed to produce slabs ranging in width from 800 to 1,900 mm and thicknesses from 180 to 240 mm. The casting speed is 1.3 m/min.

Figure 1. EAF plant at Outokumpu Calvert, AL/USA

MPT International 4/2013

Plant produces stainless steel grades up to AISI 400 The plant produces stainless steels of AISI quality grades 200, 300 and 400 for a wide range of applications. The casting plant features a number of technology packages to assure the internal and external quality of the slabs. These include a mould level control, a breakout detection system, a hydraulic mould oscillator and a system to adjust the width of the slabs. The strand containment is equipped with smart segments. The combination of the Dynacs cooling system with internally cooled I-Star rollers offers maximum flexibility in secondary cooling. The scope of supply also includes the complete basic and process automation, as well as machines for weighing the slabs. End of July 2013 Outokumpu has reported, the melt shop ramp-up continues to proceed ahead of plans as the production has expanded to cover both standard austenitic and ferritic grades as well as widths ranging from 914 to 1,828 mm (36 to 72 inches) wide. In addition, the melt shop is underway producing non-standard grades, which is showing good results. The produced slabs and black hot band will be used in the Calvert mill and black hot band will also be delivered to the Outokumpu mill in Mexico. #

Figure 2. AOD converter plant

Steelmaking

Current technology trends in steelmaking Under the roof of German Steel Institute VDEh the Steelmaking Committee is organizing QAGCLRGjA ?LB RCAFLGA?J cooperation of member steel works from Austria, Finland, Germany, Luxembourg, the Netherlands and Switzerland. Six subcommittees support the Steering Committee: Oxygen Steelmaking, Electric Steelmaking, Continuous Casting, Ingot Casting and ESR Processes, Refractory Materials as well as Scrap and Raw Materials. More than 40 steel producing companies, over 20 suppliers and 9 research institutes have been involved. The steelmaking committee and the associated subcommittees F?TC GBCLRGjCB ASPPCLR trends and developments in steelmaking processes from a European point of view. The following paper provides this overview.

Ralf Bruckhaus, AG der Dillinger Hüttenwerke, Dillingen, Germany; Reinhard Fandrich, Steel Institute VDEh, Düsseldorf, Germany Contact: www.vdeh.de E-mail: reinhard.fandrich@vdeh.de

MPT International 4/2013

The situation In 2012, 168.5 million t of crude steel were produced within the 27 countries of the EU (EU-27). The main production routes are via basic oxygen furnaces (BOF) and electric arc furnaces (EAF). The share of the BOF route amounts to 58.3%, and the remaining amount of some 41.7% is accounted for by electric arc furnaces. The production routes vary greatly from country to country: In Italy and Spain over two thirds of the production are based on EAF technology, for Luxembourg, Portugal and Slovenia the figure is 100%. In contrast, in Austria, the Netherlands, the Czech Republic, Slovakia and Hungary more than 90% of crude steel was produced in basic oxygen furnaces. In Germany, crude steel production is a mix of 32% via the EAF and 68% via the BOF route. Nineteen sites in the EU have crude steel production capacities of more than 3 million t/ year (table 1). The European steel industry was hit hard by the economic crisis in 2009. After a steep decline by an average 30% in 2009, production figures have been recovering since 2010. From rather low levels, oxygen steelmaking gained some 28% and electric steelmaking about 17% until 2012. However, the overall market experienced a slight deterioration in 2012.

At first sight, the crisis in 2009 was mastered well by the main production sites in Europe. Consequently, the steel industry pursued planned investments. These investments in sophisticated technology have strengthened the position of European steel companies compared to competitors outside Europe. Facing deteriorating steel markets in 2012, the overall situation for the European steel producers has become rather complicated especially due to strong pressure exerted by the Asian markets. This environment forces the steel industry to take further cost cutting measures.

Trends in BOF and EAF steelmaking The main customers in the steel processing industry are basically identical for EAF and BOF steelmakers. Compared to electric steelmaking, the BOF route provides the capability of producing larger amounts of specialized steel grades. Sophisticated steel grades are supplied for the production of flat and long products, semi-finished products and wire as well as hot and cold rolled coil. Customers can be identified in various manufacturing industries. Large quantities of steel are delivered for use in automotive engineering, to the con-

City

Country

Annual crude steel capacity

Duisburg

Germany

19.5 million t

Taranto

Italy

11.5 million t

IJmuiden

The Netherlands

7.2 million t

Dunkirk

France

6.8 million t

Linz

Austria

6.0 million t

Dillingen and Völklingen

Germany

5.5 million t

Gijon and Avilles

Spain

5.2 million t

Dabrowa Gornicza (Katowice)

Poland

5.0 million t

Fos-sur-mer

France

5.0 million t

Gent

Belgium

5.0 million t

Salzgitter

Germany

5.0 million t

Port Talbot

4.7 million t

Kosice

Slovakia

4.5 million t

Scunthorpe

4.5 million t

Galati

Romania

3.7 million t

Ostrava

Czech Republic

3.7 million t

Bremen

Germany

3.6 million t

Esch and Differdange

Luxembourg

3.5 million t

Bilbao

Spain

3.1 million t

Table 1. European sites with crude steel production capacity above 3 million t/year in 2012 [1]

Steelmaking struction industry, for energy producing and recovering equipment as well as to the raw materials industry for mining and handling applications. The basic oxygen process can be subdivided into three major furnace layouts: - LD converters with top blowing lances, - BOP converters with bottom blowing tuyeres, - Q-BOP converters with combined top and bottom blowing to increase scrap input. Between 1952 and 2007, crude steel production via the bottom blowing steelmaking processes was only about one tenth of the amount produced in LD converters. Different measures to optimize process and equipment have led to the worldwide success of the LD route: - sublance technology to improve automation of the process, - development of dynamic process models to improve achievement of the temperature target and the chemical composition of the heat at tapping, - slag-free tapping with different slag retaining systems and, last but not least, - the combined blowing process which is supported by stirring and purging of the heat with inert gas through bottom tuyeres. An example of this process is the TBM process developed at Thyssen (now ThyssenKrupp Steel Europe). Lime consumption and the amount of slag as well as the Fe content of the slag could be markedly reduced combined with lower content of phosphorus in the crude steel. Metallic yield was improved by 0.5 to 1%. The bottom blowing process shows improvements in metal-slag reaction and decarburization. The left diagram in figure 1 illustrates the dependency of the Fe content in the slag and the C content of the heat at tap for different types of converters. The diagram on the right shows process data for a TBM converter with intense bottom stirring at the Beeckerwerth plant of ThyssenKrupp Steel. In comparison with the LD process, in the BOP process the Fe content of the slag is lower for comparable C contents at tap. A great diversity and variety of steel products is characteristic of both BOF and EAF production routes. The steel market is the driving force for applications and quantities of steel grades needed to establish certain steelmaking routes. Comparably small amounts of 42

MPT International 4/2013

quality and structural steel grades, corrosion and heat resistant steel grades as well as tool steel grades are produced by the EAF. To meet individual customer needs a large number of chemical elements can be used as alloying material to produce the big variety of steel products demanded by the markets. Between 1980 and 2011, the share of crude steel via the EAF route more than

furnace technology are lower noise emissions, reduced electrode consumption, longer life cycle of the furnace and smaller effect on the power grid. For the EAF steel producing route, furnace sizes of up to 300 t (AC) as at MKK Metalurji, Iskenderun, and 420 t (DC) as at Tokyo Steel are available. With an annual crude steel capacity of 2.5 million t, these EAF steelmaking shops come close

Figure 1. C content in the melt and Fe content in slag for different converter types [2] (left: qualitative comparison; right: TBM converter with intensive bottom purging)

Figure 2. 5GEQPFCT[ OGVCNNWTI[ RTQEGUU TQWVGU s Ć&#x192;GZKDKNKV[ CPF FKXGTUKV[ = ?

doubled from some 20% to 42% in EU27. Sustainability is a driving force behind these figures since recycling of scrap of a great variety of grades is a basic task of the electric arc furnace. This is a significant contribution to using resources more effectively. Furthermore, absolute and relative CO2 emissions are reduced compared to integrated steelmaking processes. In Germany, three out of the 28 EAFs are DC arc furnaces. These are located in Unterwellenborn, Peine and GeorgsmarienhĂźtte. Major advantages of this

to the production figures of midsize BOF shops. The Conarc process represents a combination of basic oxygen and electric arc furnace technology. Depending on the charge material the two independently working metallurgical vessels can either be operated in parallel or in opposite phases as BOF or EAF. A maximum flexibility concerning the input material from all liquid to all solid is the hallmark of the process. Improvements in sensor technology and process modelling in BOF steel-

Steelmaking

Figure 3. Control pulpit of a 70 t secondary metallurgy station equipped with ladle furnace and twin-tank, single-cover VD/VOD station (courtesy: Danieli)

making process are measures aimed at increasing vessel availability and ensuring safe and accurate maintenance during relining and slowdown periods. Furthermore, also energy efficiency and post-combustion, converter gas recovery and increase in scrap input have been improved. The use of off-gas in the EAF process is still an important issue [3].

Element

The limited availability of high-quality scrap sets a limit to the share of EAF steelmaking in total steel production. Therefore hybrid processes are under development for - melting down scrap and sponge iron via EAF technology, - refining hot metal by oxygen blowing or - melting scrap with fossil fuels.

/KP /CZ EQPVGPV KP

Relevant secondary metallurgical aggregates

0.0010 – 2.50

VOD/VD, RH, RH-OB, stirring station

0.01 – 3.70

RH, LTS

0.08 – 20.00

0.03 – 25.00

VD, RH, LF

0.01 – 4.50

LF or primary steelmaking

0.03 – 80.00

LF or primary steelmaking

0.03 – 3.50

LF or primary steelmaking

0.0020 – 0.5000

VD, RH, LF, stirring station

0.0020 – 5.50

VD, RH, stirring station

0.020 – 6.50

LF or primary steelmaking

0.03 – 10.00

LF or primary steelmaking

0.01 – 1.50

VD, RH, LF, stirring station

0.01 – 1.50

VD, RH, stirring station

B, Se, Te, Ca, Pb, S

0.001 – 0.300

Stirring station, LF

Table 2. Content of alloying elements in liquid steel and required plant components for OKPKOWO TGF CPF OCZKOWO DNWG EQPVGPVU = ?

Currently not only investigations but investments like the new HBI plant in Texas by Voestalpine are on their way using gas as reducing agent. Due to rather low prices of natural gas in different parts of the world this technology is of significant importance.

Trends in secondary metallurgy The typical process route in secondary metallurgy in a BOF shop starts with the addition of alloying agents during tapping. Depending on the steel grade, deoxidizing agents and slag forming agents are charged. The next step is a stirring process to homogenize the analysis and the temperature, further alloying material is added and light desulphurization is performed depending on the slag condition. In an electricpowered ladle furnace (LF), the temperature of the heat can be increased. This provides the steelmaker several benefits. First, the BOF tapping temperature can be reduced for metallurgical reasons. Second, BOF lining life will increase. FiMPT International 4/2013

Steelmaking nally, it has also become possible to add large amounts of alloying materials. Heating liquid steel via aluminothermic processes provided by HALT or CASOB installations are alternatives. Vacuum degassing and decarburization can be performed in VD/VOD or RH units. During the tank degassing process, desulphurization down to lowest values is beneficial using sufficient slag conditioning. RH degassers provide the optimum process for decarburization.

ed: The higher the overall contents of alloying elements in the steel grades, the more important the installation of a ladle furnace. The energy input into the heat during primary steelmaking is not efficient enough to guarantee high quantities of alloying materials due to the maximum temperatures allowed by the process. Since the first implementation of secondary metallurgy units in the 1950s, enormous efforts have been made, leading to the development of highly sophis-

mands for highest steel quality. In about 50% of the RH units, ladle sizes above 150 t are in use. In most of the VD/VOD installations, heats of less than 150 t are treated. Several trends can be observed in the LF process and LF technology. The need for high-alloyed steel grades produced via the BOF primary route is one possible reason for the requirement of a ladle furnace. The tapping temperature can be decreased to reduce the P content in the heat. This additionally results in

Figure 5. Technological evaluation of continuous casting processes [5]

(KIWTG Evolution of vacuum treatment plants worldwide from 1990 to 2010 (RH and 8& V[RGU = ?

