MPT International 3/2014 (Jun)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

Siemens and Mitsubishi Heavy Industries to join forces in plantmaking business

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June 2014

Taking carbon capture and storage a step further

Creating solid value…

Fascinating continuous casting Intelligent continuous casting is what you get from the expertise and creativity of our engineers. There is a direct relationship between the quality of your slabs and the quality of your final products. That’s why opting for SMS Siemag top technology is as good as gold for you.

Take for instance our Intelligent Slab Casting Technology

(ISC) that links cooling and dynamic soft reduction with the drive design. This gives you 5 percent higher productivity than conventional plants. So the casting process creates what we all want – solid value.

SMS Siemag – top technology for top products

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

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Drawing on one’s own strengths During the last few months, steel industries in many regions of the world have been facing major challenges. Oversupply and growing pricing pressure have fueled competition.

Some countries are (again) resorting to protective measures in order to ward off the effects of unfair market practices. In order for a company to remain competitive in the market it is crucial to know one’s own market position and never cease improving one’s own strengths. It is common knowledge that high product quality, high efficiency of production and optimal value added are key factors for long-term market success. It may sound a bit banal here to emphasize that these criteria can be best met with modern production equipment. But in fact, in this issue of MPT International, we are presenting several very interesting examples of recently completed or projected plant modernizations. For example, Taishan Iron & Steel in China has revamped not less than three converters for stainless steel production. Since the modernization, the implemented advanced process control model has covered all special working conditions, reliably ensuring a high level of productivity and excellent quality. The operational costs have also been dramatically reduced.

Dipl.-Ing. Arnt Hannewald

Another example is the planned comprehensive upgrade of the Dolvi works at JSW Steel in Maharashtra, India. Here, the two-strand thin slab caster and the downstream hot strip mill will be upgraded. The most important aim of this project is to boost the annual capacity and to provide the preconditions for the production of high-quality low and medium carbon steel strip and HSLA grades.

In this issue, you will also find ample information on current plant technology and technical solutions, ranging from transformers for EAF plants and services for meltshop optimization up to sophisticated services aimed at minimizing the time needed to construct new buildings at steelworks and rolling mills. A critical aspect in all modernization projects is to shorten shutdown times by having various project phases take place simultaneously, e.g. engineering planning, off-site preparation and on-site work by highly specialized experts.

Plant modernizations are an exciting topic. Above all, they are signals showing that there is no stagnancy or wait-and-see attitude in the industry.

MPT International 3 / 2014

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››› CONTENTS

International industry news 26

Siemens and Mitsubishi Heavy Industries to join forces in plant making business

28

Word Steel Association short range outlook 2014 – 2015

30

Mexican-Indian alliance to establish a network of micro mills in the Nafta region

Company profile 32

Cover photo: New heavy duty wire rod block DELTA type for high-grade steels Morgårdshammar AB – part of the Danieli group www.morgardshammar.se E-mail: mh@morgardshammar.se

Tulachermet to transition from pig iron into structural steel production The new steelworks and rolling mill complex is scheduled to start up operations in 2016

Ironmaking

Environmental protection

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ThyssenKrupp Steel to modernize Europe’s biggest blast furnace The plant has reached the end of its first campaign after 21 years. It will go back into operation after a short shut-down period

Taking carbon capture and storage a step further Emirates Steel is taking part in an ambitious project whose aim is to capture, reuse and store 800,000 tonnes of CO2 from its steel plant annually

Steelmaking 40

Modernization of the converter plant for stainless steel production at Taishan I & S

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The implemented process control model has covered all special working conditions such as high carbon content and low temperature of the utilized hot metal

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Design criteria and examples of transformers for EAF plants

Micro steel mill project implemented in Iceland The plant manufactures blooms and mini slabs used as electrodes in the aluminium melting industry

54

Steel producers request tailor-made solutions for the electrical conversion system

Graphite electrodes and process-oriented services for the distinct needs of meltshops SGL Group continues on its way from an electrode supplier to a solution provider to the steel industry

Modernization 58

Building a new plant structure in almost no time

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The use of pre-assembled foundation blocks manufactured beforehand enables the reconstruction to be completed within an extremely small time window

JSW Steel to upgrade 2-strand thin slab plant at Dolvi works The most important aim is to boost the annual capacity and to enable production of high-quality strip of low and medium carbon steels and HSLA grades as well

Material flow logistics

Materials

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ArcelorMittal Eisenhüttenstadt introduces a new storage logistics system The Simetal Siloc solution optimizes workflows, simplifies stock control and shortens cycle times

MPT International 3 / 2014

New special steel wire rod to substitute quenched and tempered steels Swissbain-7MnB8 saves resources in the production of high strength parts, particularly for the automotive and construction industries

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Columns 8

International industry news

78

Literature service

68

Technical innovations

80

In the next issue

77

Cartoon

80

Imprint

Advertisers’ index ABB AB 47 Aumund Fördertechnik GmbH 67 Badische Stahl-Engineering GmbH 53 Braun Maschinenfabrik Gesellschaft m.b.H. 13 Can-Eng Furnaces 79 Castellini Officine Meccaniche S.p.A. 63 Danieli Automation Spa 31 Danieli S.P.A. 6, 7 ELKA nv 70 Emerson Industrial Automation 57 Endress + Hauser Messtechnik GmbH & Co. KG 33 Fabris InC. 61 FC Technik AG 18 Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS 23 Johannes Hübner - Fabrik elektr. Maschinen GmbH 15

INTECO special melting technologies GmbH 69 Jasper Ges. für Energiewirtschaft & Kybernetik mbH 21 JATO-Düsenbau AG 17 KettenWulf Betriebs GmbH 19, 20 Kiro-Nathaus GmbH 11 Friedrich Kocks GmbH & Co. KG 27 Maschinenfabrik Köppern GmbH & Co. KG 73 Koll Anlagenbau GmbH + Co. KG 70 Lubas Maschinen GmbH 25 Maschinenfabrik G. Eirich GmbH & Co. KG 45 Messe Düsseldorf GmbH 22 Pert srl 35 Plakoma GmbH 43 Reed Exhibitions (Deutschland) GmbH 12 REFRATECHNIK Steel GmbH 51

Schubert & Salzer Control Systems GmbH Schuh Anlagentechnik GmbH SGL CARBON GmbH Siemens VAI Metals Technologies GmbH Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG SMS Siemag AG SUS Tenova spa TML Technik GmbH Verlag Stahleisen GmbH WOKO Magnet- und Anlagenbau GmbH PAUL WURTH S. A. Z & J Technologies GmbH Zumbach Electronic AG

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Two AC EAFs with continuous scrap feeding, two twin LFs and a twin VD.

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››› INTERNATIONAL INDUSTRY NEWS

The Americas

coating will be applied at ArcelorMittal Vega do Sul.

Argentina Tenaris Siderca starts up carbon injection system. Tenaris Siderca recently commissioned a carbon storage and injection system supplied by MORE on its 100 t EAF No. 4 in Campana. Tenaris Siderca’s plant has an annual production capacity of 900,000 t of seamless tubes. The carbon storage and injection system supplied by MORE includes one dispenser of 2,500 l capacity for pneumatic transportation of carbon from the main 130 m³ external storage silo to the three day bins located inside the meltshop bay. Three dispenser units of 2,500 l located under the three internal day bins feed the carbon injectors installed on the EAF shell. The system is equipped with a precisely operating carbon flow-rate control and features for stabilization and optimization of compressed air consumption. MORE has also provided the engineering for the locally manufactured storage silo, day bins and carbon pipelines and developed the electrical and automation system.

Brazil ArcelorMittal invests in automotive steel production. ArcelorMittal is investing around US$ 15 million in the production of advanced high strength steel at its Vega do Sul flat steel rolling mill in the state of Santa Catarina in southern Brazil.

The plant’s existing production lines will be equipped to produce Usibor®, a press-hardening boron steel with an aluminium-silicon coating used mainly in the automotive industry. With a strength of 1,500 MPa after hot stamping, the material is one of the most resistant steels used in automotive applications. Since 2012, Usibor® has been imported from ArcelorMittal plants in Europe into Brazil. Production in Vega do Sul is due to start in the second quarter of 2015. Hot rolled coils will continue to be produced at ArcelorMittal Tubarão in Espírito Santo, and the patented aluminium-silicon MPT International 3 / 2014

Canada Varsteel purchases levelling technology. Herr-Voss Stamco has received an order from Varsteel of Lethbridge, Alberta, for a retrofit of its enhanced leveling technology (ELT™).

The new leveller will process material up to 12.7 mm thick and 2,440 mm wide for producing stay-flat material during and after post-processing by lasers, plasma and water jet cutting. This technology can be deployed as part of a new cut-to-length line, a compliment to an existing cut-to-length line, or as a stand-alone process with the ability to enhance individual sheets. Herr-Voss Stamco’s ELT™ includes a patent pending state-of-the-art control system, which provides operators with immediate feedback on the consistency of enhancement for all sheets processed.

poration, BlueScope Steel of Australia and IHI Corporation of Japan. The independent steelmaker will be the first licensee outside of Nucor to build a Castrip facility. The new plant will have the capability to produce 500,000 t/year of thin-gauge, high-strength sheet steel for local manufacturing and construction markets. The new twinroll casting and rolling plant will produce ultra-thin cast strip coils up to 1,680 mm wide, with gauge ranging between 0.8 mm and 1.8 mm. Start-up of the new Castrip facility is expected in early 2016. The process equipment and technical services for the new facility will be provided by a consortium comprised of Siemens Metals Technologies, IHI and Castrip. IHI and Siemens are licensed exclusively by Castrip to provide core equipment for Castrip facilities. The consortium has developed an optimized supply model for worldwide distribution of all new Castrip plants.

USA Canada Ivaco to upgrade facilities. Ivaco Rolling Mills is going to modernize its facility to increase capacity and produce higher-quality steel products, expanding opportunities to supply industries including automotive, advanced manufacturing and energy.

Also, the new technology will make the plant more energy efficient, require less raw materials and reduce particulate emissions for cleaner air. The province of Ontario is providing a loan of 7 million Canadian dollars towards the project, which has a total value of 80 million Canadian dollars.

Mill Steel to expand steel service facilities. Mill Steel, a flat rolled steel service centre company headquartered in Grand Rapids, Michigan, recently purchased a 10,000 m² facility in Jeffersonville, IN. The company has announced an immediate expansion of that facility by adding another 11,000 m². Mill Steel’s new assets will house two state-of-the art slitting lines in addition to a cut-to-length line. The new Jeffersonville facility will start operations in June 2014. It is located on the Ohio River within the Port of Indiana-Jeffersonville.

USA USA EAF steelmaker to build thinstrip casting plant. An independent North American EAF steelmaker has signed a license agreement with Castrip to build and operate a plant utilizing the Castrip® thin-strip casting process. Based in Charlotte, NC, Castrip is a joint venture of Nucor Cor-

Voestalpine to build DRI plant in Texas. Voestalpine has broken ground for the construction of a direct reduction plant in Texas. This EUR 550 million investment is the largest foreign investment in the history of the Austrian group. The Voestalpine Texas LLC plant is being constructed at the La Quinta Trade Gateway Terminal in close proximity to the city of Cor-

E10001-M1-Z50-V1-7600

“Others are experimenting.

We are producing. In endless mode.”

Giovanni Arvedi, inventor of the Arvedi ESP process, trains the next ESP operators in his plant that's operated successfully since start-up in 2009 – implemented with Siemens VAI. siemens-vai.com

Evolution of the ESP process 1992 – Start-up of ISP plant 2004 – ISP caster upgrade by Siemens VAI 2006 – Order for first ESP plant to Siemens VAI 2009 – Start-up of first ESP

After five successful years of operation at the patented ESP plant in Cremona, Italy, the Arvedi ESP technology rollout starts now with the next two installations in China.

At these new plants the operators will undergo comprehensive training at the plant in Italy, and Arvedi experts will support a smooth ramp-up to high-quality production in the first year of operation.

Highlights since 2009: t Certified API X70 production t Attested 131.6 kWh/t energy consumption t Only five breakouts per year t 0.1% cobble rate t 98% yield from liquid steel to coil t Thin strip down to 0.8 mm at full width and productivity 2013 – Order for next two ESP plants from Chinese customer

Answers for industry.

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››› INTERNATIONAL INDUSTRY NEWS

News in brief China Steel Corporation (CSC), Taiwan, has successfully commissioned the 270 t twin-ladle furnace No. 3 supplied by SMS Mevac. The furnace was installed in the No. 2 BOF steelmaking plant.

Shanxi Taigang Stainless, China, has successfully put on stream the new 80 t duplex RH-TOP plant supplied by SMS Mevac and its consortium partner SMS Siemag Technology (Beijing).