The large variety of steel grades and the necessary customer requirements result in rather complex routes in secondary metallurgy for both BOF and EAF production facilities. Typical routes are shown in figure 2, considering primary melting, stirring, RH and VD/VOD degassing, ladle furnace and chemical heating installations. The actual route is determined by the metallurgical needs. Multiple routes of production can be carried out at the same time, however, with interdependences between these routes. Therefore scheduling in steel shops has become more and more important with highest demands on personnel and equipment. Customer demands and product diversities determine the secondary metallurgy units that are needed. Table 2 shows important alloying agents in steel production and possible minimum and maximum contents for different products. Meeting lowest values of residuals or trace elements (red) is generally a different task and process than producing steel grades containing the upper level of alloying elements (blue). Furthermore, the crucial role of the ladle furnace is obvious from the different alloying necessities given in the table. The following can be conclud44

MPT International 4/2013

ticated processes. This can be demonstrated by the development of the lowest required level of residuals in the steel. In 1960, the content sum of the elements [C], [S], [N], [O] and [H] was 600 ppm. By 2010, this had decreased to some 70 ppm. Obviously, there is no development trend towards even lower levels. Today, the core components of secondary metallurgy are VD/VOD and RH degassers. Using the RH process, the final C content is just one third of the respective value of the VD/VOD route (figure 3). On the other hand, desulphurization due to slag optimization in a tank degassing vessel leads to S contents that are about one quarter of those achievable in a RH plant. Therefore the VD process plays a major role in the production of steel grades for heavy plate and line pipe applications. (KIWTG shows the number of newly erected degassing units in five-year periods. There is a predominant trend of installing RH units in BOF shops and VD/ VOD units in EAF shops. But also the variation and different combination of all processes are obvious. The overall increase in the number of installed units proves the necessity for further flexibility in steelmaking in order to meet the de-

the benefit of a prolonged vessel lining life. Water-cooled copper elements have been developed to avoid scull built-up during the heating process. The ladle furnace process will be a key factor in oxygen steelmaking facilities in the future. There is a demand for higher flexibility of the steelmaking process, combined with an increase in the number of more sophisticated steel grades, leading to a combined challenge. Permanent improvement in steelmaking logistics is another main task. Alloying systems have to be upgraded to maximum efficiency for high-alloyed steel grades at the same time allowing highest analytical flexibility. Modelling has been gaining ground for online processes. Another obvious trend is using optical measurement and camera systems combined with image analysis software. The number of units and installations in secondary metallurgy has been rising steadily. The implementation of sophisticated technologies assures maximum process variation to meet present and future demands.

Trends in continuous casting In figure 5 the added value per t of crude steel is given in relation to the R&D efforts per t of crude steel. Comparing technology over a time span of seven years, the strip casting process is in the question mark field, meaning a

Steelmaking

Figure 6. //- /GVCNWTLK QRGTCVGU C OKPKOKNN VQ RTQFWEG OKNNKQP V [GCT QH JQV TQNNGF EQKNU XKC C V '#( CPF VYQ VJKP UNCD ECUVGTU (courtesy: Danieli)

high R&D effort at relatively low added value. Process optimizations will probably raise this level during the next few years. Thin slab casting is in star position but high R&D efforts are still necessary even with a high added value. Roughly 95% of todayâ&#x20AC;&#x2122;s production is covered by conventional casting processes. This is the cash cow position. In comparison to new technologies, the need for development is lower while the added value is rather high. This creates advantages in the worldwide competition. Technical possibilities and economic success will depend on future developments. An example of near-net-shape casting is under development at German heavy plate producer Dillinger HĂźtte. A new continuous caster for slab thicknesses of up to 500 mm is currently under construction and will be put into operation in 2014, meeting customer needs in the heavy plate market. Thin slab route. Since the start-up of the first industrial thin slab plant at Nucor Crawfordsville in 1984, this technology has become an important factor in the production of high-quality hot rolled coil. The major advantage of this technology

is its comparably low energy consumption. Steel production via the conventional slab casting/hot rolling mill route uses twice the amount of specific energy consumed by CSP technology. 81.5 million t of thin slab casting capacity are installed worldwide. Besides 44 CSP (compact strip production) plants and 12 FTSC (flexible thin strip casting) plants, five other processes (e. g. DSP, ESP, ISP) are in operation (table 3). The installations are operated in EAF shops as well as in BOF shops. The sites are situated mainly in Europe and North America but also in India, South Korea and China. Today seven thin slab plants are in operation in the EU-27. These seven European sites have a combined annual capacity of 9 million t. The European sites use ESP, ISP, CSP or DSP technology. To maximize the output, there is a development trend toward higher casting speeds. The ESP plant set up in Cremona allows a casting speed up to 8.5 m/min. An FTSC plant is in operation in Iskenderun, Turkey (figure 6). Strip casting. The twin-roll casting process was developed to produce a nearnet-shape geometry with thicknesses

between 1 and 5 mm. As a result of this thickness reduction, the number of rolling stands can be reduced and the production chain is considerably shortened. Compared to the conventional (thick slab) casting/hot rolling route, energy consumption can be reduced by up to 90% with the twin-roll casting concept. Improvements in the microstructure can be achieved due to solidification intervals down to one 700th of those in conventional continuous casting installations. Micro and macro segregation can be avoided and higher values of residuals tolerated. The process is of special interest in the production of high-manganese and high-aluminium steel grades. Worldwide, three strip casting plants are in operation so far. Posco, Korea, started up a similar plant in 2002 to produce stainless steel and silicon alloyed steel grades. At Nucor, a twinroll caster with an annual design capacity of 540,000 t was erected in Crawfordsville, IN/USA in 2002. Later, Nucor built a second Castrip plant in Blytheville, AR/USA. The grades produced include carbon alloyed structural as well as low alloyed steel grades [6]. Surface defects are a major challenge for the twinroll casting technology in MPT International 4/2013

Steelmaking general. These cannot be removed by scarfing or grinding. Additional challenges are the sealing of the side plates, the shape of the edges, the control of the solidification process and the process profitability. As a world premiere, German flat steel producer Salzgitter Flachstahl is implementing the belt casting technology process (BCT) on an industrial scale (figure 7). The corresponding pilot plant was run at Clausthal University. The liquid metal is drained from a tundish-like reservoir via a revolving, cooled steel belt. Primary cooling is basically performed through the casting belt. The solidification process is carried out under inert gas atmosphere. The casting thickness ranges from 10 to 15 mm.

Surface defects are less critical compared to the twinroll process. Compared to strip casting, major advantages of this newly developed casting process are minimized segregation, a lower level of energy consumption by in-line rolling and the reduction in the number of rolling stands. Heat induced cracking is avoided due to the absence of bending and unbending during the process. The process is specialized for high-manganese alloyed steel grades.

the further development of the market position. For the near future, the thin slab casting process will be of great interest. To establish this process in a longterm perspective, it will be necessary to develop detailed machinery and process engineering. However, future development will depend on technical possibilities and economic success.

Technological outlook. At the member companies of the German Steel Institute VDEh, current developments focus on improvements in process reliability, process stability, modularity and flexibility of installations. Concerning the conventional formats, the strategy is

After the decline in 2009, the European steel industry is still struggling to reach its pre-crisis production level. About 60% of the crude steel in Europe is currently produced by the oxygen steelmaking process and 40% by the electric steelmaking process. The product range is of decisive importance for the layout of the steelworks and the equipment for secondary metallurgical treatment. Regarding steelmaking worldwide, thin slabs are increasingly being produced in addition to conventional formats such as slabs, blooms, billets and beam blanks. In order to ensure long-term economic success, however, companies have to continuously develop sophisticated technologies for steel production. The main development trends these days are aiming towards improving energy and resource efficiency, increasing competitiveness, as well as improving efficiency, flexibility, quality and works logistics. Challenges for the future remain in the production of high-purity steel grades, as well as the development of zero-error strategies with maximum productivity and flexibility. #

Figure 7. Schematic drawing of the belt casting technology [7]

No.

Plant type

Company

No.

Plant type

CSP

Nucor Crawfordsville

CSP

Company AM Sestao

others

Arvedi

FTSC

Imidro JSW Ispat

CSP

Nucor Hickman

CSP

Nucor Crawfordsville

CSP

Handan I&S

CSP

Nucor Hickman

CSP

Maanshan I&S

CSP

Hyundai

CSP

Guangzhou

CSP

Hyundai

CSP

Hunan Valin L. I&S

Conclusion

others

AK Steel

CSP

Hunan Valin L. I&S

CSP

Galatin Steel

FTSC

Tangshan I&S

CSP

Steel Dynamics, Inc.

FTSC

Benxi I&S

CSP

Ternium Mexico

CSP

Jiuquan I&S

References:

CSP

AM Sestao

FTSC

Tonghua I&S

[1] World Steel Association, Statistics 2013

CSP

Steel Dynamics, Inc.

FTSC

Tonghua I&S

CSP

AM USA

CSP

Severstal Columbus

CSP

Nucor Berkeley

FTSC

OMK Vyksa

CSP

G Steel Public

CSP

Bhushan P&S

[2] R. Fandrich, H.-B. Lüngen, G. Harp and C.-H. Schütz: State of development in basic oxygen and electric steelmaking. In: Steel is Future, Ed.: Steel Institute VDEh, Verlag Stahleisen, Düsseldorf 2010, p. 41-49

FTSC

Essar Steel Algoma

others

Arvedi

CSP

AM South Africa

others

Posco

CSP

JSW Ispat

FTSC

Dongbu Steel

CSP

Megasteel

FTSC

Dongbu Steel

CSP

Ternium Mexico

CSP

Wuhan I&S

CSP

ThyssenKrupp Steel E.

CSP

Wuhan I&S Bhushan P&S

CSP

Al Ezz Dekhella

CSP

Handan I&S

FTSC

MMK Metalurji

CSP

Guangzhou

CSP

Essar Steel Hazira

others

Tata Steel IJmuiden

CSP

Essar Steel Hazira

CSP

Nucor Berkeley

CSP*

Essar Steel Hazira

CSP

Baotou I&S

CSP

Severstal Columbus

FTSC

Al Ezz Flat Steel

59*

CSP

Tata Steel Jamshed.

FTSC

Tangshan I&S

60*

CSP

Tata Steel Jamshed.

Table 3. Thin slab plants worldwide, status: Sep. 2011 (* under construction)

MPT International 4/2013

[3] L. Bandusch, B. Dettmer, R. Fandrich, B. Kleimt, K. Krüger, P. P. Ploner, F. Treppschuh: Electric steel production in Europe – efficient and challenging. stahl und eisen 132 (2012) No. 9, p. 29 - 40 [4] R. Fandrich, B. Kleimt, H. Liebig, T. Pieper, F. Treppschuh, W. Urban: Status of secondary metallurgy and present trends. stahl und eisen 131 (2011) No. 6/7, p. 75 - 89 [5] T. Bohlender, R. Fandrich, H.-A. Jungbluth, G. Kemper, R. Müller, H.-P. Narzt, G. Ney and H. Schnitzer: State of the art in continuous casting. In: Steel is Future, Ed.: Steel Institute VDEh, Verlag Stahleisen, Düsseldorf 2010, p. 64-75 [6] Steel Institute VDEh Database „PLANTFACTS“, 2011 [7] Steel Institute VDEh, Committee on Metallurgical Fundamentals 2007

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Figure 1. QSP hot strip mill

Thermo-mechanical rolling technology for the production of API 5L steel strip from thin slabs The requirements on ductile to brittle transition temperature (DBTT) are the most important limiting factors for API 5L strip grades produced by the thin slab technology because of RFC BGDjASJRGCQ GL ?AFGCTGLE ? PCjLCB ?LB FMKMECLCMSQ microstructure. The results obtained by the Danieli QSP layout at the new OMK Vyksa KGLGKGJJ ?PC TCPW NPMKGQGLE For 12.7-mm-thick X70M strips, DBTT is -60Â°C. The possibility of greater thicknesses arises from weaker DBTT requirements.

Mauro Guagnelli, Paolo Bobig, Danieli Wean United, Buttrio, Italy Contact: www.danieli.com Email: m.guagnelli@danieli.it

MPT International 4/2013

Introduction The production of API 5L grades is of great interest because of the increasing demand for gas and the forecast installation of new pipelines in the near future [1, 2, 3]. The economy of gas transportation via pipeline asks for high operating pressures and large pipe diameters. This in turn results in the need for pipes with great wall thicknesses and/or of highgrade material. Good toughness, both in terms of high Charpy V energy and low ductile to brittle transition temperature (DBTT), and an excellent weldability complete the requirements on the steels to be used in pipeline applications. The production of API 5L grades is therefore a promising and challenging field of market development for steel strip producers. Thin slab technology, on the other side, allows a reduction in energy consumption, with consequent benefits in terms of production costs and pollution reductions, at the same time permitting

a reduction in investment costs because of the compact layout. These features make the thin slab technology the preferred choice for new mill construction, but the limitation in the products which can be produced have to be considered because of the market requirements. Such requirements push the design of new minimills towards the production of high quality coils for demanding application. It is natural that high grade, heavy walled pipeline steels are being more and more considered in the product mix of new plants. It is therefore of great interest to define the potential of the present thin slab technology for the production of API 5L grades in terms of both the mechanical properties and thickness of the strips.