Dongbei Special Steel, China, has commissioned a hydraulic radial forging machine with two forging manipulators at its works in Dalian, Liaoning province. The equipment was supplied by SMS Meer.

pus Christi. Starting in 2016, the plant will produce 2 million t/year of hot briquetted iron (HBI) and direct reduced iron (DRI), of which about half will be shipped by sea to Voestalpine’s Austrian steel plants in Linz and Donawitz.

The other half will be used as a strategic reserve and sold to long-term partners.

With the new facility, Voestalpine intends to reduce production costs in Europe, as the price of natural gas in the USA is about half of what it is in Europe.

USA Axis Pipe and Tube orders equipment for pipe production. Axis Pipe and Tube, based in Houston, Texas, has ordered a heat treatment facility and pipe threading line from SMS Meer for its Bryan works. With the two plants the company will be able to produce OCTG tubes (oil country tubular goods) used for natural gas and crude oil production. The heat treatment line will include a hardening and tempering furnace, a water quenching unit and a hot straightener. Axis Pipe

and Tube will use the heat treatment line to produce tube grades of up to HCP110.

The pipe threading line will feature two threading machines operating on the “stationary tool/rotating tube” principle. SMS Meer’s supply will include a hydrostatic pipe tester with a maximum test pressure of 15,000 psi, a finishing section and all connecting transport equipment for the threading line. The tubes and pipes processed on the threading machine will conform to manufacturing standards as per API 5CT.

Asia China General Steel signs iron ore supply agreement. Shaanxi Longmen Iron and Steel has signed a supply agreement with Rio Tinto for the procurement of imported iron ore. Under this agreement, which commenced in April 2014, Rio Tinto directly provides Longmen at least 1.5 million t of imported iron ore at a price based

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INTERNATIONAL INDUSTRY NEWS on the average monthly iron ore index upon delivery. The Longmen joint venture belongs to General Steel Holdings.

China Angang orders hot-dip galvanizing line. Angang Steel Company has placed an order with SMS Siemag for the supply of a continuous hot-dip galvanizing line. The line, designed to galvanize 450,000 t/year of steel strip, will be installed in a new plant near the city of Guangzhou in the province of Guandong. The line will be designed for strips in thicknesses ranging between 0.4 and 2.5 mm and widths between 800 and 1,880 mm. In addition to the design of the complete mechanical equipment and the manufacture of the core machines, SMS Siemag will supply all the electrical and automation systems and provide the coordination of key subcontractors as well as supervision of installation and commissioning.

To achieve high cooling rates, a vertical radiant tube furnace will be installed.

The furnace, supplied by Drever International, will have an oxidation chamber to increase the wettability of steel grades with high manganese and silicon contents through objective oxidation and subsequent reduction. Furthermore, a high-quality air-knife system from DumaBandzink will be integrated. Modern features such as a patented radial regulating device, an automatic lip cleaner and a width adjustment system for the air knife will achieve high-grade surfaces. Drever International and Duma-Bandzink are both companies of the SMS group.

Starting in the second half of 2015, the plant will produce mainly deep-drawing grades and high-strength steels for the automotive industry, including premium-surface strips for exposed vehicle parts.

Saudi Arabia Group Five Pipe Saudi to expand large-pipe production. Group Five Pipe Saudi Ltd. has placed an order with Schuler for the supply of a com-

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News in brief Deutsche Edelstahlwerke, Germany, is expanding coil production at its Hagen site through the addition of a double upset wire butt welding machine from Strecker for welding 8 and 25 mm specialty steel wire.

Oil and Gas Systems, Russia, has brought on stream the 140 MN hydraulic forging press supplied by Schuler. The press is a core element of the new facility built near Aleksin in the Tula region. A speciality of the press is the forging of large shells for valve bodies in oil and gas pipelines.

Acciaierie Valbruna, Italy, has commissioned four mill stands, supplied by SMS Meer, in the intermediate train of its long product mill as part of a mill upgrade.

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12

››› INTERNATIONAL INDUSTRY NEWS

News in brief SMS Meer Engineering China (SMEC) has expanded its workshop capacity in Shanghai. The workshop is used to produce, among others, forging and finishing equipment and components for wire rod and tube plants.

Stahl Judenburg, Austria, has successfully commissioned a bright steel centre supplied by SMS Meer.

Schuler, Germany, press manufacturing company with a long tradition, celebrates its 175th anniversary in 2014.

Tata Steel, India, has commissioned its new coke oven battery No. 11 at Jamshedpur. Operating with 88 ovens, the battery will give the Jamshedpur steel works self-sufficiency in coke.

plete pipe plant. At its heart will be an offline spiral pipe line for manufacturing pipes with diameters of 508 to 2,235 mm and lengths of 12 to 24.4 m. In addition, the pipe plant will boast four welding stands and various testing stations. Operating at a speed of up to 10 m/min, the new plant will increase the company’s capacity by up to 400,000 t/ year. Schuler will not only be building and supplying the complete plant with all peripheral equipment, but also install the entire equipment and launch production over the course of the coming year.

South Korea Hyundai orders bloom caster and rolling mills. For a new special steel mill in Dangjin, Hyundai Steel has placed an order with Siemens Metals Technologies for a continuous bloom casting machine, a large-bar rolling mill and a small-bar and wire rod mill. It is planned to produce 400,000 t/year of wire rod and

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600,000 t/year of straight bar and barin-coil. The four-strand continuous bloom caster will have an annual capacity of 1.1 million t. The caster will be equipped with mould-level control and breakout protection systems. In combination with air mist spray cooling and interior-cooled rollers in the strand guidance system, further technology packages ensure uniformly high quality of the blooms cast for direct hot-charging into the bar line. The large-bar mill will encompass a twohigh reversing breakdown stand and a finishing train with rolling/sizing stands. The large-bar mill will also provide billets to be further processed in the small-bar and wire rod mill, which will have a capacity of 800,000 t/year.

This mill will include a breakdown and intermediate mill feeding a reducing & sizing block supplied by Friedrich Kocks for the production of bars, a rod outlet and also a bar-in-coil outlet. The 5-stand heavy-duty reducing & sizing block with a nominal roll diameter of 370 mm will feature the well proven 3-roll design and be equipped with a closed-loop size control system

INTERNATIONAL INDUSTRY NEWS (SCS). A high-speed remote control of passes and guides of the 3-roll stands in the mill line will allow the implementation of stands adjustable under load (AUL). After completion of the combined wire rod and bar mill, the RSB will be able to finish roll the total production of straight and coiled bar in SBQ quality in all sizes within the dimensional range from 16.0 to 100.0 mm diameter. Commissioning of the plants is scheduled for the end of 2015.

Thailand NS BlueScope Thailand to revamp metal coating line. NS BlueScope Thailand, which is a company of NS BlueScope Coated Products, a joint venture of Nippon Steel & Sumitomo Metal Corporation and BlueScope Steel Limited, has decided to revamp its existing No. 2 metal coating line in order to commence production of SuperDyma™, a unique product of Nippon Steel & Sumitomo Metal featuring excellent corrosion resistance.

This product is steel sheet hot-dip coated mainly with zinc, but also with aluminium, magnesium and silicon.

Commencement of SuperDyma™ production is scheduled for August 2015.

Vietnam Formosa orders semi-continuous billet mill. Formosa Ha Tinh Steel has placed an order with SMS Meer for the supply of a semi-continuous billet mill for its new integrated steel plant in the Ha Tinh province.

The 160 mm und 180 mm square billets produced in the new mill will be used within the Formosa Group as starting material for the production of wire rod and bars. The maximum production capacity will be 1 million t/year, with the option to increase it to 2 million t/year in a second expansion phase. In addition to the supply of the complete mechanical equipment and the electrical and automation systems, SMS Meer will provide theoretical and practical training to Formosa’s work-

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News in brief Kobe Steel, Japan, has brought on stream a new hot-metal treatment plant at its Kakogawa works. The treatment plant comprises two desulphurization reactors and one dephosphorization furnace.

Shanxi Gaoyi Steel, China, has brought on stream two wire rod mills from SMS Meer. With the two single-strand lines, Shanxi Gaoyi will be able to produce up to 1.5 million t/year of wire rod.

Cascadia Metals, USA, recently saw the commissioning of two Herr-Voss Stamco processing lines, a cut-to-length line and a Strand Extensioner® slitting line.

Wuxi Turbine Blade, China, has brought a screw press back on stream after an upgrade carried out by SMS Meer.

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››› INTERNATIONAL INDUSTRY NEWS force. Commissioning of the new mill is scheduled for 2015.

News in brief Waelzholz New Material, China, subsidiary of German C.D. Wälzholz, has opened its new cold rolling mill in Taicang, in the Shanghai area. What started out as a service centre focusing on warehousing, slitting and the supply of steel strip from Europe, has now become a complete cold rolling mill with a four-high rolling stand and several high-convection batch annealing units.

Voestalpine, Austria, has commissioned a new tube reeler from SMS Meer. With the new reeler, Voestalpine is able to roll greater shell weights with a max. diameter of 221 mm and wall thicknesses up to 25 mm.

Changzhou ChangBao, China, has commissioned a new stretch-reducing mill and groove dressing machine from SMS Meer.

Nippon Steel & Sumitomo Metal has established an office in Dubai to provide sales support and technical services in that region.

Evraz, Kazakhstan, has brought into operation a long rolling mill from Siemens Metals Technologies at its new production location in Kostanay. The mill is designed to produce 450,000 t/year of rebar.

Australia and Oceania

a Loesche vertical roller mill of the LM 27.2 D type capable of producing 42 t/h at 15% R 90 μm. Loesche’s supply scope includes all mechanical equipment, silos, the hot gas generator for the mill, the electrical equipment, motors, instrumentation as well as detail mechanical and electrical engineering. Commissioning of the plant is planned for the end of 2014.

Australia BHP Billiton opens iron ore mine. BHP Billiton officially opened its new Jimblebar iron ore mine 40 km east of Newman in the Pilbara region of Western Australia. Jimblebar is expected to deliver a phase-one capacity of 35 million t/year by the end of the 2015 financial year. Expanding Jimblebar to 55 million t/year is a longer term option. Mobile crib rooms and fuelling stations have been positioned closer to the mine pits to reduce truck travelling time.

New Caledonia Le Nickel-SLN to install coal grinding plant. Loesche Latinoamericana is designing and supplying a new coal grinding plant to Le Nickel-SLN, which is part of the Eramet group. The plant will be integrated into the nickel production facilities already in operation in Nouméa.

Loesche will supply the complete coal grinding plant, extending from the receiving hopper through to the existing fine coal storage silos, and two silos to feed the hot gas generators. The heart of the coal grinding plant will be

Europe Belgium ArcelorMittal Industeel to upgrade slab caster. ArcelorMittal will upgrade the continuous casting line at its Industeel Belgium site in Charleroi.

The upgrade project will increase maximum slab thickness from 300 mm to 355 mm and maximum length from 2,100 mm to 2,200 mm. These larger slabs will be used to produce, for example, 125-mm-thick heavy plates, predominantly used in the boiler and pressure vessel construction market, and 150 mm and 175 mm heavy plates.

The upgrade will be performed during the annual shutdown in July and August 2015. Commercial production is scheduled to commence in the first quarter of 2016.

Finland Ruukki to replace oil injection with PCI system. Rautaruukki is to replace the blast furnace oil injection

Air Handling Systems Mist extraction systems Dust removal systems Vacuum systems Trim removal systems

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More than 550 plants for industrial processing worldwide since 2002.

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MPT International 3 / 2014

INTERNATIONAL INDUSTRY NEWS system at its Raahe steel mill with a new pulverized coal injection (PCI) system. The coal will replace the more expensive injection of oil and coke.

Claudius Peters Projects has been selected to supply the injection system.

The project involves coal storage, handling, drying and pulverizing systems, which will be located in the immediate proximity of the blast furnaces. Construction work associated with the project will take place whilst production is running. The new system will be brought into use during the second half of 2015.

Finland JV to buy Ruukki’s power plant. Rautaruukki and EPV Energy have established Raahen Voima Oy, a joint venture company, which will buy Ruukki’s existing power plant business for around EUR 16 million and invest around EUR 121 million in modernizing the plant. Ruukki owns 75% of the new company and EPV 25%. When it comes on stream, the modernized power plant will replace the technically obsolete equipment in the old power station. The Raahe works own power plant currently generates around half of the electricity used by the works.

Most of the electricity is produced from the works’ own process gases.

Besides being used for electricity production, the heat and steam generat-

ed in the processes at the Raahe works are used for heating on the works site and as district heat for Raahen Energia.

Raahen Voima Oy will continue to sell district heat to Raahen Energia. The modernized power plant is planned to start up in 2016.

Germany Outokumpu concludes negotiations on industrial plan. Outokumpu’s negotiations regarding the industrial plan have been successfully concluded with the employee representatives and unions in Germany. The industrial plan for Business Area EMEA Stainless was originally announced in October 2013, with a target of EUR 100 million annual savings, contributing to the overall annual synergy and cost savings of EUR 450 million in 2017. These are the key elements of the agreement: following a production transfer process, the Bochum meltshop will be closed in 2015; Outokumpu will invest EUR 108 million in the Krefeld cold rolling centre between 2014 and 2016 through the ferritic production optimization project; and the Benrath cold rolling mill is expected to be closed in 2016 after the production transfer to Krefeld has been completed. This now agreed industrial concept will result in a reduction of 1,000 jobs, thereby bringing the total

Germany BGH to build VAR plant. Inteco will engineer and supply a 10.5 t vacuum arc remelting (VAR) furnace to BGH Edelstahl Lippendorf. The furnace will be equipped with a drip short control, a helium cooling system and a feature to execute partial pressure remelting. The installation will start up in October 2014, with the production of the first ingot being scheduled to take place before the end of the year.

Italy ABS to revamp production facilities. Within the framework of its investment programme, Acciaierie Bertoli Safau is starting the revamping of continuous caster No. 3 and the blooming operations at its production facilities in Udine. The continuous caster currently makes 500, 600, 700 and 750 mm sections. The caster will be modified during a stoppage scheduled from the end of July until mid October 2014, adding 850-mm-diameter blooms to the size range. Blooming mill 900, which produces round bars from 230 to 400 mm and square bars from 150 to 500 mm,

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will be completely replaced by a new mill (blooming mill 1000) to be able to handle the larger bloom diameter.

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OCSA to install surface inspection system. ISRA Vision Parsytec is installing a new Surface Master inspection system at OCSA, a manufacturer of cold rolled precision steel strips and part of the Gabrielli group. The inspection system will be designed to inspect both the top and the bottom of narrow strip steel. It will make use of matrix cameras with a resolution of 170 Îźm as well as bright and dark field lighting to precisely detect any surface defect. Thanks to the compact design of the components, the system can be installed within the confined space provided. The innovative software module includes a pre-programmed defect catalogue with a comprehensive range of information about typical defect types, ensuring that defects are reliably categorized. In addition, the system detects unwanted stripes on the metal surface with outstanding precision.

HF tube welding line with API finishing facility from SMS Meer for installation at its works in Gliwice. SMS Meer will supply all the technical equipment for the line as a tailor-made all-inclusive package, including responsibility for installation and commissioning.

The new machine will have an annual capacity of 270,000 t and will be able to produce tubes with diameters from 4 ½ to 12 žâ&#x20AC;?, wall thicknesses from 3.0 to 12.7 mm, and lengths of up to 18 m. The maximum production speed will be 60 m/min. All stands will be equipped with a separate drive unit. The computer-controlled CSS-QuicksettingÂŽ system ensures that the rolls are automatically adjusted to their working positions after a size change. The produced tubes will fulfil demanding standards such as API 5L for line pipes and EN 10219 for round, square or rectangular structural sections. Thanks to the horizontal quick-change system, Huta Ĺ abe¸dy will be able to achieve a higher productivity than with conventional quickchange systems. Commissioning is scheduled for the third quarter of 2015.

Turkey Montenegro

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MPT International 3 / 2014

Tosçelik Niksic orders rotary hearth furnace. Tosçelik Niksic has awarded SMS Meer the order for the supply of a rotary hearth furnace with a capacity of up to 12 t/h. The furnace will be used to heat materials like hardening steel, ball-bearing steel and stainless steel to forging temperature for further processing. The MEER-FlameŽ burner will allow a marked reduction in power consumption and NOx emissions in comparison with the currently used furnace. The SMS PrometheusŽ level 2 control system ensures uniform temperature distribution as well as a low level of oxidation and carbon enrichment of the steel. Commissioning is scheduled for the fourth quarter of 2014.

Poland Huta Šabe¸dy orders tube welding line. Huta Šabe¸dy has ordered an

Kardemir orders bar and wire rod mill. KarabĂźk Demir Celik (Kardemir) has placed an order with SMS Meer for the supply of a special bar quality (SBQ) rolling mill for the production of surface-quenched and tempered rebars, straight bars, wire rod and bar in coils. In a first stage, the mill will have an annual capacity of 700,000 t, allowing for a capacity increase to 1,400,000 t/year in a second phase.

The mill will comprise a walking-beam reheating furnace with a capacity of 150 t/h, 18 housingless two-high stands in H/V arrangement, a precision sizing mill (PSMÂŽ), shears, cooling lines, cooling bed with finishing facilities, a wire rod line with a 10-stand MEERdriveÂŽ wire rod block, laying head, loop cooling conveyor, coil handling equipment and two coil compactors. A coiling line with two coilers and cooling facilities will complete the mill. The line will be designed to produce bar in coils in 20 to 55 mm in diameter and SBQ bars in 20 to 100 mm in diameter. The PSMÂŽ will

INTERNATIONAL INDUSTRY NEWS also serve as a wire rod outlet with a 10-stand block for rolling wire rod (5.5 to 25 mm in diameter). In the MEERdrive® wire rod finishing block, each stand will be driven individually by its own motor. An extension of the plant by the addition of a second furnace, a second roughing and intermediate mill and a second MEERdrive® block has already been taken into consideration in the plant concept. Commissioning is scheduled for the first quarter of 2015.

Turkey Isdemir to upgrade surface inspection system. ISRA Vision Parsytec will be installing an expansion to the Surface Master surface inspection system in place at Isdemir. The new equipment will be installed on the plant’s hot wide strip conveyor. In addition to special cameras capturing the top surface, a movable sensor directed towards the bottom surface of the steel coil will be fitted to the production equipment. Being optimally coordinated to each other, these components will allow Isdemir to inspect both sides of the coil at the same time.

The result is the ability to seamlessly detect even the smallest defects. Isdemir will also receive an upgrade to the Surface Master software, integrating the modules CoilRelease and ProcessAnalysis. These enable the user to always make the optimum coil grading decision depending on the coil quality in each case.

Companies Schmolz + Bickenbach to sell distribution units. Schmolz + Bickenbach has decided to start a selling process for specific distribution units in Germany, Belgium, the Netherlands and Austria. The final resolution will be taken after evaluation of all offers. Schmolz + Bickenbach’s restructuring programme will continue to be implemented according to plan. It mainly incorporates a reorganization of the sales area, process optimizations as well as further personnel reductions and the closing of some sites.

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The affected distribution units belong to the Sales & Services division and focus on selling third party products. As the future focus of Schmolz + Bickenbach will lie on production and sales of ownmill products, the units no longer fit into the group’s strategic direction.

TMW and Zhejiang Jingu form technology JV. The Material Works (TMW) and Zhejiang Jingu have formed a joint venture company, TMW Jingu Environmental Protection Equipment Manufacturing Company Limited, to supply EPS cells exclusively to the Chinese and Korean markets.

The EPS process is an environmentally friendly replacement for acid pickling of hot rolled steel strip developed by TMW. This patented process removes mill scale from the surface of hot rolled steel using ordinary water and fine steel grit. It does not require an oil film to prevent the treated steel from rusting.

Zhejiang Jingu, manufacturer of steel wheels, operates seven production sites. A new 25,000 m² facility will be built in Fuyang, near Zhejiang Jingu’s headquarters, to host the EPS cell manufacturing.

Adjacent to that facility, Zhejiang Jingu will build an advanced steel service centre, in partnership with Anshan Iron and Steel. Included in that facility will be a two-cell EPS coil line to produce EPS-processed steel for Zhejiang Jingu’s wheel production and for other manufacturers. Both facilities are expected to be operational in the first half of 2015.

Outotec to cooperate with Tomra Sorting. Outotec has agreed with Tomra Sorting to cooperate in the supply of Outotec-branded sorting solutions for the mining and metallurgical industries. Tomra Sorting is a global supplier of sensor-based sorting solutions used to separate ore from waste rock at mine sites. Tomra’s sorters can significantly reduce specific energy consumption and the amount of water used. By combining Tomra’s sorting equipment and Outotec’s comprehensive application and comminution expertise, customers can be offered energy-efficient process solutions.

MPT International 3 / 2014

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Evraz to dispose of Vitkovice Steel. Evraz has signed and closed the deal on the disposal of its wholly-owned subsidiary Evraz Vitkovice Steel (EVS) to a group of private investors for a gross consideration of US$ 89 million adjustable for the actual level of EVS working capital. In addition the buyers have assumed US$ 198 million of EVS’s debt, including the repayment of US$ 128 million of Evraz’s inter-company loan.

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ThyssenKrupp MSS takes over operations of Schaumann. ThyssenKrupp MillServices & Systems has taken over the entire operations of Schaumann. Besides the employees, ThyssenKrupp MillServices & Systems has acquired the workshop and adjacent employee facilities plus the complete fleet for Schaumann’s in-plant logistics. The equipment includes wheel loaders, excavators, telescopic excavators and special metallurgical equipment.

Unifrax to purchase share in Luyang. Unifrax, manufacturer of specialty fibre products, has entered into a share purchase agreement to acquire a 29% stake in Shandong Luyang share. Concurrently, it was agreed to establish a strategic cooperation relationship between Unifrax and Luyang. This includes a technology license agreement that will allow Luyang to use certain Unifrax manufacturing technology. Luyang develops, manufactures and sells a variety of refractory and insulation materials used primarily in China. This investment and the related agreements will make Unifrax the largest shareholder of Luyang and establish Unifrax as the exclusive distributor of Luyang products in the Americas, Europe and India.

NSSMC to amalgamate Thailand-based subsidiaries. Siam Nippon Steel Pipe and Thai Steel Pipe, both companies of Nippon Steel & Sumitomo Metal Corporation (NSSMC) producing electric-resistance-welded

pipe and tube in Thailand, will be integrated effective July 2014. The new company’s name will be Nippon Steel & Sumikin Pipe (Thailand) Co., Ltd. (NSPCT). The company will have a total of 1,600 employees and a production capacity of 176,000 t/year.

ArcelorMittal wins energy efficiency award. ArcelorMittal Europe has been presented with an ener.con award 2014 for its work in low impact steelmaking. Recognized in the “energy efficiency strategy and management framework” category, ArcelorMittal was commended in particular for its Energize project which aims to substantially reduce the energy consumption of ArcelorMittal’s Flat Carbon Europe mills by 2016. The Energize project is halfway through its four-year plan to reduce energy consumption by 9% in ArcelorMittal’s flat steel-producing sites.

Tata Steel to begin fourth HIsarna trial production campaign. Tata Steel is to begin a fourth test production campaign on the HIsarna pilot plant at its IJmuiden works. HIsarna is a new technology, partly developed in IJmuiden, which enables the direct input of coal and fine iron ore into the ironmaking furnace. The technology saves energy consumption by eliminating two of the key raw materials processing stages in blast furnace ironmaking: coking and sintering. The trial is scheduled to last about six weeks. In the project, Tata Steel is working closely with several other major steel companies in the ULCOS (ultra low CO2 steelmaking) consortium and with the mining company Rio Tinto. The fourth test campaign aims to produce liquid iron in a series of production runs, each lasting several days, and to test the use of different types of coal and iron ore. After analysing the results of this campaign, Tata Steel and its partners will start preparing for a prolonged fifth campaign in 2015, which would last six months. Should the HIsarna technology prove technically and commercially viable, the elimination of these processing steps MPT International 3 / 2014

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condition monitoring (UK), training (Belgium) and application knowledge (South Korea).

Schaeffler adds new locations to global technology network.

Schaeffler is gradually expanding its global technology network with additional locations. Presently, there are 25 Schaeffler technology centres worldwide, providing technical expertise locally and in immediate proximity to the customer. Four new certified Schaeffler technology centres (STC) were certified in the last few months: the locations in Santiago (Chile), Seoul (South Korea), Sutton Coldfield (England) and Braine L’Alleud (Belgium). To be awarded the “Schaeffler technology centre” title and receive the corresponding certificate, a location must meet high requirements and global standards. Each location places particular focus on individual areas of expertise depending on the regional market requirements, for example, the four new STC, on assembly services (Chile),

Siemens invests in LanzaTech.

The Siemens Metals Technologies business unit and LanzaTech have been cooperating since the end of 2012 on the development and marketing of integrated environmental solutions for the iron, steel and ferroalloy industries based on a fermentation process developed by LanzaTech. Now, LanzaTech has received US$ 60 million from its existing investors and new investors including Mitsui & Co., Ltd., CICC Growth Capital Fund I, L.P. and Siemens’ Venture Capital unit. These funds will help LanzaTech to further commercialize its fermentation technology for industrial waste gases, to extend their core gas fermentation platform and further develop their product portfolio. To date, products include fuels such as ethanol or jet fuel. The first commercially operated plants are expected to start running in 2015.