QSP minimill layout According to the Danieli minimill concept â&#x20AC;&#x201C; called quality strip produc-

Hot rolling tion (QSP) layout – the whole hot rolling process is divided into two steps (figure 1). This concept corresponds to the twostep thermo-mechanical rolling route which has been adapted to the typical thin slab conditions. The two-step thermo-mechanical rolling route has been successfully developed in plate rolling. It is used to produce linepipe plate grades X100M (20 mm), X80M (25 mm) and X70M (40 mm) with a DBTT lower than -20°C. This classical route for plate mills can be described as follows. In the first step the microstructure at the exit of the reheating furnace is refined by subsequent pass rolling at high temperature: during the time between subsequent passes the microstructure, which has been deformed in the first passes, recrystallizes; by adjusting the alloying content (in particular Nb, Ti, C and N play the most relevant role) and the pass temperatures, the recrystallization process brings to a refinement. Typical values of austenite grain sizes entering the finishing mill are in the range of 20 – 30 μm (figure 2). In the second step the microstructure is refined by strain accumulation: when the temperature is lower than a typical value called no-recrystallization temperature (TNR), the recrystallization process is retarded or fully stopped and pass after pass the strain is accumulated and the austenite is elongated and flattened. (This feature is called pancake and the strain accumulation is referred to as “pancaking”.) Typical total reductions in finishing are in the range of 67 – 75%, and the pancaked thickness can reach values in the range of 5 – 7 μm.

After hot rolling, the plate is artificially cooled at temperatures in the range of 650 – 350°C and the microstructure is transformed from austenite to the final type which, depending on the cooling rate, the finish cooling temperature and the steel composition, can be a mixture

high temperature for a total reduction of about 50%. - After artificial cooling to a proper temperature below TNR, the finishing stands accumulate deformations at each pass and a pancaked microstructure is achieved.

Figure 2. Examples of the microstructure evolution during hot rolling, left: recrystallized grains after roughing TKIJV RCPECMGF FGHQTOGF ITCKPU CHVGT ƂPKUJKPI

of polygonal ferrite (the classical form of ferrite in structural steels), acicular ferrite, bainite and also small amounts of martensite and retained austenite. The thin slab mill differs from the plate mill and the conventional hot strip mill because of: - lower slab thickness and consequently limited reduction available for a given final thickness, - direct rolling after casting and consequently the coarser microstructure entering the mill, - higher reduction that can be realized, particularly in the roughing step. The thin slab two-step thermo-mechanical rolling can be described as follows (figure 3): - In the first step, the coarse microstructure obtained after casting and in the tunnel furnace is refined by two/three heavy roughing reduction passes at

- After hot rolling, the strip is cooled on the run-out table (ROT) and coiled as in conventional hot strip mills.

Modelling the transition temperature in thin slab rolling plants In the presented approach, the steel grade is defined by two main parameters which describe the strength and the toughness. The strength is represented by the yield strength, measured as the tensile stress under load at a total elongation of 0.5% (Rt0.5) while toughness is represented by the ductile to brittle transition temperature (DBTT), measured by the temperature at which the shear area of a specimen broken by a drop weight tear test (DWTT) is 85% (85% SATT).

Figure 3. Schematic representation of the Danieli minimill concept (QSP layout) MPT International 4/2013

Hot rolling The API 5L standard states that the yield strength has to be measured and verified that it is within a range specified as a function of the grade, the minimum value being reported in the grade name. Considering the toughness, the 85% SATT is not directly measured, but a DWTT has to be performed at a specified temperature (0°C or lower depending on the temperature at which the pipeline has to be installed and used) and the corresponding shear area should be at least 85%. This implies that in this case the

The DBTT of thin-slab strips produced in a QSP layout has been modelled by a number of assumptions. Details of the modelling can be found elsewhere [4]. Firstly, the DBTT was described as a function of the steel grade, the strip thickness and the effective grain size of the microstructure; then the effective grain size was quantified based on the assumption that in thin slab QSP two roughing passes at high temperature with a total reduction of 50% are able to refine and homogenize the as-cast mi-

ture of micro-constituents, whose volume fractions depend on the chemical composition, the austenite grain size, the accumulated strain and the cooling rate; typical values for the different steel grades are assumed as described in table 1. By means of such a model, the DBTT can at the end be calculated as a function of the slab thickness, the strip thickness and the yield strength of the strip that represents the steel grade.

Tuning by experimental data API 5L grade

Ferrite volume fraction (fF)

Bainite volume fraction (fB)

X60M

1.0

0.0

X70M

0.6

0.4

X80M

0.2

0.8

Table 1. Reference volume fractions of main micro-constituents for different steel grades

Figure 4. DBTT modelling as a function of the strip thickness for different slab thicknesses in comparison with experimental results (X70M steel)

Figure 5. Variation of DBTT with the strip thickness for different slab thicknesses (X70M steel)

85% SATT of the pipe is lower than the specified test temperature. The critical properties which limit the feasibility of API 5L grades is the toughness and in particular the DBTT. It is in fact possible to increase the yield strength by a number of ways, but for the toughness the grain refinement is the only way. The limitation of grain refinement in the thin slab product is the consequence of the limitation in hot rolling, in particular when the strip thickness increases. 50

MPT International 4/2013

crostructure to a typical reference value. The finishing passes at low temperature, below the TNR, provide further refinement which can be quantified as the final thickness of the pancaked microstructure. The effective grain size of the final microstructure can consequently be determined as a function of the pancake thickness, the cooling rate on the ROT and the typology of microstructure. The microstructure usually consists of a mix-

The developed model has been tuned based on available industrial data, and the results are shown in figure 4. The experimental values are close to the respective theoretical curves. More data is needed to be able to better validate this approach. In particular, care has to be taken as the strip thickness increases beyond 13 mm. In the absence of further data, the relationship is considered reasonable up to 13 mm, and for higher thickness a linear relationships corresponding to the tangent at 13 mm is suggested for more conservative estimation (dashed lines in the picture). In any case it is possible to see that a DBTT of 60°C for a 12.7 mm strip corresponds to a DBTT of 20°C for a strip thickness of about 19 mm starting from the same slab thickness of 90 mm.

Feasibility of the production of API 5L grade strip from thin slabs In figure 5 three curves are shown for different slab thicknesses and the same steel grade and a reference chemical composition. (The grade is X70 and the chemical composition results from an optimization based on the industrial data.) From the picture, the effect of the slab thickness on the DBTT can be understood and quantified. In particular the theoretical curves have to be interpreted in two ways: - For a given steel grade, chemical composition, slab thickness and strip thickness, the curve gives the minimum temperature at which the shear area is expected to be higher than 85%: for example, considering a 14 mm strip thickness, the expected DBTT is lowered from 36°C to 50°C and 62°C passing from a slab thickness of 70 mm to 90 mm and 110 mm respectively.

Hot rolling - For a given steel grade, chemical composition, slab thickness and DWTT 85% SATT requirement, the curve gives the maximum strip thickness: for example, considering a requirement for DBTT of 60Â°C, the maximum strip thickness is increased from about 10.5 mm to about 12.4 mm and 14.2 mm pass-

API 5L grade

Strip thickness, mm

X60M

X70M

X80M

Reference DBTT

0Â°C

-20Â°C

-40Â°C

Table 2. Potential application of QSP in terms of strip thickness for different DBTT values for a 105 mm thick slab

Figure 6. DBTT as a function of the strip thickness for different steel grades (105 mm slab thickness)

graph represents average values. As an example of application, the X80M blue curve is considered. The production of X80M strips for standard application (more than 85% SATT at 0Â°C) turns out to be possible only for a slab-to-strip thickness ratio higher than 4.4; this means, for a 12 mm strip, a slab thickness higher than 53 mm. In the case of X80M for low temperature applications (e.g. 40Â°C DBTT), the ratio between slab and strip thickness should be higher than 7.1, which means a slab thickness higher than 85 mm for the same 12-mm-thick strip. However, it must be clearly stated that such a graph represents an average best estimation based on the actually available knowledge and should be used mainly for qualitative analysis of the DBTT that can be obtained in a thin slab minimill.

Conclusions

Figure 7. Variation of DBTT with slab-to-strip thickness ratio

ing a slab thickness of 70 mm to 90 mm and 110 mm respectively. Considering the slab thickness of 105 mm, the expected DBTTs as a function of the strip thickness are shown in figure 6 for the three API grades X60M, X70M and X80M. Based on such results, the QSP with a slab thickness of 105 mm is able to produce API grades up to the thickness summarized in table 2. In order to design the mill configuration based on a specific product mix, a further development of the model is useful. This is possible, for example, considering the ways by which the strip thickness influences the DBTT: - affecting the value of the accumulated strain (together with the slab thickness),

- affecting the cooling rate in the ROT, - directly affecting the DBTT which is sensitive to the specimen thickness. Among these effects, the effect of the cooling rate is the weakest. Even if passing from 10 to 20 mm and the cooling rate reduced from 18 to 9Â°C/s, the effect on the DBTT is only 2Â°C. The specimen thickness has the second strongest effect at about 16Â°C, while the effect of the strain accumulation is the strongest at about 35Â°C. If only this last effect is taken into account, the two variables slab thickness and strip thickness can be considered together via their ratio. The diagram which results from such assumption is shown in figure 7; the coloured regions around the curves indicate that this

A model for DBTT has been developed for high grade API 5L strips produced in thin slab QSP mill layouts. By means of such a model, the potential of QSP technology for API 5L production has been assessed. Based on this assessment, X80 grade strips can be produced up to 19 mm thickness, starting from a slab thickness of 105 mm; X70 and X60 grade can be produced from a 105 mm thick slab up to 22 mm and 26 mm strip thickness, respectively. It has also been shown how this methodology can be used for defining the slab thickness required for producing a given product mix. #

References [1] ExxonMobil: The outlook for energy: a TGCU RM

[2] R. Tubb: Pipeline and Gas Journalâ&#x20AC;&#x2122;s 2013 worldwide construction report. Pipeline ?LB %?Q (MSPL?J TMJ ,M (?LS?PW 2013. [3] J. Share: Pipeline outlook 2013. Pipeline ?LB %?Q (MSPL?J TMJ ,M (?LS?PW 2013 [4] P. Bobig, M. Guagnelli: API grades toughness analysis for thermo-mechanical rolling in QSP Thin Slab Rolling plants. 9th Int. Rolling Conf. and 6th European Rolling Conf., Venice (Italy), June 2013.

MPT International 4/2013

Quality assurance

Fig Fig i u ure re e 1. 1 Opt Optica icall slab ica slab iinspection

Topographic surface inspection system for slabs and heavy plate Surface defects originating from the continuous casting process often persist throughout the entire process chain of strip and plate production. Therefore it is vital for the quality of the jL?J NPMBSAR RF?R RFC NPMBSAR surface be inspected throughout the complete process route from continuous casting RFPMSEF RM RFC jLGQFCB AMGJ MP plate. In the past, no optical surface inspection system was available for this in the steel industry. This gap has now been closed by the combined 3D and 2D surface inspection system â&#x20AC;&#x153;X-3Dvisionâ&#x20AC;? from Surcon GmbH. X-3Dvision can inspect slabs also immediately after the continuous casting process.

Rainer Fackert, Christian Mittag, Surcon GmbH, Heiligenhaus, Germany Contact: www.ims-gmbh.de E-mail: info@ims-gmbh.de

MPT International 4/2013

The X-3Dvision surface inspection system was developed to detect and classify surface defects such as cracks, inclusions, or mechanical impressions. The system generates both a 3D and a 2D image of top, bottom and edges of slabs surfaces. These images are instantly checked for any surface anomalies (figure 1). In doing so, the system not only captures the area but also the depth of the surface defects. At the same time, the edge contour is inspected in order to obtain information about any edge defects as well as about the shape and the width of the slabs. X-3Dvision works in real time, instantly delivering information about the condition of the slab. Thus it is possible to immediately take any necessary countermeasures while production is running, leading to a sustainable optimization of the continuous casting process. The results from the surface inspection can, for example, be used to optimize the plant parameters and casting powder addition. Also the downstream process steps benefit from this optimization. For example, the grinding and scarfing effort is minimized because the

position and structure of the defects on the slab surfaces are already known from the information delivered by the system. Linking the surface data with the geometry values of the slabs provides a perfect product documentation. Subsequent weighing of the slabs becomes obsolete and the risk of mixing up slabs is minimized. The benefits of the X-3Dvision system can be summarized as follows: - The system captures surface defects and provides the possibility of immediate optimization of the continuous casting process. - The combination with X-2Dvision systems for the inspection of hot and cold strip makes it possible to track the surface defects along the complete process chain (figure 2). - If the surface data are linked with other measuring data, such as geometry or material data, defect sources that have their roots in upstream stages of the process can be identified and eliminated. This is a decisive feature in achieving uninterrupted quality assurance from continuous casting all the way through to the finished coil or plate.

Quality assurance

Figure 2. Possible installation positions for the surface inspection units in a CSP plant

Surface topography enables TGNKCDNG ENCUUKƂECVKQP Inspecting the surfaces of slabs used to be problematic with conventional systems. Because of the irregular surface textures, numerous defects could not be reliably distinguished on the basis of grey-scale images alone. In addition to the grey-scale image, the Surcon-developed X-3Dvision system now also provides a 3D topography of the surface. From the form of lines projected onto the slab surface, X-3Dvision generates a high-resolution image of the 3D surface contour. The system clearly distinguishes between grey-scale differences and three-dimensional defects. It is capable of reliably detecting cracks, inclusions, impressions and oscillation marks, etc. Additionally, the system delivers threedimensional information about the depth and volume of the defect. This triangulation-based method has – in a similar form – also proved successful in flatness measurements in hot strip mills. During measurement of the slab’s upper and lower side, the entire thickness profile of the slab is captured. In connection with the feature for the edge contour measurement integrated into the X-3Dvision system, it is possible to calculate the volume and hence also the weight of the slabs.

User friendliness through user-optimized software Thanks to their intuitive HMI, the systems can be quickly started up and easily maintained. The core feature of the software is its capability of fully automatically detecting and classifying defects of any kind. To draw maximum bene-

fits from this technology, Surcon offers: - easy-to-use tools for adapting the detection and classification features, - fast training of the classifier involving little configuration effort, - rules editors for defining optional classification rules, - offline simulation tool for thorough testing of new classifiers on existing databases prior to going live. The main defects of cast slabs in the defect catalogue are (figures 3 – 5): - non-metallic inclusions, - longitudinal cracks, - transversal cracks, - edge cracks, - irregular oscillation marks, - mechanical scratches and marks, - holes, - bleeder. Additional to the surface defects the following size defects are measured: - spread camber, - transversal depression, - edge camber. The classified defect data are stored on an SQL server as inspection results. Arrays of hard discs of several terabytes of storage capacity allow the production from several years to be backtracked. The databases have a transparent structure, allowing external access. Through this structure it is possible to make individual adaptations and integrations to the database complementing the existing reports and evaluations. The available RAM is large enough to store the complete video material taken from individual slabs or plates. This material can be used for comprehensive offline diagnostics. These data are also used for simulating and optimizing detection and classification performance. Consequently, going live and training of the system take much less time.

Figure 3. Mechanical impression (left: X-3Dvision, right: X-2Dvision)

Figure 4. Casting powder inclusion (left: X-3Dvision, right: X-2Dvision)

Figure 5. Irregular oscillation marks (left: X-3Dvision, right: X-2Dvision)

The system is easy to handle as the number of tools is reasonably small: - “Inspector” is used to view, search and evaluate any stored data. - “Trainer” is the tool for setting up, managing and testing the classifier. - The produced material can be disMPT International 4/2013

Quality assurance

Figure 6. Modules of the quality management system

played at any place by means of the “online view” module. - Diagnostics by the system is fully supported by graphical HMIs.

Integrated quality management system MEVInet-Q is a quality management system developed by IMS Messsysteme

GmbH. It is a proven tool for performing comprehensive analyses of all process-relevant data (figure 6). MEVInetQ collects and archives all information deriving from the process – both surface data and any process data provided by other measuring systems. By correlating surface data from the continuous casting, the hot strip and the cold strip, it is possible to identify defect sources which have their roots in

Figure 7. Slab reporting after modifying the casting speed

MPT International 4/2013

upstream process stages and the effects of which may become visible only at a later stage. The MEVInet-Q quality management system is an easy-to-use tool capable of performing comprehensive analyses of the entire process. For displaying the data, the “DataViewer” module is provided, via which production and quality experts may at any time access the archived data. The module displays individual measured values and data curves (longitudinal profiles, transverse profiles and defect profiles). The data displays can be freely configured and managed either centrally on a server or locally at one’s work place (figure 7). If required, all displays can be published on the company’s intranet via the web browser. The MEVInet-QDS module is a rulebased decision-support tool for quality management. Via MEVInet-QDS, rules can be defined that are automatically applied to every product in the production chain. These rules check quality on the basis of all available data. The operator may use the results from these rulebased calculations as an aid in decisionmaking. #

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Automation

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MPT International 4/2013

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The core of ProfileOpt is a non-linear physics-based model developed on the principle of thermal-elastic-viscoplastic material deformation and the conservation of mass and heat. The basic flow of ProfileOpt is also shown in figure 1. Basic mill configuration inputs are required to run the model along with initial set-up values. These include the number of stands, their distances, types and dimensions of rolls and grooves, alloy composition of input billet etc., and initial set-up values as reduction factors and roll gaps. Once these inputs have been fed, ProfileOpt can simulate the rolling process for this specific grade and predict various output parameters as rolling power, material exit dimension, interstand tension etc. But, as any other model, ProfileOpt also gives best results when it is adapted to real mill conditions. Hence, it has a powerful feature to adapt the model for major process parameters, e.g. rolling power, speed, temperature etc. This is done by feeding the measured values of these process parameters for a particular grade. Once adapted, ProfileOpt can be considered as a precise mathematical replica of the mill floor level. It can then accurately simulate the rolling process in the mill and predict material spread, torque, power and temperature at the exit of each stand of the mill. Figure 2 presents material spread adaptation and simulated results. The spread adaption is very well captured by the model. Similar adaptation performance is shown by the models for other process parameters such as elec-

trical rolling power, speed-neutral angle, temperature etc. The simulated rolling power, temperature of the material and shape show interesting behaviour. The effect of plastic heat which leads to a local increase in material temperature in various deformation zones is shown (see simulated temperature) as stairstep temperature profiles on the surface and inside the material. The material cross-section as it passes through several stands takes the shape of the grooves while deforming as shown with “red” lines, while grooves outlines are shown with “black” lines. But the most important feature of ProfileOpt is that it can be used to optimize rolling energy consumption, thermal energy consumption, productivity while keeping groove utilization and stand loading at the desired level and generate pass schedule values. Once the model is adapted to a particular product, a user can select an optimization objective from the options described below, and generate set points as reduction factor and roll gap values for the specific optimized condition. Various optimization objectives include: - minimizing total rolling power, - maximizing production speed, - minimizing specific rolling power at maximum productivity, - minimizing billet entry temperature, - optimum load sharing of stands, - optimum groove utilization. All these optimization objectives are run under user defined process constraints as, for example, maximum allowable changes in roll gaps or max-

Automation

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imum permissible stand loads or inter-pass tension, so the optimization outputs remain practical and implementable. For example, while running “minimizing total rolling power”, allowable upper and lower limits are defined for bar width, area, speed, inter-pass tension, roll gap and motor speed. The finishing dimension and production speed are kept unchanged. The optimizer tool then solves this non-linear minimization problem and provides the optimal rolling energy consumption value, or power, as well as the influence of the determined parameters (usually roll gaps and reduction factors) on width, area, tension etc. The complex dependencies between process parameters are handled

by consistent rolling models linking mass flow, spread, inter-pass tensions, torque and power. Figure 3 presents the optimization for minimum rolling power and maximum productivity. Apart from optimization, another important feature of ProfileOpt is the simulation functionality. It allows predicting bar width, area, speed, inter-pass tension at each stand depending on process inputs as roll gap, motor speed and billet temperature. This feature is very useful when analyzing the effect of small changes or disturbances on the process parameters. This is called sensitivity analysis. ProfileOpt is an advanced service offering from ABB for long-product roll-

ing mills. It has been developed to help customers reduce energy consumption, increase productivity or improve availability through a better know-how of the process. Using this service, the user can achieve tangible benefits such as 4 – 10% reduction in rolling power consumption or 8 – 12% productivity improvement depending on the process and operational constraints. #

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Figure 1. Pipe forming presses at the Chelyabinsk pipe works (courtesy: SMS Meer)

Analytical monitoring of production data A Russian producer of longitudinally welded large-diameter steel tubes commissioned a new tube plant at its Chelyabinsk works. German plant manufacturer SMS Meer implemented a data acquisition system from Iba AG for smooth process analysis. By means of this technology, SMS Meer was able to capture objective process data from the machines during technological commissioning. On the basis of the Iba data, the plant manufacturer could BGPCARJW GLkSCLAC RFC QCRRGLEQ MD the machines, improving their functioning and optimizing the sequences in the plant.

Dr. Ulrich Lettau, CEO, Iba AG, FĂźrth, Germany Contact: www.iba-ag.com E-mail: ulrich.lettau@iba-ag.com

MPT International 4/2013

The Chelyabinsk pipe works produces longitudinally welded steel tubes for oil and gas pipelines with diameters of up to 1,422 mm and lengths of up to 18.2 m. SMS Meer, a division of the SMS group and a globally leading manufacturer of machines and plants for the steel, aluminium and copper industries, supplied all processing stations as well as the complete electrics and automation for the large-diameter tube plant. With an annual capacity of 500,000 to 800,000 t, this plant is the largest of its kind SMS has ever built in Russia. The plant manufacturer equipped the Chelyabinsk tube plant along the whole production chain, among other things, with machines for strip edge preparation, with a strip edge bending press, two pipe forming presses (figures 1 and 2), tack welding machines, a mechanical expander, a hydrostatic pipe tester, and equipment for tube end processing. In this project SMS Meer focused on making the commissioning of the plant more efficient than previously possible. An end-to-end process analysis in the

tube production plant was introduced to realize this aim. SMS Meer installed data acquisition technology from Iba AG for the production machines. The aim was to verify theoretical models for the processes in the machines during technological commissioning of the plant and collect technology data in a database, thus achieving an improved plant design. The engineersâ&#x20AC;&#x2122; attention was to obtain knowledge about possible optimizations for the processes in the plant, achievable performance characteristics of the plant and possibilities to improve the performance of the plant from one project to another. With the objective process data provided by the Iba system, the company could meet these demands and perfectly match the processtechnology settings of the machine to the production environment.

Accelerated commissioning Before installing the Iba measurement and automation systems in the entire

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Automation tube plant, a test phase was implemented to provide theoretical models for the machine operations. For the test, the Iba system was integrated in a tube end sizing press: “We tested different software systems, but only the process data acquisition system from Iba provided comprehensive analytical options for comparing real practical data and process models and examine the current state for weak points and savings potential,” says Dr. Jochen Vochsen from SMS Meer. After the positive tests, Iba products were installed in all core machines of the tube production process in the Russian pipe works. Vochsen explains the background: “It is our goal to further develop our process expertise and that of our clients and hence establish a technology partnership. We can only reach this goal if we can look into our machines in an efficient way by means of process data provided by e.g. the Iba system. Thus we can analyze and optimize these machines.” Performance tests for the acceptance of the plant play an important part in a technological commissioning process. For this purpose, SMS Meer needs, among other things, to account for the cycle time that is defined in the contract. If the plant is running within the specified limits, the supplier can be sure that the machine works in compliance with the contract. “When commissioning machines of a dimension like that in Chelyabinsk, it is crucial to have efficient access to the processes in the plant and be able to understand the way they work,” Vochsen explains the challenge. Up to now, SMS Meer, like many other plant manufacturers, measured the cycle time by means of stopwatches – a really time-intensive and only partially objective method. By means of the systematic process analysis of the plant by the Iba measurement technology, SMS Meer could follow exactly the processes in the machine and accurately capture the cycle times. This method offered several advantages: The time required for commissioning could be reduced as well as the travelling effort of the staff assigned by SMS Meer to the plant commissioning activities on site. Some of the machines in the Russian pipe works are as big as a house. This is why they could only be built up and tested on site. “We have clients all over the world – Russia is comparatively near,“ Vochsen says. By means of the objective data provided by 60

MPT International 4/2013

Iba measurement technology, the project managers from SMS Meer in Germany could communicate with the workers in Chelyabinsk – which is 4,200 kilometers away – about the functioning of the plant during plant commissioning.