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Electralloy earns certifications. Electralloy, a custom melter of specialty and stainless alloys, has earned the American Bureau of Shipping (ABS) certification to produce steel castings for marine applications. The certification qualifies Electralloy to produce steel castings in alloy and stainless steels in grades 304N, 17-4, 15-5, Nitronic®50, Nitronic® 50ESR in weights up to 28.5 t.

The American Bureau of Shipping is the recognized authority for marine and offshore classification services.

Additionally, Electralloy has added the highly regarded GE S1000 certification to its long list of aerospace credentials. Electralloy has been supplying metals for GE engines for many years through a GE-approved third-party supplier. GE recently requested, that in addition to the third-party supplier, Electralloy should also earn the GE S1000 designation. The accreditation was awarded in October 2013 and is valid until October 2019. Electralloy specialty alloys can now be supplied directly to any GE facility in the world for use in any other GE application.

MPT International 3 / 2014

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››› INTERNATIONAL INDUSTRY NEWS

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Paul Wurth becomes licensee for Midrex® process. Kobe Steel and Paul Wurth, a member of the SMS group, have signed a construction license agreement that enables the SMS group to market, design and erect Midrex® direct reduction plants around the world. Kobe Steel, Ltd. is owner of both Midrex Technologies, Inc., and the Midrex® direct reduction process. Paul Wurth joins Kobe Steel, Siemens VAI Metals Technologies and Midrex Technologies as a construction licensee for Midrex® direct reduction plants. In combination with a Midrex® direct reduction plant, the MXCOL® process uses synthetic gas made from coal or coke oven gas. Being a leading provider of coke-making technology, Paul Wurth brings a new and beneficial dimension to the Midrex family of partners.

Materials Services stops disposal process for railway/construction activities. The management board of ThyssenKrupp’s Materials Services business area has decided to stop the disposal process for the railway/construction operating unit initiated in May 2013. Railway/construction comprises the companies ThyssenKrupp GfT Gleistechnik (railway equipment) and ThyssenKrupp Bautechnik (construction equipment). After an intensive exploratory phase, purchase bids have been reviewed and talks held with potential buyers over the past few weeks.

None of the bids met the financial expectations of ThyssenKrupp. Against this background the business area management board has decided to discontinue the railway equipment activities. This will result in part sales and closures of sites. The associated job cuts will affect altogether up to 260 employees. The aim is to implement the personnel measures in a socially responsible way by the end of the 2014/2015 fiscal year. The decision is subject to the approval of the supervisory board of ThyssenKrupp Materials International GmbH.

NLMK and Posco enter into cooperation agreement. NLMK, Russia, and South Korean Posco Engineering & Construction have signed a general agreement of strategic cooperation to jointly implement investment projects to modernize blast furnace, steelmaking and rolling operations at the Lipetsk production site. Under the agreement, the companies are going to cooperate in the area of equipment and technology supplies, planning and implementation of investment projects, automation and project management.

Kobe Steel provides license to FLSmidth for iron ore pellet process. Kobe Steel and FLSmidth, India, have entered into an exclusive license agreement enabling the Indian partner to market, design MPT International 3 / 2014

NORD DRIVESYSTEMS Intelligent Drivesystems, Worldwide Services

and construct iron ore pellet plants using Kobe Steel’s Kobelco pelletizing process. This agreement gives FLSmidth the exclusive right to supply pellet plants in India. Projects in other countries will be evaluated on a case by case basis. FLSmidth’s cement plants and the Kobelco systems share core technology such as rotary kilns and burners.

ArcelorMittal to sell stake in ATIC. ArcelorMittal and H.E.S. Beheer have signed a sale and purchase agreement for the sale of ArcelorMittal’s 78% stake in European port handling and logistics company ATIC Services to H.E.S. Beheer, which currently holds 22% in ATIC. The transaction, which is consistent with ArcelorMittal’s stated strategy of selective divestment of non-core assets, will give H.E.S. Beheer 100% ownership of ATIC.

Robust, long-life geared motors Gear Unit Q Special Unicase housings Q Robust housing material GG20, optionally GGG40 Q Quadralip sealing with material VITON to suit high ambient temperatures Q Optional labyrinth seal for increased protection

Schuler and Weldec form alliance. Press manufacturer Schuler and plant construction company Weldec have forged an alliance to supply equipment to pipe mills. Under the name “Pipe Alliance”, the two companies will offer a range of solutions for the production of large longitudinal welded pipes. The product spectrum ranges from stand-alone machines and production lines to the modernization and overhauling of equipment.

Personalities BlueScope appoints non-executive director.

John Bevan has been appointed as a non-executive director of BlueScope Steel. Bevan is also currently a non-executive director of Ansell Limited.

Motors Q Suitable for high ambient temperatures Q Roller table steel mill duty motors with

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vibration and shocks CEO transition at Harsco. Patrick K. Decker has stepped down as president and chief executive officer and member of the board of directors of Harsco to become CEO of Xylem Inc. Harsco director David C. Everitt has been appointed interim president and CEO until a permanent CEO has been found.

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metals.nord.com Harsco names group president. Harsco has appointed Richard E. Lundgren, Jr. as group president of its metals & minerals business, which is nearing the completion of its simplification-led organizational review. Lundgren takes over from Michael Monberg, who has been serving as interim president.

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››› INTERNATIONAL INDUSTRY NEWS iel Aebli has assumed the role of chief operating officer and chairman of the board, effective April 2014. He has been a member of the board for six years. Linda Krenn is the new manager personnel and communication and a member the extended board.

Clemens Iller

New CEO of Schmolz + Bickenbach. Clemens Iller has taken over the function of CEO at Schmolz + Bickenbach. He will lead the company together with CFO Hans-Jürgen Wiecha, who has been acting as CEO ad interim since the end of December 2013.

Executive appointments at NDC. NDC Infrared Engineering has announced two senior executive appointments. Drew Cheshire is the new president of NDC, replacing Dr. Bromley Beadle, who recently retired from NDC as president. The second appointment is that of Mahesh Havildar as vice president of global operations for the sensors, systems and metals divisions. Mahesh Havildar is responsible for overall manufacturing operations including production, quality, supply chain, material planning, project management, shipping logistics, radiation safety and product engineering.

Posco’s new chairman and CEO. Kwon Oh-joon is the new chairman of Posco. Kwon has previously led the company’s R&D centre and the Posco European Union office based in Düsseldorf, Germany. He was chosen unanimously by the board to become Posco’s eighth chairman and CEO.

Aperam appoints head of division. Aperam has appointed Frédéric Mattei as the new chief executive officer of its alloys and specialties division and member of Aperam’s management committee.

Management team appointments at Stahl Gerlafingen. DanMPT International 3 / 2014

Change of management at Oschatz. After exactly 20 years at the head of the company, Dr. HansJürgen Schrag, managing partner of the Oschatz Group, handed over the management to the next generation.

New managing directors are Dr. JanChristopher Schrag, eldest son of the family, and Andreas Albrecht, who most recently held the position of technical director at Oschatz. Dr. HansJürgen Schrag will be with the company for at least another two years as an advisor.

Appointment of general director of Stoilensky. Yuri Larin, NLMK group vice president, technology development & operational efficiency and member of the management board, has been appointed general director of iron ore producer Stoilensky. Yuri Larin played an active role in the development of Stoilensky’s programme aimed at increasing operational efficiency.

Executive management changes at United States Steel Corporation. A series of executive management appointments have been taking place at United States Steel Corporation. David L. Britten, senior vice president – tubular operations, will assume the newly created position of senior vice president and chief technology officer. Britten will be responsible for a further expansion of the company’s worldwide innovation, technology, engineering, and research and development of products, services and solutions. Anthony R. Bridge, vice president – engineering and technology, retired at the end of May 2014. David J. Rintoul will assume the role of senior vice president – tubular business.

ALBA group reduces number of board members. Joachim Wagner has stepped down from the top management level of the ALBA Group and its subsidiary ALBA SE for personal reasons. In future, Dr. Eric Schweitzer, CEO of ALBA Group plc & Co. KG, will be responsible for the waste and metals segment. He will be supported by Rob Nansink, member of the administrative board and, henceforth, sole managing director of ALBA SE. Other responsibilities on the board of directors will remain unchanged. In the future, the board of directors of the holding company ALBA Group plc & Co. KG will therefore comprise five members instead of the six.

Fine Tubes appoints technical and quality director. Phil Adderley has been appointed as technical and quality director of Fine Tubes, a UKbased manufacturer of precision tubes.

As part of his new role, Phil Adderley will have overall responsibility for quality assurance and compliance, quality control, technical and laboratory services.

Fine Tubes appoints new agent in Kuwait. Fine Tubes has appointed Bait Al-Aseel to act as its agent in Kuwait. The decision forms part of Fine Tubes’ strategic plan to secure further growth in the market for exotic alloy tubing across the Middle East region.

2014 AIST steelmaker of the year. Mark D. Millett, president and chief executive officer of Steel Dynamics (SDI), was named “Steelmaker of the Year” at AISTech 2014. This award is presented annually by AIST to recognize notable leaders for their impact on the steel industry.

Change in presidency at Mitsubishi-Hitachi Metals Machinery. After having actively promoted various M&A measures in 2013, such as business integration in the field of rolling mills with IHI Metaltech and the acquisition of Concast (India), Mitsubishi-Hitachi Metals Machinery de-

INTERNATIONAL INDUSTRY NEWS cided to reshuffle its management.

Ryoichi Nishi is the now president of the company. He was appointed to this role from his previous position of executive vice-president. Former president, Yasukuni Yamasaki, retired as an executive officer of MHI. He will serve as a director of the company and continue to support the new management team.

Events ›

23 – 26 June 2014 Graz, Austria Organizers: Asmet www.eccc2014.org

8th eccc. The 8th European Continuous Casting Conference is a forum for the European continuous casting community to exchange views on the status and future development of CC technology. This year’s event will see the first presentation of the Young Scientist award dedicated to authors of academic theses on subjects related to continuous casting.

cycling industry, the conference will cover the following topics: scrap demand and prices in China and the world, scrap import and export flows, updates on the regulatory situation in the EU and North America, recycling regulation and legislation in China, recovery of metals from metallurgical wastes, etc.

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MMMM 2014. The 10th International Exhibition on Minerals, Metals, Metallurgy and Materials will be held concurrently with four other international technology events: exhibition on cutting and welding equipment (CWE), machine tool expo (IMEX), exhibition on pre-owned machinery (UMEX), and exhibition on engineering and manufacturing (Techindia).

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29 – 31 August 2014 Beijing, China Organizers: Metallurgical Council of CCPIT www.metalrecycling.cn

China International Metal Recycling Conference 2014. Being an important forum for the metal re-

4 – 7 September 2014 New Delhi, India Organizers: International Trade and Exhibitions India www.mmmm-expo.com

10 – 12 September 2014 Zhengzhou, China Organizers: Metallurgical Council of CCPIT www.coke-china.com

CCC 2014. The 12th China International Coking Technology and Coke Market Congress serves as a platform for coke producers, consumers and cokemaking equipment suppliers. The

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main topics will include: China’s coke and steel industries, short range outlook for the Chinese and world coke markets, coke trade and export, innovations in cokemaking technology, utilization of coke oven gas, etc.

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21 – 25 October 2014 Hanover, Germany Organizers: Mack Brooks Exhibitions www.euroblech.com

Euroblech. The 23rd edition of this international sheet metal working technology exhibition will once again present the entire technology chain, including sheet metal, semi-finished and finished products, handling, separation, forming, joining, welding and surface treatment, hybrid structures, tools, quality control and R&D.

›

10 – 13 January 2015 Dubai, UAE Organizers: Messe Düsseldorf www.metalmiddleeast.com

Metal Middle East. This international trade fair for metallurgical technology, thermo process technology, foundry machinery and metal working will be staged concurrently with Tube Arabia, international trade fair for the tube and pipe industries, and Welding & Cutting Arabia, international trade fair for joining, cutting and surfacing.

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MPT International 3 / 2014

26

››› INTERNATIONAL INDUSTRY NEWS

Siemens and Mitsubishi Heavy Industries to join forces in plant making business Mitsubishi Heavy Industries, Ltd. (MHI) concluded an agreement with Siemens AG of Germany calling for the establishment of a joint-venture company (JV) in steel and metal production machinery effective as of January 2015, subject to regulatory approvals. The move has two aims: expansion of the product line in the steel and metal production machinery business and acceleration of globalization.

In early May this year Siemens and Mitsubishi Heavy Industries (MHI) formally announced an agreement to establish a joint venture (JV) in steel and metal production machinery business. This move aimed at achieving full product lineup supply capability and accelerating global development of steel and metal production machinery business.

The JV will swiftly take steps to put in place a structure enabling the provision of a full lineup of products involved in everything from upstream to downstream processes, and to build a business network that will span the entire globe, in a quest to provide more valuable products and services to customers in the worldwide steel and metal production machinery market.

Six regional bases around the world The new JV will be established in the United Kingdom integrating Mitsubishi-Hitachi Metals Machinery, Inc. (MH) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and IHI Corporation – and Siemens MT Business, Siemens group companies undertaking metals production in countries including Germany, Austria and the U.S. Equity ownership shares in the

Siemens AG, München, Germany; Mitsubishi Heavy Industries, Tokyo, Japan Contact: www.siemens.com/metals www.mhi-global.com

MPT International 3 / 2014

new venture will be 51% for MH and 49% for Siemens.

Under the initial plan, the new JV will operate six regional bases in Japan (Tokyo/Hiroshima), Austria (Linz), Germany (Erlangen), the U.S. (Pittsburgh), China (Shanghai) and India (Mumbai) enabling worldwide coverage. Business units for each product line will be based respectively in Tokyo/Hiroshima, Linz or Erlangen, and other existing business bases of Mitsubishi-Hitachi Metals Machinery, Inc. and Siemens will operate under Tokyo/Hiroshima or Linz, based on product line responsibility. The U.K. Headquarters will manage the regional bases, including respective business units, and will hold a cross division function in charge of sales/marketing, customer management, procurement, manufacturing, R&D planning, etc. to support each business location.

The new JV will operate with a collective staff of approximately 9,000 employees.

Complementing technological competences In October 2013, Mitsubishi-Hitachi Metals Machinery, Inc., which had been initially launched in October 2000 as a joint venture of MHI and Hitachi, completed an integration with IHI Metaltech Co., Ltd. in the area of rolling mills. Mitsubishi-Hitachi Metals Machinery, Inc. thereby acquired capabilities in product areas from continuous casting, hot and cold rolling, and bar steel rolling to downstream continuous annealing and galvanizing equipment. Now, through the JV with Siemens, Mitsubishi-Hitachi

Metals Machinery, Inc. will add upstream blast furnaces and electric furnaces to its product portfolio, significantly enhancing its ability to supply products for all metals production processes through expanding the product line.

Mitsubishi-Hitachi Metals Machinery (MH) and Siemens also complement each other substantially with respect to geographic areas in which they excel, a factor that will now enable acceleration of worldwide business expansion including Asia, Europe, Russia, the Americas, Africa, etc. Also, by pursuing synergy merits from MH’s knowhow in project management and Siemens’s abundant expertise in product servicing as integrated mechanical/electrical supplier, expansion of business opportunities will be sought.

Going forward, the global iron and steel industry, beset by adverse factors including overcapacity, increasing material costs and declining product prices, is projected to continue exercising restraint toward new capital investments. Against this backdrop, the agreement on the new JV was achieved on the back of the meshing of the two partners’ respective aims: MHI and the Japan side looking to strengthen their business through enhancement of product offerings and the development of a global network of business bases, and Siemens eager to improve its steel and metal production machinery business structure as it undertakes a review of its business portfolio. MHI and Siemens will both work closely with the new JV and offer their full support to its business development. 쐍

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››› INTERNATIONAL INDUSTRY NEWS

Word Steel Association short range outlook 2014 – 2015 worldsteel forecasts that global apparent steel use will increase by 3.1% to 1,527 million t in 2014, following growth of 3.6% in 2013. In 2015, it is forecast that world steel demand will grow further by 3.3% and will reach 1,576 million t.

On the occasion of their spring meeting in London in early April, worldsteel Committee on Economic Studies provided the new short range outlook. The global steel demand recovery is expected to continue, but growth is stabilizing at a lower rate with continued volatility and uncertainty. Overall growth of apparent steel use in the developed economies will be above 2% in 2014 and 2015. However, the developing and emerging economies will continue to grow faster than the developed economies despite their more subdued performances.

Chairman of worldsteel Economics Committee, Hans Jürgen Kerkhoff said “Many emerging economies continue to struggle with structural issues and financial market volatility. This, along with China’s deceleration, is the reason for our slightly lower global growth rate forecast for 2014. In 2015, growth in most parts of the world will accelerate thanks to a continuing steady recovery in the developed economies and an improvement in the situation for the emerging economies. But China’s steel demand will further decelerate and this will prevent the broad recovery momentum from registering a higher global growth rate for 2015.

We continue to see challenges. The recovery in Europe is still only mild and constrained by high debt and unemployment. Structural problems in the emerging economies are less likely to be resolved in the short term leaving them fragile and susceptible to external shocks. We are still seeing unexpected unstable political situations in many emerging economies. In this regard, the development involving

World Steel Association (worldsteel), Brussels, Belgium Contact: www.worldsteel.org E-mail: info@worldsteel.org

MPT International 3 / 2014

Crimea raises a high downside risk for our outlook for the CIS region. Finally issues remain surrounding China’s debt and real estate bubble.”

Forecast by region In China, the government’s efforts to rebalance the economy continue to restrain investment activities. After growth of 6.1% in 2013 with support from government infrastructure investment, apparent steel use in China is expected to slow to 3.0% growth in 2014 to 721.2 million t. In 2015, steel demand growth is expected to further decelerate to 2.7%.

In India, steel demand is expected to grow by 3.3% to 76.2 million t in 2014, following 1.8% growth in 2013, due to an improved outlook for the construction and manufacturing sectors, even though this will be constrained by high inflation and structural problems. Despite uncertainties relating to the impact of upcoming elections, steel demand is projected to grow by 4.5% in 2015 supported by the expectation that structural reforms will be implemented.

Following a 2.0% increase in 2013, because of the moderate GDP recovery as a result of “Abenomics”, apparent steel use in Japan is expected to contract by -1.0% to 64.6 million t in 2014 due to the consumption tax hike affecting the construction and automotive sectors negatively. In 2015, steel demand is expected to increase by 0.5%.

In the USA, after a decrease of -0.6% in apparent steel use in 2013, years 2014 – 2015 are expected to deliver a return to growth and recovery. Apparent steel use will grow by 4.0% to 99.4 million t in 2014 and by 3.7% in 2015.

The impact of the Federal Reserve Bank tapering programme on the US economy has been contained so far, but future actions still remain a risk. Apparent steel use in Mexico is expected to

grow by 3.4% to 19.2 million t in 2014 and to grow further by 3.9% in 2015.

In Central and South America, apparent steel use is projected to grow by 3.4% to 50.9 million t in 2014 down from 4.3% in 2013. This is forecast to slow further to 2.7% in 2015 due to contraction in Argentina and a sharp slowdown in Chile. In Brazil, steel demand growth will slow to 3.0% to 27.2 million t in 2014 and 3.2% in 2015 as high inflation and interest rates continue to restrain economic growth.

After a contraction of -0.2% in 2013, apparent steel use in the EU (28) is expected to grow by 3.1% in 2014 to 143.3 million t with help of the construction sector which is gradually bottoming out. Underlying trends at national level will continue to differ, but it appears that Southern Europe has passed its lowest point. Apparent steel use in Germany is expected to increase by 4.5% in 2014, Italy by 2.6%, France by 1.0% and Spain by 3.0%. A steady transition to a broader and more durable recovery will result in steel demand growth of 3.0% in the EU (28) in 2015.

Apparent steel use in the CIS region is projected to grow by only 1.1% reaching 59.5 million t in 2014 due to slow investment, but will grow by 3.7% in 2015 with Russian steel demand accelerating to 4.4% growth. Steel demand in Ukraine will continue to contract in 2014 but the fall will be limited to -3% to 5.4 million t due to financial assistance from the International Monetary Fund.

In the MENA region, steel demand is expected to grow by 6.1% to 66.7 million t in 2014 after a 0.9% increase in 2013. Growth in the region is strengthening as political uncertainties moderate. Strength in the non-oil sector in the GCC (Gulf Cooperation Council) countries is expected to stretch into 2014, and the Egyptian economy as well as the rest of the region will continue to recover. In 2015, steel demand in the re쐍 gion is expected to grow by 9.4%.

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30

››› INTERNATIONAL INDUSTRY NEWS

Mexican-Indian alliance to establish a network of micro mills in the Nafta region Mexican PMP Group and Indian Preet Machines Ltd. have announced a partnership to develop scrap-based micro steel companies to produce rebar, wire rod and structural products in the USA, Canada and Mexico. According to estimations, initial investment for each unit is expected to be in the range of 40 to 100 million US$.

During the Iron & Steel Technology Conference and Exposition – AISTech 2014 in Indianapolis, USA, the Mexican company PMP Grupo (Planeación, Mantenimiento y Proyectos) and Preet Machines Limited from Delhi, India, announced their commercial alliance to boost the construction of micro facilities for the recycling and transformation of scrap iron. The micro steel meltshops shall be established strategically located in different regions of the USA, Mexico and Canada in the framework of North American Free Trade Agreement (Nafta), and Latin America.

During the event, which provides a global prospective on the technology and engineering expertise necessary to power a sustainable steel industry, the companies announced plans to franchise “MicroSteel” facilities comprising meltshop, continuous casting and direct rolling technologies. Each of them counts with an initial investment of 40 to 100 million US dollars, and generates 200 to 400 direct jobs.

The “MicroSteel” meltshop technology facilities will capture and transform scrap iron from local resources. Designed for an annual production of minimum 35,000 t, the meltshop shall comprise a 30 t/h induction furnace (IF) and a continuous casting machine for the respective range of long products, for example rebar, wire rod or structural steel sections. A twin IF installation can provide higher melting capacity if requested. For higher demands, i.e. production

MicroSteel Meltshop Technology – a company of PMP Group, Apodaca, Nuevo León, Mexico Contact: www.microsteel.mx www.pmpgrupo.mx www.preetgroup.com

MPT International 3 / 2014

2TGGV 5KPIJ %JCWJCP NGHV CPF 2QTƂTKQ )QP\½NGU JCXG LQKPVN[ ETGCVGF C UVTCVGIKE CNNKCPEG VQ DQQUV VJG EQPUVTWEVKQP QH OKETQ UVGGN HCEKNKVKGU

of more than 200,000 t/year, the meltshop can be equipped with an electric arc furnace.

Preet rolling mill technology is designed to directly process the continuously cast billets while omitting an intermediate reheating cycle. Such direct rolling technology together with the highly energy efficient induction furnace underlines the ecologically friendly approach of the “MicroSteel” concept. Finally, electrical equipment and process automation is provided by AMB s.r.l., Italy.

As commodities, the rebar, wire rod or structural products shall be supplied to the regional market within an area of an approx. 200 km circle. Produced at affordable costs and sold at competitive prices, the final products shall not travel over great distances. For this reason the “MicroSteel” plants shall be developed at the most auspicious locations across the USA, Canada, Mexico and Latin America. PMP Group and Preet Machines Ltd. have committed to setting up a “MicroSteel” plant within a time frame of 18 to 20 months. Three projects with

capacities of 150,000 to 200,000 t/year are already under consideration – two in Mexico and one in the USA. Initiated in February 2014, the commercial alliance between PMP Group and Preet Machines will facilitate the recycling of regionally available scrap material into long products at competitive prices, reducing the need for imports of such products from countries as, for example, China. Established in 1990, Mexican PMP Grupo provides solutions to the steel industry. It specializes in the commercialization, manufacturing and services, focusing on the development of technology and innovative solutions for the handling of steel material and equipment. The company works with three leader brands: Arko furnaces, SK cranes, and Chicago Blower fans. Preet Machines Limited is an Indian company designing and manufacturing rolling mill equipment. Preet Machines has a reference list comprising more than 200 mills, and 33 different industrial solutions, with clients from South America, Africa, Iran, Iraq, United Arab Emirates, Afghanistan, Pakistan and Malaysia. 쐍

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››› COMPANY PROFILE

Tulachermet to transition from pig iron into structural steel production The Russian pig iron producer has ordered a complete steelworks with two connected light-section mills. The 180 million euros order was signed with SMS group in April this year.

The new steelworks and rolling mill complex is scheduled to start up operations in 2016.

Tulachermet will install a 160-t BOF converter shop, equipped with a restraint-free lamella suspension system and a dedusting plant

Tulachermet is a metallurgical company in Russia, located in the city of Tula, a regional capital about 200 km south of Moscow. Tulachermet is a joint stock company with more than 8,000 employees. The controlling stock of shares belongs to OAO “Koks” – an industrial group which includes several technologically integrated companies, involved in the production of high

SMS Siemag AG, Düsseldorf, Germany; SMS Meer GmbH, Mönchengladbach, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com

MPT International 3 / 2014

quality coking coal and coal concentrates and production of metallurgical coke and pig iron.

Until recently, Tulachermet has been specialized in production of high quality pig iron for foundries and steel mills. It is a very universal pig iron producer able to offer practically all grades of the material. Pig iron is produced in three blast furnaces and is cast into 10kg pigs on six casting machines.