Data analysis independent of plant providers When implementing measurement systems, the plant operators are often faced with a great challenge, because

and the Slave mode – and can read up to 512 analogue and 512 digital signals per millisecond. A clear advantage of the device is that the Profibus is not additionally burdened as the Profibus Sniffer itself is not an active participant on the bus. Only the communication between the automation devices and the drives as well as the decentralized periphery is captured. The data received by the Profibus are converted and transferred to the ibaNet fibre optic interface. Via an input card of the ibaFOB family, which is part of the acquisition

Figure 2. The Iba measurement systems provide process data for the whole tube plant (courtesy: SMS Meer)

the plants usually operate with components provided by different manufacturers. This is also true for the Chelyabinsk plant. “Originally, there had been no possibility for data exchange. Iba developed a special programme for the data exchange,” Vochsen explains. Via the connectivity of the Iba data acquisition systems, it was possible to connect the automation systems provided by different manufacturers and belonging to different generations. Due to dedicated interface technology, Iba products offer outstanding connectivity to other systems and bus technologies. In the Russian pipe works, Iba data acquired from the Siemens Simatic-S7 automation system and the MAC-8 automation system from Bosch-Rexroth could be read using an ibaBM-DPMS Profibus-Sniffer. ibaBM-DPM-S is an interface device for fast data exchange on the Profibus. The device offers two modes of operation – the Sniffer mode

computer and can connect this computer to Iba peripherals, the data from the large tube plant installations were read into the ibaPDA-V6 data acquisition software. With the PC-based measured data acquisition system, the process data have been centrally recorded. Generally, Iba offers the software in different versions depending on the number of signals. Licenses for 64, 256, 1,024 and 2,048 signals are available as well as licenses for an unlimited number of signals – no matter if the signals are analogue, digital or analogue and digital at the same time.

Software easy to use After having recorded the process data, the measured values from the machines were stored as DAT-files and analyzed by means of the ibaAnalyzer, which is provided by Iba free of charge.

Automation The analysis software manages the files using a graphical user interface. It allows a fast and simple selection of the desired signal channels. Depending on the analytical requirement, several signals can be assigned to one scale or each signal can be assigned to an own scale. “The advantage of the ibaAnalyzer is that the software can be simply downloaded and used intuitively. Our company decided very fast to equip all main machines in the large tube plant with Iba technology and its modules,” Vochsen explains. By comparing actual values and setpoint values, the potential for optimizing the machine settings became evident very quickly. Using the powerful report generator, customized analysis reports on process stability and velocities can be generated. Vochsen continues: “Thanks to Iba technology, we have recognized very quickly how to minimize plant downtimes and machine damages in the future.” The faster errors in the machine settings are detected, the faster these errors can be corrected and the

less plant operation is disturbed by interruptions.

'PF WUGT DGPGƂVU Primarily, ibaPDA acquires the data on a time basis. Using a time/lengthconversion in ibaAnalyzer, the measured data can also be shown on a length basis and hence be consulted for judging the product quality. Actually, this functionality of the Iba system is also interesting for the plant operators who may be cautious about integrating a new technology into an existing plant. They fear that it might take too much time to learn how to use the new technology and at the same time maintain the product quality. “With Iba, we give our clients the possibility to gain insight into the whole production process and improve production during the start-up. This clearly lowers the hesitant stance of the clients when it comes to introducing a new

technology or machine,” Vochsen describes the situation. The technical optimization measures launched in the commissioning phase have convinced the Russian pipe manufacturer. After the acceptance tests, the client of SMS Meer decided to continue using the Iba system installed for commissioning. This decision was supported by the fact that the Russian automation specialists were already very familiar with the Iba system as Iba had not only supplied the technology but also provided on-site training and advised the staff of SMS Meer and the staff of the Russian pipe producer at the Chelyabinsk construction site. The several-day instruction on the technology was provided by the colleagues from the Russian Iba location at Lipetsk. On-site training, objective communication with the construction site, practical data for improvement of the models, acceleration of commissioning – Vochsen gives a positive summary: “We are fully satisfied with the Iba solution.” #

Water-cooled components for the steel industry Electric arc furnaces Ladle refining stands Converters Waste-gas cooling systems Cooled equipment

We are able to design and supply the complete set of equipment. The modernisation of existing EAF and converter plants can be done by us as well as planning and manufacturing complete new exhaust gas cooling systems. We are also your partner in finding functional solutions in detail design. Contact us for our competence.

2\OSTHUU :`Z[LT 2 OS[LJOUPR .TI/ D - 45721 Haltern am See . An der Ziegelei 11 Tel.: +49(0)2364/10 53 9-0 . Fax: +49(0)2364/10 53 9-16 E-Mail: info@k-s-k.de . Internet: www.k-s-k.de

MPT International 4/2013

Automation

IT toolbox to analyze processes and to reveal potential in the metals industries Simatic IT is already a common standard for automation in many industries. Now this platform has been opened up to the metals business. Siemens Metals Technologies integrates its knowledge of metallurgy and plant design into the modular IT platform Simatic IT. The result is a new approach for transparency as well as for analysis of production and processes – from the receipt of goods and the purchase of raw materials and energy all the way down the process chain to shipping the coils or bars etc., from the repair workshop to accounting.

Under the brand name “IT4Metals”, Siemens Metals Technologies not only offers steel companies a holistic automation concept with extremely broad functionality. This IT platform also draws upon a broad base of expertise in the process and manufacturing industry and demonstrates its ability to plan and control complex production systems all over the world every day. IT4Metals is a specified IT solution based on the sector-neutral IT platform Simatic IT. Provided by Siemens Industrial Automation, Simatic IT includes internationally defined standards and interfaces for basic automation, for control systems, and for enterprise resource planning (ERP). However, Siemens Metal Technologies has now opened up the Simatic IT platform to the world of steel production and processing. Steel-specific applications have been integrated into this operational IT platform in the form of functional modules and libraries. The libraries integrate the industry- and company-specific knowledge steel manufacturers need to model their processes and

control and implement event-driven optimizations in the complete production chain. Steel manufacturers are able to collect data from all areas of production from the shop floor level (sensors) up to plant operating and management level, to then evaluate this data and prepare it in the form of key performance indicators (KPIs). The management uses the platform to control the entire plant or parts of it according to certain criteria, and thus more effectively. A holistic tracking of events and materials in production is possible, from the raw material received to the finished product, e.g.: - monitoring and analyzing of energy consumption, - planning current customer contracts into running production, from the raw material used – including the quality of the raw material – right through to the final product the customer requires and in line with the delivery date, - producing different steel grades; and all that in a just-in-time production process.

Siemens AG, Industry Sector – Metals Technologies, Erlangen, Germany Contact: www.siemens.com/metals E-mail: georg.bytomski@siemens.com

MPT International 4/2013

Figure 1. Siemens Metals Technologies process visualization system

Automation Preliminary planning for production can be carried out over a year in advance. The steel manufacturer can then improve its purchasing of the raw materials required to produce goods for one of its customers in 14 months’ time, for example. On the technological side of plants, mechanics and electrics have reached a level where further optimization can only be achieved at a considerable cost. That means that now people are also taking a close look at the individual processes: How to pass the semi-finished goods on? How long does the material spend in intermediate storage? How much raw material to purchase? How much scrap will be left? How to purchase energy cheaply, for example by melting down the material during periods when energy costs are lower? Overall optimization of a plant has quite a different focus today than it did in the past.

Integrated holistic IT solution for steel producers IT4Metals is currently the only holistic IT solution in this segment. For over four years Siemens has been shifting all existing IT solutions to the Simatic IT platform. In the metal manufacturing process various IT products have been integrated into a holistic solution. The operating philosophy – the look and feel – of the software was unified. From the condition monitoring system, for instance, information is passed on directly to an advanced planning system and

to a maintenance system, and these in turn are linked to an energy management system. These links make a whole range of aspects in the production chain visible and available to the companies. This means they are prepared for all the KPIs relating to analysis and optimization that affect the business: they have an answer for the changing framework conditions in regard to different production and product requirements, to energy matters and to the environment. IT4Metals works also as the backbone of life-cycle management. The computerized maintenance management system (CMMS) is directly linked to the IT4Metals platform. Diverse maintenance plans can be developed, such as personnel shifts, plans for proactive spare parts storage, and plans for preventive maintenance. All these solution approaches can be integrated in the IT4Metals platform in order to generate and distribute targeted maintenance requirements and instructions. IT4Metals opens up optimization potential and also identifies errors and weaknesses. It is certainly a doubleedged sword. On the one hand, errors can be identified where being made in production. On the other hand, plant operators – even those who are only responsible for a certain part of a plant – will surely be grateful to learn why they are encountering problems in production when using certain input materials under certain production conditions, and why they are unable to attain the quality they are aiming for. Ultimately

the entire process becomes more transparent, creating a more objective basis for discussions and decisions about production. This is the key point for managers. They want to sell the materials they produce to steel users, to the automotive industry for example. The requirements placed on materials in these industries are so high these days that the manufacturers can’t afford to make any mistakes. That means, steel manufacturers need in-depth knowledge of the processes and have to know where are the critical points and how to handle each material. Without transparency for all process steps, ultimately their customers will have a problem providing proof of their product quality.

Conclusion IT4Metals is a holistic automation concept. It extends from technical process optimization (Level 1) to holistic production coordination (Level 3) all the way up to the ERP interface, and it basically involves the linking and integration of all key IT functions, from an manufacturing execution system (MES) and storage logistics to an energy management system. Its additional functionality includes an advanced planning system to optimize production of customer contracts, a condition monitoring system for the manufacturing units as well as a computerized maintenance management system (CMMS) for service activities. #

Innovation in Quality Assurance For more information contact us at: +49 (2405) 47 999 40 www.quinlogic.com MPT International 4/2013

Automation

New process expert system optimizes production CPF GPGTI[ GHƂEKGPE[ The new process expert system PlantStruxure PES from Schneider Electric allows industrial companies to meet automation needs while optimizing operations and energy management by AMLLCARGLE RFC jCJB NPMACQQ and enterprise levels within a business. The system further @CLCjRQ DPMK 1AFLCGBCP Electric’s platform of integrated QMDRU?PC ?NNJGA?RGMLQ ?LB QSGRCQ 1RPSVSPC5?PC UFGAF NPMTGBCQ SQCPQ QGKNJC GLRCEP?RGML ? consistent experience and a scalable platform across any organization.

Schneider Electric 0?JCGEF ,! 31 !MLR?AR FRRN RGLW AA DFCNXU www.schneider-electric.com # K?GJ greg.magdanz@schneider-electric.com

MPT International 4/2013

Schneider Electric, a global specialist in energy management, recently announced PlantStruxure™ process expert system (PES), integrating the functionalities of Schneider Electric’s PlantStruxure collaborative architecture with StruxureWare™ process expert, a single software environment that integrates control applications, supervision and field devices to configure an entire control system. PlantStruxure PES allows industrial companies to meet automation needs while optimizing operations and energy management by connecting the field, process, and enterprise levels within a business. The system further benefits from Schneider Electric’s platform of integrated software applications and suites, StruxureWare, which provides users simple integration, a consistent experience and a scalable platform across any organization. PlantStruxure PES brings together the programmable automation controllers (PAC) and distributed control systems (DCS) to form an innovative energyaware process automation system. The system combines energy and process data in one platform, providing a consistent, real-time control and operational interface. PlantStruxure PES delivers data that drives timely and accurate decision-making to reduce energy consumption and increase process efficiency. StruxureWare process expert, the software component of PES, leverages a single database to enable users to directly interface with a single process element, such as a pump, during runtime operations with a single click. This integration delivers significant value through streamlined operations. The software also allows object libraries built for StruxureWare process expert to be easily modified, streamlined and customized for individual processes and users.