To add more value to the products, Tulachermet decided to implement a converter-based steel and rolling mill complex in the immediate vicinity of the Tulachermet iron works. Tulachermet intends to produce light sections, bar steel and wire rod, using equip-

ment designed for an annual capacity of 1.5 million tons in the first phase, with the possibility of a later increase to two million tons. The major part of the production will be supplied to Moscow and to other regions in Central Russia. Here, there is a demand for high-quality steel products, above all from the construction industry and from mechanical engineering and automotive companies.

During the Tube & Wire 2014 trade fair in Düsseldorf, Germany, Tulachermet and SMS group have concluded a contract for the supply of the major metallurgical plants, i.e.: ▪ a complete BOF steelworks, ▪ a continuous billet caster and

▪ two connected light-section mills.

The order value comes to around EUR 180 million.

BOF shop. SMS Siemag will supply a 160-t converter shop, equipped with a restraint-free lamella suspension system and a dedusting plant. The latter will be fitted with electrostatic precipitators from SMS Elex. SMS Siemag will also be supplying an energy recovery system. For the further optimization of energy efficiency, SMS Siemag can provide a converter-gas recovery and

Produce and process metal more efficiently.

One of the rolling mills to be built will be equipped with a wire rod and bar line

mixing plant for subsequent combustion of the gas in the existing Tulachermet power station.

Secondary metallurgy. SMS Concast is supplying a ladle furnace and a twin-tank vacuum degassing facility for secondary metallurgical treatment.

Billet caster. The six-strand billet caster to be supplied by SMS Concast will be equipped with CONVEX® technology. It will be able to produce square sections in sizes from 150 x 150 to 180 x 180 millimeters.

Rolling mill. SMS Meer is supplying two almost identical light-section mills. A walking beam furnace will have a capacity of 160 tons per hour.

One of these light-section mills will be equipped with a wire rod line for the production of high quality bar steel and wire rod. SMS group is also supplying the electrical and automation systems for all production lines.

Tulachermet will assume the project management and the construction activities. The contracts for the construction and installation work will be placed with Russian companies.

The steelworks and rolling mill complex will go into operation in 2016. 쐍

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34

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş IRONMAKING â&#x20AC;&#x201C; MODERNIZATION

ThyssenKrupp Steel to modernize Europeâ&#x20AC;&#x2122;s biggest blast furnace First blown-in on October 28, 1993, Europeâ&#x20AC;&#x2122;s biggest blast furnace â&#x20AC;&#x201C; BF No. 2 at ThyssenKrupp Steelâ&#x20AC;&#x2122;s Duisburg-Schwelgern ironmaking site in Germany â&#x20AC;&#x201C; has reached WKH HQG RI LWV Ć&#x201A;UVW FDPSDLJQ DIWHU \HDUV ,Q PLG -XQH WKH XQLW ZLOO EH FRROHG down to allow modernization work to begin. After a short shut-down period, it will go back into operation at the end of September.

ThyssenKruppâ&#x20AC;&#x2122;s Schwelgern No. 2 of more than 20 years is unusually icant portion of the work will be carblast furnace is 90 m tall and produces long. The capacity of the furnace will ried out by companies from other segaround 12,000 t of hot metal a day. remain unchanged. ments of the ThyssenKrupp group. The Every day, 25 twenty-car freight trains The approx. two-meter-thick refrac- reline will require around 1,100 exterdeliver the ore, sinter, coal and coke re- tory lining will be entirely replaced. nal personnel every day. For coordinatquired for this output to the blast fur- Around 7,100 t of refractory material ing the work, a container village, covernace. Daily, a total of 19,000 t of bur- will be needed for the 75-m-tall fur- ing about 10,000 m², has been specially den and up to 4,000 t of coke built. The containers will proare charged into the furnace vide space for mobile offices, top. By last year, the furnace, fabrication and storage. which features a 14.9-m-diaThe project has been meter hearth, had produced planned down to the last detail 75 million t of hot metal. The over a period of one and a half years in order to keep downhot metal is used in two basic time as short as possible. The oxygen steelmaking shops of ThyssenKrupp in Duisburg. project team drew on experience from previous relines to In preparation for the reline, blast furnace 9 in Duisoptimize work processes and burg-Hamborn had been recarry out certain jobs ahead of the furnace shutdown, for exstarted in October 2013 to produce the required amount ample, on the auxiliary units. of hot metal during the modBlast furnace Schwelgern 2 ernization of blast furnace 2. provides 550 jobs at ThyssenKrupp Steel Europe, plus severThe blast furnace had been al times that number at service built using 75,000 mÂł of concrete, 43,700 t of steel, 800 km partners in the region. â&#x20AC;&#x153;With of electric cable and 35 km of the reline of blast furnace 2, cooling pipes. Its reline repre- After 21 years, the blast furnace Schwelgern No. 2 has we are bringing another core sents a significant capital in- TGCEJGF VJG GPF QH KVU Ć&#x201A;TUV ECORCKIP unit of our production chain vestment. Including dismanup to date,â&#x20AC;? says ThyssenKrupp tling and other maintenance and nace vessel alone. A specialized con- Steel Europe board member Dr. Herbert repair work, ThyssenKrupp Steel Eu- tractor will carry out the relining work Eichelkraut. â&#x20AC;&#x153;Itâ&#x20AC;&#x2122;s an investment in the rope is spending more than 200 mil- simultaneously from six platforms ar- future and a good sign for the Duisburg lion euros on the project. ranged at different levels. site and our employees.â&#x20AC;?

The blast furnace will undergo a For the modernization of the coolThyssenKrupp Steel Europe has four comprehensive revamp. Moderniza- ing system, more than 2,300 copper blast furnaces in total. The two units tion is essential because a campaign cooling plates will be replaced. Further in Duisburg-Hamborn, the blast furrepair and replacement work will take nace 8 and the recently relined blast place, for example, in the cast house, furnace 9, which together produce at the hot blast stoves, the gas clean- around 3.7 million t/year of hot metal. ing system, slag granulator and expan- The two blast furnaces No. 1 and 2 in ThyssenKrupp Steel Europe AG, Duission turbine.

Duisburg-Schwelgern are roughly twice burg, Germany A team of about 300 employees of as big and have a combined output of Contact: ThyssenKrupp Steel Europe will han- about 7.7 million t/year. How the four www.thyssenkrupp-steel-europe.com dle this gigantic modernization project blast furnaces will be operated in the fuE-mail: with the help of around 100 national ture will depend on further market decommunications@thyssenkrupp.com and international contractors. A signif- velopments. ě??

MPT International 3 / 2014

Thanks to the wish and the ability to innovate and to continuously improve its equipment and plants, PERT has studied a new generation of rolling stands for long products mills.

The revolution is in the concept of rolling stand introduced with the new model of PERT BS, which immediately became a milestone in the field of rolling technology.

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UAE steelmaker ESI produced 2.6 million tons of rolled products in 2013 (pictures by courtesy of Danieli)

Taking carbon capture and storage a step further Emirates Steel in the UAE is taking part in an innovative and ambitious project whose aim is to capture, reuse and store 800,000 tonnes of carbon dioxide (CO2) from its steel plant annually. The project is scheduled to be completed by 2016. The goal is to produce steel with lower carbon dioxide emissions to the atmosphere by capturing the CO2 SURGXFHG LQ WKH LURQ DQG VWHHO PDNLQJ SURFHVV LQMHFWLQJ LW LQWR H[LVWLQJ RLO Ć&#x201A;HOGV IRU enhanced oil recovery (EOR) and storing it at the same time.

Emirates Steel is one of the leading steel manufacturers in the Middle East region with the capacity to produce 3.5 million tons of rebar, wire rod and

World Steel Association â&#x20AC;&#x201C; worldsteel, Brussels, Belgium; Emirates Steel Industries, Abu Dhabi, UAE Contact: www.worldsteel.org www.emiratessteel.com

MPT International 3 / 2014

heavy sections. Established in 1998, Emirates Steel grew in a relatively short period of time from a simple re-roller of imported steel billets to a complex integrated manufacturing plant, using the DRI-EAF route.

In November 2013, Emirates Steel joined hands with Abu Dhabi National Oil Company (ADNOC) and Masdar, the UAEâ&#x20AC;&#x2122;s renewable energy company, in developing a carbon capture, usage and storage (CCUS) project. The project will involve ADNOC and Mas-

dar building a US$123 million CO2 compression facility and a 50 kilometer pipeline, along which the captured CO2 will be pumped to ADNOCâ&#x20AC;&#x2122;s oilfields.

Emirates Steel is a key partner in this project; the CO2 generated in the companyâ&#x20AC;&#x2122;s plants will feed the project when it goes operational in 2016 and the compression plant will be located close to Emirates Steelâ&#x20AC;&#x2122;s premises. The project will sequester up to 800,000 t of CO2 annually â&#x20AC;&#x201C; the effective elimi-

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ENVIRONMENTAL PROTECTION nation of a major element of Emirates Steel’s carbon footprint, which will improve ADNOC’s oil recovery.

“CCUS presents a viable technology for energy-intensive industries to lower their carbon footprint,” said HE Saeed Ghumran Al Romaithi, CEO of Emirates Steel. By capturing and storing its CO2 stream, Emirates Steel will be setting a clear example in the support of Abu Dhabi’s sustainability objectives.

“This is far from the first time that gas has been pumped underground to improve oil recovery, and in the past the UAE has used surplus hydrocarbon gases for this purpose. However, with the increasing demand for energy the CCUS project will allow the UAE to preserve its natural gas for domestic electricity generation,” said Al Romaithi.

The CO2 supply stream from the Emirates Steel plant contains approximately 90% CO2 and will be transported to a compression and dehydration facility at the storage site in Mussafah.

After compressing, the CO2 with a purity of 98% will be transported through the 50 km of pipeline network. Finally it will be injected into an onshore oil field to enhance oil recovery, while storing the injected CO2 underground.

The UAE has traditionally used hydrocarbon gases in some of the Abu Dhabi fields to enhance oil production. However, with the rise in energy demand, this carbon capture usage and storage project will allow the UAE to preserve its natural gas for domestic electricity generation.

Various initiatives around the world to reduce CO2 emissions generated during steel production The Emirates Steel carbon capture and storage project complements other technologies to reduce carbon emissions currently being researched at a global scale.

In Europe, ULCOS is the EU-sponsored ultra-low CO2 steelmaking project made up of a consortium of 48 European companies and organizations from 15 European countries. ULCOS is working on projects which ultimately could reduce carbon dioxide emissions from steel production by at least 50%. The most promising breakthrough technology researched by ULCOS is the HIsarna process which is running in a pilot operation at the Tata Steel site in IJmuiden, the

Energiron direct reduction plants enable

‹‹‹

39

ther decrease energy consumption per unit of CO2 captured. Additionally academic cooperation projects include BOF slag carbonation and microalgae carbon fixation.

In Australia, CSIRO is working with BlueScope and OneSteel on two significant projects aimed at cutting CO2 emissions: biomass, which uses renewable carbon derived from biomass in steel manufacturing, and heat recovery from molten slags through dry granulation, which captures the waste heat released from slag cooling, thus reducing CO2 emissions. These programmes have received large support from the Australian government.

Emirates Steel to produce high quality direct reduced iron (hot DRI)

Conclusion Netherlands. In this process fairly pure CO2 is produced which can be used for carbon capture and storage with little further cleaning necessary. The expected reduction in CO2 intensity per tonne of crude steel produced is 20 – 25%. To be able to be effective, this process will also rely on carbon capture and storage (CCS) to realize the 50% reduction in CO2 intensity or more.

In Japan, the COURSE-50 programme is strongly supported by the government as they are investing in the transportation, reuse and storage of the CO2.

A number of projects have been established for a long period of time, especially on storing CO2 in rock structure one or two kilometers underground.

The sites have been significantly tested in recent earthquakes, and no loss of CO2 has been detected by the sensors placed on the surface.

In Korea, Posco runs its own programme to look at the adaptation of CCS to the Finex smelting reduction processes. They are also completing trials on capturing CO2 from a blast furnace which uses similar technology than that being researched by the ULCOS programme.

Taiwan CCS Alliance is composed of eleven companies and organizations amongst which China Steel Corporation is a participant. This alliance is currently focusing their research activities on two main technologies: the oxy fuel burner technology which aims at purifying CO2 by burning without nitrogen content, and the chemical absorption pilot plant which seeks to fur-

Some of these R&D projects potentially can reduce CO2 emissions by more than 50%. Research is now focused on feasibility at various levels of production, from laboratory work to pilot plant development, demonstrators and eventually commercial implementation.

However, initial R&D investment of several million dollars will be required for these projects to come to completion.

Further cuts in CO2 emissions will be achieved in future decades through the increased use of the R&D technologies currently funded, but also through the increased recycling of scrap and its use in the production process. According to the Global CCS Institute, around 70 – 80% of emissions can be avoided by using scrap in steel production, avoiding the need for using carbon to reduce iron ore and by only using melted scrap.

However, scrap and scrap availability is dependent on the cost of recovery and usually matches the economic level of iron ore and coal requirement.

The International Energy Agency 2013 roadmap demonstrates that CCS is an integral part of any lowest-cost mitigation scenario. The total CO2 capture and storage rate must grow from the thousands of tonnes captured in 2013 to billions of tonnes of CO2 in 2050 in order to address the emissions reduction challenge (2DS scenario).

The steel industry is fully aware of the need for implementing technological solutions to reduce carbon emissions to the atmosphere through CCS or other forms of breakthrough technologies and will continue to concentrate its efforts on this goal for decades to come. 쐍 MPT International 3 / 2014

40

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STEELMAKING

Modernization of the converters for stainless steel production at Taishan Iron & Steel Co., China In June 2013, Shangdong Taishan Iron & Steel Corporation commissioned three modernized 70 t converters for stainless steel production. Since the modernization, the implemented advanced process control model has covered all special working conditions such as high carbon content and low temperature of the utilized hot metal, reliably ensuring a high degree of productivity and excellent quality. The operational costs have also been dramatically reduced.

Induction furnace

EAF (EBT)

Converter Ladle furnace

Slab caster

Blast furnace Converter Ladle furnace EAF (EBT)

Converter

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Shangdong Taishan Iron & Steel Corporation, China, awarded Siemens VAI the contract for the modification of the three existing 70 t GOR converters into

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MPT International 3 / 2014

a state-of-the-art K-OBM-S (called TSR

by Taishan) converter for stainless steel production.

The contract was awarded in October 2012 and included all modifications to the existing auxiliary equipment, the dry dedusting system and the supply of new key components, such as valve stands, basic automation and level 2 process control, required to reach the rated plant capacity of 800,000 t/year. The plant was successfully commissioned in June 2013, only eight months after signing the contract.

/GNVUJQR EQPĆ&#x201A;IWTCVKQP At Taishan Iron & Steel Co. hot metal and pre-melt is provided by a blast furnace, two EAFs and an induction furnace. The dephosphorized hot metal with high-carbon content is then processed by the three 70 t converters applying a duplex process. The range of products includes ferritic, austenitic and austenitic manganese stainless steel grades.

The modification of the previous GOR plants into K-OBM-S/TSR converters for stainless steelmaking was initiated with the objective in mind

STEELMAKING

Gas cooling

Steam

Evaporation cooler

Electrostatic precipitator

Fan

Flare stack

Gas switch over station

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

41

Gas cooler

Steam

Water

Coarse dust

Gas holder

Fine dust

Converter

Hot briquetting plant Dust briquettes

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to enhance the range of stainless steel products â&#x20AC;&#x201C; with a view to meeting the demand of the market and improving the product quality. At the same time the operational costs were to be lowered. All this was to result in a strengthened market position in the field of stainless steel. The existing dry dedusting system was revamped to meet the new process requirements and the new local emission standards of less than 30 mg/mÂł (stp).

2TQEGUU TQWVG CPF OCKP HGCVWTGU QH VJG PGY - 1$/ 5 654 RNCPV In consideration of the actual location of the meltshop, supply conditions for raw materials and hot metal, existing production lines, argon availability as well as the reuse of existing equipment, the duplex route is used as the main production route.

Other stainless steel plants with AOD operation mainly use medium-C pre-melt from the EAF with a typical C content of 1.2 â&#x20AC;&#x201C; 1.8%, and an AOD charging temperature between 1,550 and 1,600°C. Compared to these conditions, the pre-melt conditions for the

converters at Taishan Iron & Steel Co. are characterized by the following parameters: â&#x2013;Ş use of hot metal with high carbon content, â&#x2013;Ş low pre-melt temperatures between 1,390 and 1,460°C (after charging into converter), â&#x2013;Ş 100% alloys (HCCr) charged into the converters for ferrite grades, resulting in huge total C input, â&#x2013;Ş limited availability of good-quality scrap at a reasonable price.

The pre-melt properties for the new K-OBM-S plant depend on the specific plant configuration and the existing production facilities as well as the dephosphorization and transportation

of the hot metal. The pre-melt can be provided to the converters in two different ways: â&#x2013;Ş EAF pre-melt with dephosphorized hot metal for ferritic grades, â&#x2013;Ş additional utilization of an induction furnace for austenitic and austenitic manganese grades.

For ferritic grades, the pre-melt consists of 100% dephosphorized hot metal. The pre-melt is charged into the K-OBM-S/TSR converter by crane.

The pre-melt weight is measured at the charging crane.

In order to minimize the investment of the revamping, the company decided to reuse the existing equipment as much as possible. The existing convert-

Heat size

70 t (nominal)

No. of the tuyeres

5

Diameter of the tuyeres

16 mm

Top lance

for O2 and inert gas, max. 160 mÂł/min (stp)

No. of the high-level bins

10

Tapping system

Tap hole and converter mouth

Bottom blowing

with exchangeable bottom

6GEJPKECN FCVC QH VJG OQFGTPK\GF EQPXGTVGTU MPT International 3 / 2014

42

››› STEELMAKING

er vessels and drive units remained unchanged. In contrast, top lances were installed and the bottom blowing system including the rotary joints was replaced with a new system with single mass flow control lines for cooling gas.

Additionally, the handling system for alloying material and fluxes was modified to enhance its capacity. Also an advanced process control system was implemented in combination with a new level 1 system.

The main features of the new converter equipment are as follows: ▪ top lance with lance position control for high decarburization speed and CO post-combustion to meet the energy demand of the process, ▪ combined, single-line flow and pressure control of the shroud gas to ensure optimum cooling and long lifetime of the tuyeres, ▪ high blowing intensity for high productivity and large amounts of

solid additions into the converter, ▪ three operational modes in level 1 (including K-OBM-S operation in computer mode), which can be used to achieve the target process conditions, ▪ advanced level 2 process control system for heat pre-calculation and online process control, allowing fully automated converter operation and computer controlled fulfilment of the process requirements.

After revamping, the converter plant now consists of three stationery 70 t converters, a top-lance system, a process gas valve station and a dedusting system. The additive bunker system consists of ten high-level storage bins, six weighing bins and two discharging bins, the basic automation system and level 2 automation including the process control model. Preheating and warming are via the bottom tuyeres (CH4 and O2).

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/CVGTKCN JCPFNKPI U[UVGO

$NQYKPI EQPVTQN UETGGP QH NGXGN U[UVGO MPT International 3 / 2014

The whole process in the K-OBM-S converter (after charging the hot metal, homogenization of the pre-melt, sampling and temperature measurement) is performed in several decarburization steps, followed by a reduction step with simultaneous desulphurization. For each decarburization step, target values are defined for the C content and the temperature of the metal bath. The main targets during the first three decarburization steps are as follows: ▪ increase of bath temperature as quickly as possible to approx.

1,680°C (usually accomplished during the first decarburization step) in order to achieve a high decarburization rate with high carbon removal efficiency and reduced Cr oxidation, ▪ addition of the main quantity of the lime, dololime, all high-C alloys (like FeCrHC and FeMnHC) and – if required – scrap, Ni or Ni alloys.

Combined blowing by top lance and bottom tuyeres is applied during these decarburization steps. After the third decarburization step, a short cleanup is usually performed by combined blowing to minimize the build-up on the upper cone of the vessel. The target C content in the heat after the clean-up step depends on the steel grade and is roughly between 0.2 and 0.4%.

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Individual solutions – without limits

››› STEELMAKING

2TQEGUU EQPVTQN A basic automation system – level 1 – was implemented in order to achieve optimum process control. The system can be operated in different modes: ▪ manual mode – recommended in case of maintenance using manual setpoints, ▪ automatic mode – operation with various pre-defined steps using setpoints calculated by level 2, ▪ computer mode – fully computer-controlled operation using setpoints calculated and continuously controlled by level 2.

The operation mode can be changed during heat processing, as required.

MPT International 3 / 2014

The main advantages of the new level 2 system for the K-OBM-S converters at Taishan Iron & Steel are: ▪ increased productivity, ▪ minimized number of required samples, ▪ stable chemical composition and temperature of the tapped steel, ▪ transparent process operation by

ard melting practice contains all necessary basic data concerning process patterns and target product specifications for both steel and slag during heat processing.

The continuous control of the bath temperature and composition as well as the calculation of other physical and chemical parameters for metal and slag

Thermal model Steel bath temperature

By combined top and bottom blowing, a total oxygen-blowing rate of a maximum of 190 m³/min (stp) is possible. During start-up, a total combined oxygen blowing rate of maximum 140 m³/min (stp) was applied. The main advantages of the combined blowing technique can be summarized as follows: ▪ quick rise in temperature, ▪ higher decarburization rates with high carbon removal efficiency and less Cr oxidation, ▪ partial CO post-combustion for improved converter heat balance, ▪ improved bath agitation, ▪ possibility of high ratio of solid additions, ▪ shorter blowing time, ▪ higher productivity of the converter process.

In case of the duplex route, final decarburization is usually carried out in three or four steps. One of the main targets of final decarburization is to keep the steel bath temperature at a constant level, if possible, between 1,680 and 1,730°C. This is achieved by adding slag formers and metallic cooling additions such as scrap, Ni or Ni alloys (Ni in case of 300 grades). In order to avoid high Cr oxidation and to keep silicon consumption for reduction at a low level, the ratio of oxygen and inert gas flow (N2 or Ar depending on the steel grade) is changed during final decarburization in various steps depending on the carbon content of the steel. After the end of decarburization usually a combined reduction and desulphurization step is performed.

Carbon content

44

Analysis tracking Precalculation Precalculation

Decarburization

Tapping Final adjustment Reduction

Charging

Prozess time Tapping Reduction

Charging Decarburization

Desulphurization

1XGTXKGY QH UVCKPNGUU UVGGN RTQEGUU OQFGN CRRNKECVKQP

data visualization, recording and heat reporting, ▪ on-line process control including automatic optimization of setpoints, ▪ off-line process simulation for process optimization and development of new grades, ▪ operator control with graphical user interface (GUI) based on Windows technology.

The core component of the patented level 2 optimization system is a set of on-line models supporting the metallurgical processing of the K-OBM-S/ AOD heat. The model includes an offline pre-calculation functionality for calculation of the complete heat before the converter process starts (i.e. simulation of the K-OBM-S process from charging to tapping). A cyclic calculation is performed on-line during the whole heat. Triggered calculations for reblowing or cooling can be carried out at the operator’s request or in the event of special process incidents.

For each heat, the model calculation is based on the standard melting practice (SMP), which is defined for each steel grade and included in the technological model database. The stand-

during the different phases of the heat is supported by various models. These models are based on mathematical equations for mass and heat balance, metallurgical thermodynamic and kinetic calculations. The model calculations describe the complete thermal, chemical and kinetic behaviour of the steel and slag inside the converter for the selected (or current) process pattern. During the process, the current state of the steel and slag is cyclically calculated and displayed to the operator. In order to reach the target values of the current step, adjustments of the setpoints for the current process phase are made automatically in the computer mode.

The pre-calculation model determines the duration and setpoints for process gases and additions (alloys and slag formers) to achieve the target steel and slag conditions for each process step and for the tapped steel.

Additional target values for the calculation are the temperature and the C content for each process step. The model allows the distribution and sequencing of alloys, cooling additions and slag formers over the different process phases to achieve the required process temperature development for

46

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STEELMAKING

the heat. The calculated setpoints are downloaded to level 1 to be used in the computer mode. This usually does not require any operator involvement.

At the start of blowing, the cyclic online model is automatically started.

Based on the current operational data (such as additions, blowing status, steel and slag conditions and converter lifetime) the on-line model determines the decarburization process as well as steel bath and slag conditions (amount and compositions). It also predicts the nitrogen content and the steel temperature taking into account the heat and mass balance and the kinetic environment.

The implemented level 2 process model covers all standard operation conditions of the K-OBM-S converter, including some plant-specific items, such as 100% hot metal as pre-melt for stainless steel production or chute addition of Ni, Mn and Cu. For standard steel grades, the heats are performed fully automatically in the computer mode (with one sampling during the blow to confirm the model calculation). The heats are tapped without sampling before or after reduction.

2NCPV UVCTV WR CPF EQPXGTVGT RGTHQTOCPEG After the start-up in June 2013, the K-OBM-S converter successfully underwent the functional tests, machine adjustments, process optimization and the final performance test. In order to stabilize the entire production line, the pre-melt condition for the K-OBM-S converter in case of ferritic grades has been agreed

to be 100% dephosphorized hot metal. All the solid alloys required are charged into the converter. For austenitic grades, the EAF tap weight was reduced to a minimum in order to decrease the EAF tap-to-tap time.