Automation, SCADA, and energy management integrated into a common platform “PlantStruxure PES is a leading edge offer in the field of process automation

systems that brings the best from the PLC/SCADA and DCS worlds and combines this with integrated energy management features to deliver superior value throughout the lifecycle of a plant,” said Mary Ramsey, senior vice president, U.S. Industry Business, Schneider Electric. “The tight integration of the system ensures efficiency from design engineering through operation, and engineers can develop the configuration faster and more accurately, and maintenance teams can diagnose and solve problems faster to reduce the downtime of a facility.” Historically, choices have been limited to simple PACs or more complex DCS, with no customizable option for processes with different needs. The runtime services provided by PlantStruxure PES gives operators a complete picture of the production process, and enables single-screen configuration and diagnostic access traditionally found only in a DCS operator interface. PlantStruxure PES has the ability to provide clear process information that is crucial to driving production efficiency, including trend data, advanced alarm and events capabilities, and historical knowledge of performance. PlantStruxure PES is also unique in its scalability and integration with a range of PAC systems, from basic PACs to more complex ones, depending on the needs of a machine or process. Schneider Electric’s PlantStruxure PES also improves efficiency throughout the engineering phase, accelerating plant start-up and minimizing project risks. An all-in-one configuration allows for faster system design through a single point of data entry. The user interface embeds all the software tools necessary to design a process application, including an application manager, topology manager and project manager. Several functionalities, including control, supervision, network and others, can be combined in the platform to offer a unified engineering lifecycle. Once control system standards have been approved, they can be standardized and reused to kickstart the design for other processes. #

Manfred Sachse

DAMASCUS STEEL 3rd Edition

Myth History Technology Applications

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Figure 1. Two vertical furnaces from Drever were installed at ThyssenKrupp Steel in Alabama, USA

Heat treatment technology as an integrated part of investment projects In the steel and aluminium industries, it used to be standard practice for many years for investors to split orders for new rolling mills or strip processing lines into three different packages, namely mechanical equipment, electrical equipment and heat treatment, and to award these packages separately. It was the task of the investor to coordinate the individual packages and assume responsibility for the interfaces arising from these. However, the investing companies have shown increasing interest in plantmakers who are prepared and have the technology to supply the overall integrated plant, including the process know-how. 66

MPT International 4/2013

Solution-based approach to plant supplies A few years ago, SMS Siemag, a leading supplier of rolling mills and strip processing lines to the steel and aluminium industries, gradually started to change the long-established practice of splitting orders into separate packages. Firstly the mechanical and electrical packages were integrated into the overall supply and, more recently, also the furnace technology. This brings the metals manufacturing process into the foreground and consequently results in major advantages for both parties: The plant operators are now responsible for fewer interfaces. As the plant builders also accept process responsibility, they are accountable not only for the functioning of the plant but also for the resulting product. This market development provided SMS Siemag with the

opportunity to expand its business and use the option of assuming overall responsibility as a competitive advantage. At SMS Siemag, this trend commenced when the company first began to supply drive engineering and control electronics building on its extensive experience in mechanical plant engineering. This soon led to the development of process models which, for example, ensured constant strip dimensions and flatness. Thus, it soon became possible to influence the geometry of a rolled product and guarantee compliance with geometry specifications. Nevertheless, the effects of heat treatment on the properties of the rolled product remained an open question. SMS Siemag regarded this deficit as a challenge of the market and tackled this challenge by searching a solution for integrating heat treatment of rolled products into its own portfolio.

Heat treatment

Figure 2. A universal annealing and galvanizing line can be operated in different modes

Furnace Technology becomes a new division of SMS Siemag The decision to establish Furnace Technology as a new division was already taken five or six years ago, triggered by the acquisition of the Belgiumbased company Drever International. Drever is a long-established leader in the construction of furnaces for continuous strip processing lines, such as annealing and galvanizing lines for carbon and specialty steels. The driving force for entering this sector came from the Strip Processing Lines Division which previously had always awarded the furnace technology portion of integrated plant orders to sub-suppliers or consortium members, such as Drever. It had become evident that the various types of processing lines for steel strip all comprised the

Dr. Fritz Brühl, Furnace Technology Division; Thilo Sagermann, Corporate Communications; SMS Siemag AG, Düsseldorf, Germany Contact: www.sms-siemag.com E-mail: communications@sms-siemag.com

thermal treatment as a critical process step responsible for defining the material properties of the product. This process step, which takes place in the furnace and during the downstream cooling process, requires a great deal of know-how. Anyone not understanding the processes underlying the heat treatment of strip will not be able to offer the customer any added value beyond the mere consideration of the interfaces between the processes. Fritz Brühl, executive vice-president of the new Furnace Technology Division at SMS Siemag, says: “Clients are increasingly tending to rely on our expertise when it comes to achieving specific material properties. In the long term, only those companies capable of taking a comprehensive approach to the process in its entirety will survive in the marketplace. This, for example, applies to modern steel grades such as TRIP and dual-phase steels. These materials cannot be produced without a product-oriented heat treatment.” In the succeeding years, the market demanded from SMS Siemag an ever greater number of new and varied tasks relating to the heat treatment of semi-finished rolled products. Initially, while continuing the successful business with Drever, Drever’s general furnace know-how was

used for new developments. This resulted in SMS Siemag’s accumulating ever more knowledge in this field, generally in close cooperation with the Strip Processing Lines Division, which was responsible for the mechanical equipment. This process eventually led to the formation of the new Furnace Technology Division at the beginning of 2011. SMS Siemag is a well-known supplier of rolling mills and processing lines for flat products. Therefore it was a natural consequence that the new business unit would also concentrate on the flat products segment. “Two terms characterize our product portfolio: heat treatment and flat products. We see the greater added value and the greater technological challenge not so much in the field of reheating but in the field of heat treatment, in other words in the targeted heating and cooling of the material,” summarizes Brühl. It did not take the new division long to position itself in the market. Thanks to numerous new developments and sophistications of existing solutions and the close cooperation with the Hot and Cold Rolling Mills and Strip Processing Lines Divisions, numerous orders of seminal importance to the new division, which has around 250 employees worldwide, have been obtained. MPT International 4/2013

Heat treatment Thanks to target-oriented further developments, the division has been able to draw upon its Europe-wide assets to establish the following main areas of application of proprietary furnace technology, especially for carbon and special steel grades and for electrical steel strip: - vertical and horizontal furnaces for continuous annealing and galvanizing lines, - floater furnaces for coating and annealing lines, - heat-treatment facilities, roller hearth furnaces and batch-type furnaces, - technology for CSP® plants of the latest generation.

a view to fulfilling the ever stricter requirements on high-quality steel grades as used in automotive construction. Cooling rates of 100 to 120 K/s per mm strip thickness represent the widely accepted state of the art. By means of a modified cooling system, Drever is aiming at an increase to 150 K/s. To this end, highly promising tests with gas-jet cooling are currently underway. This represents a major step forward in the development of cooling techniques. To implement this technique, Drever makes use of especially long cooling boxes which at both sides extend very close to the through-running strip and

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Evolution in vertical furnace technology for continuous annealing and galvanizing lines Vertical furnaces from Drever for the heat treatment, i.e. annealing and cooling, of steel strip are an essential constituent and success factor of the new Furnace Technology Division (figure 1). The sustained success of Drever products has been confirming the company’s leading market position, particularly for furnace plants in continuous annealing and galvanizing lines for automotive strips, and in annealing and pickling lines and bright annealing lines for special steel strips. Drever furnace technology has been further developed primarily by measures that enhance energy efficiency and avoid nitrogen oxides (NOx) and, in the case of strip cooling solutions, increase the cooling rate. The latter aspect is important not only for reasons of efficiency but also with 68

MPT International 4/2013

have special outlets that influence the impact of the gas on the strip. Also of great importance in this context is the fact for the past ten years that Drever has been increasing the hydrogen content in its plants to 15 to 30%. This has of course often given rise to the critical question as to the apparently higher consumption of hydrogen. In response to this question, Drever refers to the special, highly efficient concept according to which the hydrogen is introduced centrally, at only three or four positions in the cooling chamber, and not via each cooling nozzle. Cooling the strip with water in a controlled manner, which had not been possible 20 years ago, is today a possible alternative thanks to modern process practices and new process technology. SMS Siemag is currently building a continuous annealing line for Protec in the USA. The new line will again be equipped with a water quench. Cooling rates of more than 1,000 K/s are to

be attained here. However, with special steel strips the situation is different. For these grades, Drever uses an efficient water spray-cooling system. Whereas annealing and galvanizing lines used to be built as independent, separate plants, SMS Siemag offers a solution that combines both annealing and galvanizing in one combined line for applications in which efficiency and flexibility have very high priority. The underlying idea is that the basic function of the furnaces is similar for both tasks and, considering that the furnace is the most expensive unit in the line, it makes sense to only have one furnace. SMS Siemag is currently supplying the third plant of this type. It will be installed at Hyundai Hysco, Korea. The first combined line has already been in operation since 2006, likewise at Hyundai Hysco. The second one has been in operation since mid-2012 at MMK in Russia. They are primarily used for galvanizing/annealing automotive strip. The annealing process determines the design of the furnace. The heat treatment is different in annealing and galvanizing and some minor changes must be made to the plant when changing over from one mode to the other. The plant has a similar structure as a hot-dip galvanizing line. However, following the annealing process in the furnace, the strip can be further-processed in two different ways. Firstly, as in the hot-dip galvanizing line, the still hot strip can be routed through a zinc pot, coated with liquid zinc and then cooled down. The other possibility is to guide the strip into an overageing furnace. Here, it is treated for up to 180 s at temperatures between 270°C and 430°C. This leads to the desegregation of carbides and minimizes the risk of ageing. Thermal treatment is completed by final cooling and additional water cooling. The combined line (figure 2) is thus equipped with a furnace which allows the production of the same high-quality grades as in a modern continuous annealing line. The changeover from the hot-dip galvanizing mode to a purely annealing mode takes only around 16 hours. The concept put forward by SMS Siemag is that in future the plant operator will specify the mechanical and metallurgical properties of the steel strips to be produced. The plant supplier will then make use of models to identify the best suitable process in terms of temper-

Heat treatment ature control during rolling and during the subsequent heat treatment. In order to make this process reproducible, it is monitored and controlled by measurements of the mechanical properties attained. A suitable measuring method is the “Impoc” system from EMG, which is also a member of the SMS group. The trials currently conducted by SMS Siemag in a production facility in Belgium have been providing promising results. An activity pursued in parallel is the modelling of the mechanical properties and their in-line measurability. With heat treatment facilities for grain-oriented and non-grain-oriented electrical steel strip the situation is different. The complex manufacturing process for these steel grades requires either an annealing and coating line (ACL), an annealing and pickling line (APL) or a decarburization and coating line (DCL). For these plant types, partly the annealing technologies of the Drever furnace are combined with the floater furnaces used after coating. Apart from pure equipment design, SMS is focusing on the heat treatment process. Under the name “Intelligent Furnace” SMS developed new models for process control.

Floater furnaces for coating lines In 2011, upon the acquisition of the know-how and employees of the company GATV, a supplier of drying furnaces for strip processing lines, SMS Siemag commenced activities in the fields of thinner gauges and drying of colourcoated strips in what are known as floater furnaces. GATV contributed perfected technology for floater furnaces and for free-loop furnaces for carbon and silicon steels. A floater furnace (figure 3) performs not only heating but also cooling, for which SMS uses air and water. This is the only way to achieve the high cooling rates that are essential for setting the complex metallurgical properties of special steels. SMS Siemag recently supplied two such floater furnaces to ThyssenKrupp Steel Europe in Eichen, Germany. These furnaces will be used for drying and curing the prime and finish coatings in an existing strip coating line. Remarkable about this project, in which only the mechanical equipment for strip guiding was retained, is the fact that the plant shutdown took only four weeks.

During this period, the existing furnace modules were dismantled, and the fully prefabricated new modules installed and put into operation. The SMS Siemag supply scope also included the gas cleaning system and the electrical and automation package. The gas cleaning system is highly important in coating lines, not only for environmental protection. It also has strong influence on the energy efficiency of the furnace. SMS Siemag thus pursues the strategy of designing the gas cleaning

Figure 4. Quench for heavy plate

system such that the volatile paint constituents contained in the offgas are returned to the combustion process. The know-how here lies in the design of the flow-conducting system. The heat in the exhaust air is used for burning the paint constituents in the gas. Under certain preconditions it is even possible that the plant does not need any external gas input. In this case, the plant operates under autothermic conditions leading to a considerable reduction in energy consumption while ensuring low emission values in the exhaust air. The hydrocarbon content, for example, is below 10 mg/m³ (stp). For both carbon monoxide (CO) and nitrogen oxides (NOx), the value is less than 50 mg/m³ (stp). Among others, these results have opened the Chinese coating line market for SMS Siemag.

Heat treatment of heavy plate SMS Siemag has been active in the field of model building, e.g. for the development of metallurgical and flatness models. Here, Drever can draw upon its own experience from plants built in the past. Within SMS Siemag, the Furnace Technology Division and the Rolling Mill Division closely cooperate in order to offer the customers fully integrated process solutions.

With regard to the heat treatment of heavy plate, the company’s objective is to provide a flexible, controllable and reproducible alternative to the common difficult-to-control cooling practice, which involved the rapid cooling of the plate over a cooling section of only about three meters with as much water as possible. The objective of the flexible process is to objectively set certain material properties, as known from strip processing lines. The approach takes into account the complete process, i.e. including rolling, reheating and cooling. SMS Siemag is currently executing a challenging heat treatment project for special steel heavy plate at Outokumpu Stainless AB in Sweden. The remarkable feature here is that annealing does not take place in a roller-hearth furnace, which would have been the usual practice, but in four large batch-type furnaces arranged in parallel. Each furnace unit consists of two separate chambers which can be differently heated as required. The up to 16-m-long plates are fed and discharged via a roller table in front of the furnace chambers. After the heat treatment, the roller table transports the plates into a common quench (figure 4). The advantage of this arrangement is the enormous flexibility provided by the possibility of simultaneously treating single plates from very small batches. Also the lower space requirement in comparison with a rollerhearth furnace was an important criterion in favour of this furnace plant. This is the first integrated heat treatment facility for heavy plate designed, built and supplied under the leadership and responsibility of SMS Siemag’s Furnace Technology Division. All of the involved plants are designed and constructed according to a uniform standard specified by Outokumpu. Thus SMS Siemag is not only responsible for the supply of the equipment but for the entire process. The advantage of this becomes particularly obvious in the field of water supply. It is no longer necessary for the customer and the supplier to specify any “take-over points” (interfaces) for the water supply system. Instead, the customer buys a cooling rate that achieves the desired material properties, i.e. an integrated process. In this case the integration goes even further, as the electrical and automation package, likewise supplied by SMS Siemag, also incorporates an existing cold-plate leveller built by SMS Siemag, too. ComMPT International 4/2013

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CSPÂŽ facilities of the latest generation SMS Siemag developed the CSPÂŽ thin slab technology 22 years ago and, with more than 28 plants supplied worldwide so far, has enabled an economically and technologically significant alternative to the traditional hot-strip production method. Although the investment boom of earlier years has been slowing down recently, the demand not only for new plants but also for modernizing existing facilities has been remaining at a level that allows the company to continue to invest in the further development of the process. This is true also for the roller-hearth tunnel furnace, which performs an important role in the temperature control between the casting machine and the rolling mill. These furnaces have in the past been supplied by

a third-party furnace builder. In the future, these plants will be a key product of the Furnace Technology Division. The development of a new tunnel furnace makes it possible to incorporate the latest findings with regard to energy efficiency and environmental impact. This issue is not only a competitive factor for new plants but is also a driver for modernizing existing lines. Thus, energy consumption per ton of hot strip produced is today a key aspect when deciding on investments. It is a fact that the tunnel furnace is the biggest consumer of energy in the entire casting and rolling plant. Various criteria need to be considered when trying to reduce energy consumption here. The degree of energy consumption is not only a question of the furnace design but it is also very strongly influenced by the process itself. In addition to the key factors â&#x20AC;&#x2DC;increase of the casting temperatureâ&#x20AC;&#x2122; and â&#x20AC;&#x2DC;reduction of the temperature decrease during rollingâ&#x20AC;&#x2122;, SMS Siemag also pursues the option of intermediate induction reheating be-

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tween the furnace segments in cooperation with SMS Elotherm. Also the furnace rolls have a strong impact on the energy consumption of the furnace. The heat loss of the watercooled rolls developed by SMS Siemag is 25 to 30% lower, and the currently pursued development of dry furnace rolls gives rise to the expectation that the heat loss can be cut by up to 90%. Further factors to be considered are the choice of refractory material, the burner design and the structural design of the offgas system. For SMS Siemag, the new CSPÂŽ concept involving an in-house built tunnel furnace of future-oriented design that takes into account the continuous casting machine and the hot rolling mill is an answer to the growing requirements of the market, particularly in terms of energy consumption. Irrespective of whether electricity or gas is used, the decisive factor is always the number of kWh consumed per t of steel produced. For SMS Siemag, this has given new impetus to the CSPÂŽ discussion. #

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MPT International 4/2013

Technical innovations

Heat retention boxes for slabs save energy and CO2 emissions ENVIRONMENTAL PROTECTION Newly installed heat-retention boxes will help Tata Steel to save 10 million m3/year of gas at its IJmuiden plant in the Netherlands. The boxes will store freshly cast steel slabs, keeping them hot until they are required for rolling on IJmuiden’s hot strip mill. The 4.5-million-euros investment, which will pay for itself in little more than a year, will reduce the amount of heat lost from slabs left to cool between the casting and rolling stages of the production process. As a result less time and energy will be required to reheat the slab prior to rolling. Each of the three heat retention boxes is 14 m wide, 23 m long and 4 m tall. The hot slabs are transported by train from the steel melt shop to the heat retention boxes, each of which can store 2,500 t of steel. When the slabs arrive they have a tem-

perature of 650°C. The boxes are lined with a 25-cm-thick layer of insulation material. While slabs stored inside the boxes cool down only 25°C per 24 h, slabs not stored in the boxes lose all their heat within 48 h. The roofs consist of moving hatches that can be opened at precise points, allowing an overhead crane to hoist slabs in or out. About half a day’s hot strip mill production can be stored in the boxes, significantly increasing the quantity of slab that can be fed hot into the mill. In addition to reduced production time on the hot strip mill and the lower energy requirement, the project will reduce CO2 emissions from power generation by about 22,000 t/year. Contact: www.tatasteeleurope.com E-mail: feedback@tatasteeleurope.com

Precision disc pack coupling SPECIAL EQUIPMENT The new LP2 series of disc pack couplings introduced by coupling specialists R+W consists of two precisely machined hubs with keyway connection, a spacer, and two flexible disc packs, allowing for a high level of misalignment compensation. The transmission of torque across the friction fit of the disc packs provides a high degree of precision with zero backlash and minimal torsional windup. Larger distances between shaft ends are easily accommodated by custom-length spacers. The all-steel construction provides high fatigue resistance and infinite service life. The LP2 is available in six sizes with torque ratings ranging from 350 to 10,000 Nm. Together with the models LP1, LP3 and LPA, a very wide range of industrial applications can be covered, including all options and requirements for couplings in API 610 pump systems. Contact: www.rw-kupplungen.de E-mail: info@rw-kupplungen.de

New coupling model

Water detection technology for the EAF STEELMAKING Thanks to water detection technology that combines continuous and reliable EAF off-gas analysis for both H2O vapour and H2, EAF operators are provided with three distinct real-time alerts indicating the likelihood of a water leak. EFSOP Water Detection Technology™ developed by Tenova Goodfellow is an extractive or in situ system that is capable of continuously analyzing EAF off-gas for both H2 and H2O vapour. When liquid water enters the EAF, a portion will remain as H2O vapour and a portion will be re72

MPT International 4/2013

duced to H2. Since the relative proportions cannot be predicted in advance, effective water leak detection requires analysis of both. The system interprets the H2 and H2O vapour off-gas analysis with proprietary software that is capable of differentiating between normal operations and situations when there are abnormally high water levels in the EAF. The software is self-training and dynamically adjusts for changing scrap conditions (wet/dry/oily) to minimize the number of false alarms according to the steel

plant’s required set points. The system provides EAF operators with three alert levels: green for normal, amber for caution and red for immediate action. EFSOP Water Detection Technology™ is available as a module that can be integrated into an existing EFSOP® analyzer or as a standalone water detection system which can be upgraded in future to a full EFSOP Holistic Optimization System® for process control and optimization. Contact: www.tenovagroup.com E-mail: goodfellow@ca.tenovagroup.com

Technical innovations

Versatile and safe four-way forklifts MATERIAL HANDLING Customized four-way forklifts designed for the safe and space saving handling of the large and bulky loads typically handled in the sheet metal sector are a key competence of Combilift Ltd. They work as counterbalance, sideloader and narrow-aisle forklifts. Their versatility to operate both inside and out on semi rough terrain and in harsh weather conditions enables users to not only maximize available storage space but to also improve productivity in and around the warehouse. Sideways travel with loads resting on the platform enables the trucks to work in aisles widths of just 2 m, and avoids the need for hazardous high-level transportation, significantly improving safety procedures. With fully synchronized four-

way steering guaranteeing excellent manoeuvrability and flexibility of use, Combilifts can be deployed from the initial stages of offloading raw materials, during the manufacturing process, through to the handling, storage and dispatch of finished product. Capacities range from 2.5 to 25 t, with a choice of diesel, LPG and AC electric power options. The wide variety of lift capacities, mast heights, platform dimensions and range of attachments available means that practically every Combilift is purpose-built to provide a truly customized handling solution. Contact: www.combilift.com E-mail: info@combilift.com

Position sensor for hydraulics cylinders MEASURING EQUIPMENT A new, compact magnetorestrictive position sensor that can be completely integrated into the hydraulics cylinder has been developed by MTS Sensor Technologie. The new TemposonicsÂŽ E-series embedded sensor (EE) with its stainless steel housing, pressure-resistant sensor rod and flange is suitable for installation in small or clevis head cylinders. The sensor head is located in the cylinder base, the rod is fitted into the piston rod. A ring shaped position magnet, which slides over the sensor rod without making any contact, is fitted in the piston and calculates the cylinder stroke position. As the measuring process is contactless, the sensor does not wear out. The TemposonicsÂŽ EE measures positions with high precision, thus achieving a practically infinite resolution with the analogue output (4â&#x20AC;Ś20 mA). Its repeatability is < + 0.005% F.S. (full scale) with a linearity deviation of < + 0.02% F.S. Thanks to progress in waveguide technology and the advancement of electronics, the EE works with extreme resistance to interference. Its set points are calibrated at the factory.

Compact sensor for integration into cylinders

No recalibration of the position sensor is required throughout its entire lifetime. Connection to assembled cables is costeffective using an M12 plug. It is available in stroke lengths from 50 to 2,500 mm. Contact: www.mtssensor.de E-mail: info@mtssensor.de

MPT International 4/2013

Technical innovations

Drive technology for rolling mills HOT AND COLD ROLLING An improved version of its rugged TMdrive-70 variable frequency drive used to provide high torque and overload capability to main drives on hot strip mills and cold mill has been developed by TMEIC. Other applications include driving fans, pumps, compressors, grinding mills and mine hoists. The TMdrive-70e2 features lower cost, higher power level, reduced footprint, and enhanced safety features. Designed and built in Japan for high reliability, the drive has a very high mean time to failure (MTBF) similar to the original model. The IEGT-based drive is water-cooled and designed for operation with induction or synchronous motors. It operates at up to 3,300 Vac, and offers 3-level pulse width modulated output power at levels up to 36,000 kVA. The drive has a full regenerating converter which can operate in either the conventional pulse width modulated mode with the incoming

power factor at 1.0, or in the patented fixed pulse pattern control mode for enhanced voltage stability. The inverter output frequency is variable from 0 to 75 Hz (up to 90 Hz with derating), allowing operation with a wide variety of motor designs. Inverter frequency can be controlled over a variety of standard local area networks allowing computer speed control for coordinated drive system applications such as driving multiple stands on a hot strip mill. The new drive has enhanced safety features meeting IEC 618005-2 (safety integration level 2) and ISO 13849 (category 3). These requirements are met with independent gate command lockouts via two hardware inputs. Contact: www.tmeic.com E-mail: info@tmeic.com

4?PG?@JC kMU NSKNQ DMP NPCQQCQ HYDRAULICS For decades, industries all over the world have used triplex mechanical pumps in conjunction with accumulators and throttle valves to drive water equipment. Disadvantages of these mechanical pumps are their poor efficiency, high maintenance costs and the limitation to fixed delivery. Moreover, these pumps need a mechanical reduction gear box between the electrical motor and the shaft to reduce pistons speeds which are not constant but sinusoidal. Valve timing and piston sealing are critical due to sinusoidal speeds of the pistons. To overcome these drawbacks, Oilgear Towler developed a pure water pump capable of delivering a variable flow to the accumulators or directly into the press cylinders. Basically, these Transfer Barrier® (TB) pumps operate with pistons powered by non-aggressive fluids, such as HWBF (high water based fluid) or pure water. The water pistons are driven by oil cylinders, allowing variable control of the volume or pressure and a better overall efficiency compared to crankshaft-based fixed-flow pumps. In contrast to triplex pumps, which need dampeners as they deliver a pulsed flow, the TB pumps operate without pulsation due to the constant speed of displacement. The slow speed of the rams (0.25 m/s) reduces piston and seal wear. In Russia, Oilgear recently commissioned a 30,000 t closed die forging press after installing a new hydraulic system and software and control complete with the latest standard MMI interface. In particular, the obsolete mechanical water triplex pump, accumulator and intensifier drive were replaced by Oilgear’s patented Transfer Barrier® HWBF (high water based

Layout of a variable pressure pump

fluid) pumps. As they pump directly into the press cylinders, accumulators are not needed. These variable-delivery Transfer Barrier pumps allow position, speed, force and parallelism control of the press. In this application, the pumps operate at 450 bars without intensifiers. Contact: www.oilgear.de E-mail: info@oilgear.de

Non-contact laser gauge for improving process control and controlling production costs MEASURING EQUIPMENT Today’s ever-increasing market demands are rapidly forcing changes in the iron and steel in74

MPT International 4/2013

dustries as manufacturers attempt to remain economically competitive. Global competition is making these industries

take a fresh look at waste, wherever it exists in the production process. One area of concern is the use of contact-type

Technical innovations methods to measure product length and speed, such as contact tachometers and drive encoders, which are prone to a host of measurement errors from extreme heat, scale-build-up, and mechanical failure of parts. To solve this problem, the LaserSpeedÂŽ from Beta LaserMike uses advanced, laser-based technology to precisely measure the length and speed of hot and cold iron and steel products without making contact. This laser gauge projects a unique pattern on the productâ&#x20AC;&#x2122;s surface. As

the product moves, light is scattered back to the LaserSpeed gauge. This information is translated into product speed and pulses are produced to determine the product length. Length and speed measurements are captured with better than +/- 0.05% accuracy and +/0.02% repeatability. LaserSpeed uses no moving parts and is factory-calibrated. It works on all types of products, such as rod, bar, tube, pipe, slabs, cold/hold strip and profile, and is proven in mill applications involving continuous slab

casters, billet and bloom casters, cutting control, elongation control in temper and skin pass mills, and gauge control in cold rolling mills. Beta LaserMike offers a complete family of LaserSpeed measurement systems for a wide range of applications.

Contact: www.laserspeedgauge.com E-mail: sales@betalasermike.com

Online light element analyzer for light and heavy elements ANALYTICAL EQUIPMENT A new analyzer answering the need for dependable online monitoring and process control of light elements in mineral slurry has been launched by Outotec. The Outotec CourierÂŽ 8 SL analyzer is designed for accurate and reliable on-stream measurements of elemental concentrations in slurries for up to twelve sample streams. The laser-induced breakdown spectroscopy (LIBS) technology is able to measure both light and heavy elements. The unit provides realtime test data to complement measurements from X-ray fluorescence (XRF) analysis for monitoring and controlling the operations of mineral processing plants. It can measure the light element concentration in plant feed, tailings and concentrates, allowing the impurity content in the concentrate to be optimized while maintaining the best possible recovery. Applications that can benefit from the real-time test data provided by the analyzer include iron ore concentrators and pellet plants. Benefits include optimized recovery, savings on laboratory resources and labour, and more efficient use of energy and raw materials.

Light element analyzer in operation in mill environment

Contact: www.outotec.com E-mail: automation@outotec.com

High pressure pumps for forging line upgrade SPECIAL EQUIPMENT For a major forging line upgrade in Austria, Hydrowatt successfully supplied, installed and commissioned two high-pressure radial piston pumps. The electrical automation for the two 315 kW pumps was provided by Automatic Klein GmbH. The scope of this order comprised the electric engineering, the turnkey supply including commissioning on site of the electric cabinets, programming of the PLC and HMI systems, electrical installation and cabling. The electrical cabinets have a capacity of 1,600 A. The attached safety equipment is validated to SIL 3 according to EN/IEC 62061. Energy monitoring is by means of two Siemens Sentron PAC3200 systems. All protective equipment and contactors are Siemens-made. The PLC is a Simatic S7 315-2 DP made to customer specification.

Contact: www.automatic-klein.com E-mail: kontakt@automatic-klein.com

Pump station MPT International 4/2013

Technical innovations

New controller to improve charging at Corex plants IRONMAKING ArcelorMittal is modernizing the Corex plant at the Saldanha works, South Africa. Gimbal controllers from Siemens Metals Technologies will replace systems which have been in use since 2004 and 2006, respectively. Their range of functions will be transferred to a Siemens IT platform and expanded. The Corex C-2000 plant has been in operation at ArcelorMittal South Africa’s Saldanha works since the end of 1998. Two Gimbal charging systems feed the iron ore or pellets into the reduction shaft, and the coal into the melter gasifier, respectively. The new controllers will enable the chutes to be moved smoothly with low mechanical forces, and so distribute the raw materials precisely. The process engineer will be able to define not only standardized distribution patterns, such as rings, but also any desired pattern with the aid of the “Free Shape” function, for example offset ellipses, clover-leaf patterns and kidney shapes. This will allow geometric and/or process asymmetries to be compensated and improve process operation. The Gimbal automation system is based on rugged, industrially proven components from Siemens. The modular hardware platform will be complemented by a standardized programming environment. The operator and monitoring system has been expanded to include extensive diagnostic and condition monitoring functions. These include, for example, the detection of loss of the chute, impermissible pressures, electric short circuits, cable breaks and sensor faults. Important operating and diagnostic data are also displayed to the plant personnel on a Simatic Mobile Panel. This makes maintenance considerably easier. For example, hydraulic cyl-

The automation system allows the charge to be distributed precisely and dynamically in many different charging patterns

inders can be centred locally, valves can be checked or various process values can be displayed and subjected to a trend analysis. The Gimbal controllers are scheduled to be commissioned for real plant operation in August this year. Contact: www.siemens.com/metals E-mail: rainer.schulze@siemens.com

CNC edge trimming lines for tubes and narrow strips QUALITY ASSURANCE For improved product quality and increased production speed in strip machining, hplNeugnadenfelder Maschinenfabrik has developed new solutions together with its Swedish subsidiary Bergs Engineering. Nowadays, tools can be equipped with a motorized fine adjustment device to reach closest product tolerances and relieve the operator from this task. Together with the newly developed double dancer roller and the well-proven S-roller unit, a significantly increased range of strip edge contours can be machined in one strip edge trimming line. Furthermore, a new cooling and strip flushing system has been developed ensuring significantly improved cooling of the tools. Using this system allows continuous production speeds of up to 350 m/min. Especially for the machining of strips for the production of longitudinally welded steel tubes and copper strips used for transformer production, Bergs Engineering offers reliable solutions. Contact: www.hpl-neugnadenfelder.de E-mail: info@hpl-neugnadenfelder.de

MPT International 4/2013

CNC strip edge trimming line of the latest generation with OQVQTK\GF ƂPG CFLWUVOGPV QH VJG KPFKXKFWCN VQQNU CPF ECOGTCU for quality assurance

Technical innovations

"CTCJMNKCLR MD CLCPEW CDjAGCLR GPMLK?IGLE technology significant improvements in energy efficiency and emissions. Berry Metal Company’s role in the project will be bringing the technology to life through the design and manufacture of the equipment, enabling practical application. Most recently, Berry Metal Company’s technical and manufacturing specialists have devised the solution to advance the project from small-scale laboratory experiment to its current state, a much larger-scale pre-pilot reactor that is set to begin testing during the next two years.

Contact: www.berrymetal.com E-mail: info@berrymetal.com

IRONMAKING In collaboration with AISI and the University of Utah, Berry Metal Company is lending its expertise to the development of a flash ironmaking process aimed at establishing an energy-efficient and environmentally preferred alternative to the traditional blast furnace process. This project has been selected by the U.S. Department of Energy as part of its Innovative Manufacturing Initiative. This collaborative research effort has seen strong support – both from the government and within the steel industry due to its potential to cut down on energy use and environmental emissions, particularly carbon dioxide. The novel process utilizes direct gaseous reduction of fine iron concentrates in order to make iron and is being powered by natural gas. The mechanics, coupled with the use of natural gas, enable

At present, the steel industry is somewhat reluctant to place orders for new plants.

MPT International 4/2013

Literature service

Corrosion-resistant steel for mould manufacturing 6 pages, English, German A brochure featuring the precipitation-hardenable high-performance steel, Formadur PH X Superclean, developed by Deutsche Edelstahlwerke for use in plastic mould manufacturing. The brochure lists the properties as well as the benefits of this steel for the plastics-manufacturing industry. Contact: dew-stahl.com E-mail: sales.plasticmouldsteel@dew-stahl.com

Refractory lances and shaped refractories 14 pages, English, German A brochure describing the newly established Indian subsidiary of Germany-based GSB Group. It presents the new production unit of the group in India, which has positioned itself successfully in the Indian steel market as a supplier of refractory lances.

Contact: www.gsb-group.de E-mail: info@gsb-group.de

Force measurement systems 6 pages, English, German A brochure presenting force measurement systems from IMS. It contains descriptions of measuring amplifiers, force transducers, the measuring principle, the basic configuration, optional features and examples of application in strip or web tension measurement. Contact: www.ims-gmbh.de E-mail: info@ims-gmbh.de

Steel bar straighteners 4 pages, English A product brochure outlining the key features of the ASV-series straightening machines built by MAE Maschinen- und Apparatebau Gรถtzen. Descriptions of the movable straightening head, workpiece supports, manual or automatic loading/ unloading, fully automatic changeover, etc. are provided. Contact: www.mae-goetzen.de E-mail: sales@mae-goetzen.de

Mist eliminators 12 pages, English A detailed brochure describing mist elimination technology provided by Munters. It describes the process principle and the main equipment used to eliminate mist in evaporation and other processes. It also explains the benefits of the technology for the operator and the environment. Contact: www.munters.com E-mail: munters@muntersac.de

MPT International 4/2013

Literature service

Partners for steel 4 pages, English Vernet Behringer, manufacturer of machine tools, Rösler, manufacturer of surface finishing technology, and Behringer, provider of sawing solutions, have joined their knowhow to respond to the demands and expectations of steel fabricators and distributors. Contact: www.partners4steel.com E-mail: info@partners4steel.com

Lubricants 4 pages, English A concise brochure summarizing the range of oil and lubrication products offered by Quaker for use in aluminium processes; for example, casting, continuous casting and scalping lubricants, lubricants for reversing/breakdown operations, finishing lubricants and cold rolling lubricants. Contact: www.quakerchem.com E-mail: info@quakerchem.com

Carbon and graphite products 76 pages, English, German The new magazine-style image brochure of SGL group – The Carbon Company – showcases not only the company but also its comprehensive portfolio of carbon, graphite, and carbon fibre materials and products, as well as their innovative applications. Contact: www.sglcarbon.de E-mail: cms@sglcarbon.de

Modern logistics systems 16 pages, English, German A brochure describing in detail the range of logistics systems and services in this field supplied by SMS Logistiksysteme, for example, logistics planning, transport and handling systems, storage systems, packaging systems, strapping machines and marking systems, and grinding machines. Contact: www.sms-logistiksysteme.com E-mail: info@sms-logistiksysteme.com

Refractory systems for ingot casting 4 pages, English, German A brochure outlining shaped refractory products from Steuler-KCH for use in ingot casting. The brochure gives the dimensions of available centre runners, spider bricks and runner bricks as well as the chemical composition and the physical properties of the various product types. Contact: www.steuler-kch.de E-mail: ff.info@steuler-kch.de

MPT International 4/2013

In the next issueâ&#x20AC;Ś Ironmaking Steel Authority of India started up Indiaâ&#x20AC;&#x2122;s largest blast furnace Danieli Corus has commissioned the greenfield blast furnace No. 5 built for SAIL (Steel Authority of India Limited) at their Rourkela (Odisha, India) steel plant. This blast furnace was built by a consortium consisting of Danieli Corus and Tata Projects Limited and is currently Indiaâ&#x20AC;&#x2122;s largest blast furnace. The first hot metal was tapped after 27 hours.

Continuous casting Coating technology to increase life time of slab mould plates Worn mould plates are usually repaired by milling to remove the cracks created during casting. However, the plates become thinner and thinner each time they are refurbished. Recently, an electroplating technology has been developed that compensates the wall thickness decrease of the mould plate usually caused during refurbishing. As a result, life time of the mould plates increases significantly and associated costs are reduced. This newly developed copper-to-copper plating technology solution for slab mould plates has already been successfully used in German and American continuous casting plants.

Environmental protection Efforts to reduce cooling water consumption in a steelmaking facility The water treatment plant (typically referred to as an auxiliary plant) is essential to ensure the continuity of production and plant operations in a steelmaking facility. If water resources are limited, a non-conventional approach is needed to design a water treatment plant with low water consumption. For a steel plant in a desert area, auxiliary facilities have been developed that reduce raw water consumption down to approximately only 120 m3/h on a daily average, while respecting the limits imposed by the availability of water on site and maintaining a safety margin for the extension planned for the future.

This preview may be subject to change.

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MPT International 4/2013

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SERVICE MAKES THE DIFFERENCE Reducing electrode consumption, shorter tap-to-tap times and high arc stability enable an efficient melting process. Our graphite electrodes come with a comprehensive service package and various options to optimize your operations. Everything around the graphite electrode, and more.

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