An induction furnace is used to melt down the charge chromium. After final adjustment of the process model parameters, the refining process can now be controlled entirely by the level 2. For the main grades, direct tapping was possible after the reduction process. The lifetime of the converter refractories increased noticeably, while the operation was becoming more and more stable. The main benefits of the revamping are reduction of operational costs, quality improvement and higher productivity.

The final carbon and nitrogen contents for grade 410 S have been lowered compared to the respective levels before the revamping. This was done in order to overcome problems in connection with carbon and nitrogen pick-up, which are due to the given steel plant conditions. At the same time, the operational costs were reduced by more than 50 RMB/t. The most important factors contributing to the decreased operational costs are the increase in Cr yield, lower Cr2O3 in the slag and lower Si consumption for reduction as a result of a higher carbon removal efficiency. The higher consumption of argon is related to the lower nitrogen level in the steel bath before tapping as requested by Taishan Iron & Steel. Additionally the double hitting rate for C and S has been improved from 70% before revamping to 97.1%. The more

Parameter

GOR converters

TSR (K-OBM-S)

Process time

93 min

65 min

N content (tapped)

190 ppm

150 ppm

C content (tapped)

0.03%

0.02%

S content (tapped)

53 ppm

28 ppm

Si reduction

18.5 kg/t

16 kg/t

Consumption

effective protection of the tuyeres as a result of improved cooling through the combined, single-line shroud control also extended the lifetime of the converter bottom; even the final carbon content is less than before.

%QPENWUKQP CPF QWVNQQM Start-up and commissioning of the K-OBM-S/TSR plant at Taishan Iron & Steel were an outstanding success for all parties involved. The advanced process control model covers all special working conditions such as high carbon content and low temperature of the utilized hot metal. It also reliably ensures high productivity and an excellent quality standard. Operational costs have been dramatically reduced.

There is further potential for improvements, such as: â&#x2013;Ş dolomite bricks instead of MgO-C bricks for teeming ladles to reduce C pick-up, further reducing the operational costs, â&#x2013;Ş direct tapping as a standard procedure after reduction to avoid waiting time, increase lifetime of the refractory lining and further improve productivity, â&#x2013;Ş tapping via converter mouth to reduce N pick-up and temperature loss and minimize the heat processing time, â&#x2013;Ş continuous operation of the converters to keep the vessels in hot condition, at the same time improving the lifetime of the vessels, â&#x2013;Ş exchangeable vessels to reduce the times for vessel relining on the blowing stands.

Benefit

Direct tapping

9.0 ÂĽ/kg Si

22.50 RMB/t

Ar (stp)

34.13 mÂł/t

38.6mÂł/t

4.0 ÂĽ/mÂł

-17.88 RMB/t

N2 (stp)

76.5 mÂł/t

48.9 mÂł/t

0.4 ÂĽ/mÂł

11.04 RMB/t

Cr yield

96.5%

98%

11 ÂĽ/kg Cr

23.09 RMB/t

Lifetime

150 heats

170 heats

4.50 ÂĽ/kg

12.00 RMB/t

Cost reduction 1RGTCVKQPCN EQUV EQORCTKUQP DGHQTG CPF CHVGT TGXCORKPI HQT 5 ITCFG MPT International 3 / 2014

Remarks

50.75 RMB/t

Cr2O3 < 0.4% for TSR

STEELMAKING Additionally, side blowing instead of bottom blowing tuyeres combined with the use of low-C bricks (instead of high carbon bricks) for the converter bottom refractory would minimize C pick-up during reduction. This would reduce the process time and lead to lower consumption of Ar and Si for the reduction process. Furthermore, the production capacity would be boosted.

With the implemented modernization measures, Taishan Iron & Steel is now able to extend its range of high-quality stainless steel products

supplied on the domestic market and strengthen its position in the global stainless steel market. 쐍

‹‹‹

47

Steel Industry (ISES’03) October 28-30, 2003, Beijing [3] S. Dimitrov, Y. Zhai: Neues Level 2 Prozessmodell für die Erzeugung von rost-

References

freiem Stahl im Konverter. Forum für

[1] Y. Zhai et al.: Start-up of the New AOD-L

Metallurgie

Converter and Automation System at ACESITA. ISC-2002, Linz, 26-27 June 2002

und

Werkstofftechnik

2003, 27. bis 28. Mai, Leoben [4] Y. Zhai et al.: Start-up of the New 80 t

[2] Y. Zhai et al.: VAI Technologies and Ad-

AOD Plant with Advanced Process Con-

vanced Automation System for Stainless

trol at ACESITA. Iron & Steel Review,

Steel Making and Highlights of Recent

Vol. 46, No 6, 2002

Start-ups in Different Melt Shops. CSM

[5] K. Stohl, Y. Zhai: Advanced Process Mod-

Annual Meeting & International Sym-

els for Stainless Steelmaking. CISA 2003,

posium on Global Environment and

Shanghai

Stressometer® Systems. Extended actuator teamwork.

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by ABB. To optimally make all mill actuators work together as a team is a complex task. Different actuator combinations will in these mills give the same flatness effect.

The problem is to select the one actuator combination with the minimum actuator movement. The ABB patented method of Extended Singular Value Decomposition (ESVD) will optimally make this selection and make your actuators work together as a genuine team.

Stressometer Tools & Services for a better strip. www.abb.com/pressductor

ABB AB Force Measurement Phone: +46 21 32 50 00

MPT International 3 / 2014

48

››› STEELMAKING

Micro steel mill project implemented in Iceland A compact steel meltshop has been commissioned in Iceland. The plant comprises a modern EAF with 15 t (30 t) capacity equipped with an ultra-high performance electrode control system and a single-strand continuous caster. The blooms and mini slabs are directly used as electrodes in the aluminium melting industry. The initial capacity of the meltshop is only 30,000 – 40,000 t/year, expandable up to 200,000 t/ year, matching current regional scrap availability and market requirements.

EAF with ultra-high performance electrode control system

Iceland is a beautiful country. Its inhabitants are a people of few words and with a strong will to show how concepts based entirely on the utilization of locally available resources can be brought to industrial success. In a clean-up campaign, scrap dumped in the environment is collected all over the country. The collected scrap is considered a precious resource that can be used to limit the expensive imports of large-size hot rolled bars.

Giorgio Cabai, STS s.r.l. Selected Technologies Supplies, Udine, Italy Contact: www.stssrl.com E-mail: giorgio.cabai@stssrl.com

MPT International 3 / 2014

At present, Iceland exports all the scrap. The high freight costs involved reduce the margins for the scrap exports. At the same time, steel products are 100% imported, again requiring the payment of freight costs. Also for strategic stocks, steel products need to be imported. Therefore is it quite logical to use the scrap locally to produce a finished product critical to the local aluminium and other industries. This idea becomes even more attractive as the cheap locally available electrical energy can be used to make the product, reducing an otherwise major cost factor in steelmaking.

Arthur Gudmundsson and his partners were faced with many obstacles in convincing a bank about this idea in order to secure solid financing in the aftermath of the country’s financial crisis.

From the very beginning, STS has been a strong supporter of the idea, joining forces with the team of Geothermal Metal Recycling (GMR) located in the Grundartangi industrial area to come up with a suitable plant solution. The result is a steelmaking plant, equipped with most modern machinery but covering the smallest imaginable area to minimize the initial investment. As a suitable industrial area was extremely expensive, the facility covers an area of only 81 m x 46 m and uses no more than two cranes running at a height of only 10 m.

Another technical challenge was to initially produce only 30,000 – 40,000 t/year of steel at an acceptable yield and at competitive production costs, allowing a gradual expansion to an internationally more viable output of approximately 200,000 t/year.

This was not the first unusual progressive project attracting STS. 13 years ago, the company commissioned a complete and unique steel meltshop in Cape Town based on induction melting technology – with yields and an efficiency still unsurpassed despite the heavily growing number of induction meltshops built in recent years.

STS felt attracted by the challenge of setting up another steel meltshop on the opposite side of the world, especially as this project was completely different from the first one in terms of both melting technology and the type of finished products, namely blooms and slabs as a substitute for rolled material.

Meltshop and continuous casting plant Electric arc furnace. From the very beginning, the EAF was designed

STEELMAKING

‹‹‹

49

for 15 – 30 t capacity and the requirement of very fast-acting controls and ultra-high power concentration. In the design, extra fast electrode movements and controls were adopted to reduce power and electrode consumptions without increasing the need of maintenance. The vessel is lined with RHI refractories. The meltshop produces low and medium carbon steel, mainly for anodes and cathodes to be used in primary aluminium production. Ladles of 20 t (30 t) capacity are equipped with a sliding gate system and porous plugs. A ladle car is used to sequence the two ladles in operation.

Single strand CCM. The continuous casting machine is designed with an 8-m radius. The single-strand machine can optionally be expanded by a second strand in future. Tundish capacity is 3 t. Casting dimensions include rounds from 130 to 180 mm diameters and squares from 90 to 180 mm (casting equipment: 160 mm dia., 180 mm dia., 120 mm x 120 mm, 140 mm x 140 mm, 150 mm x 150 mm, 100 mm x 150 mm, 107 mm x 122 mm, 90 mm x 200 mm).

The curved, tubular, multi-tapered mould is 800 mm long. The hydraulic mould oscillator operates with various patterns optimized for each casting shape and steel grade. The cast blooms are cut to lengths between 2.5 and 6 m. The plant is automated with

Single-strand bloom caster

a sophisticated level 1/level 2 system including HMI.

Conclusion STS supplied the most compact modern steel meltshop ever commissioned in Iceland. The meltshop is installed in two steel buildings 12 m high and covering an area of 26 m x 81 m and 20 m x 81 m respectively.

The EAF is equipped with a unique ultra-high performance electrode con-

trol system. The plant includes a single-strand bloom caster. The blooms and mini slabs are directly used as electrodes in the aluminium melting industry. The initial capacity meltshop is only 30,000 – 40,000 t/year to match current scrap and market requirements. Production can be expanded in phases to up to 200,000 t/ year. Future options for a capacity increase include adding a second strand, a ladle furnace, additional cranes and 쐍 other auxiliaries.

WORKING SOLUTIONS FOR EXTREME CONDITIONS

TML Technik GmbH | A Company of the E-Mail: info@tml-technik.com | www.tml-technik.com

ENGINEERING | PRODUCTION | SERVICE

MPT International 3 / 2014

50

››› STEELMAKING

Design criteria and examples of transformers for EAF plants TES – Transformer Electro Service S.r.l. – is a designer and developer of large industrial transformers. The company is a regular supplier to Italy’s main steelmaking groups and to major international contractors for steelmaking plants. The company’s success story comprises projects at Simec, NLMK and a framework contract with JSPL covering not less than seven industrial transformers for electric arc furnaces. as Danieli, SMS Siemag, Siemens VAI, Tenova, Fuchs, CVS and Concast.

State-of-the-art electrical conversion systems require special solutions.

Large steel producers need tailor-made solutions to meet this requirement.

TES has implemented numerous projects in the steel industry. In 2013 alone the company added to its portfolio orders worth 8 million euros. Some of the most interesting projects are outlined below.

New transformers to power JSPL steel mills in India and Oman

220 MVA EAF transformer and 40 MVA LF transformer supplied to JSPL

Simec site

Plant

Rated power kV

Republic Steel

EAF

135 MVA

34.5 / 1.15 – 1.015 – 0.647

Grupo Simec S.A.B de C.V

POW EAF LF

134.4 MVA 80 MVA 10 MVA

230 ± 2 x 2.5% / 13.8 34.5 / 1.02 – 0.85 – 0.55 34.5 / 0.28 – 0.26 – 0.18

EAF

70 MVA

23.0 / 1 – 0.8 – 0.6

Simec USA

Aceros DM SA de CV

EAF

70 MVA

13.8 / 1 – 0.8 – 0.6

EAF

60 MVA

23.0 / 0.99 – 0.834 – 0.6

EAF

42 MVA

13.8 / 0.745 – 0.65 – 0.5

EAF LF

60 MVA 10 MVA

34.5 / 0.9 – 0.834 – 0.6 34.5 / 0.28 – 0.26 – 0.18

Technical data of the three-phase transformers for the Simec group

TES Transformer Electro Service S.r.l., Brescia, Italy Contact: www.testransformer.com E-mail: info@tes.st

MPT International 3 / 2014

TES Transformer Electro Service S.r.l., designer and developer of large industrial transformers, is based in Brescia, Italy. TES is a regular supplier to Italy’s main steelmaking groups, such as Feralpi, Lucchini, Riva, AFV Beltrame, Alfa Acciai and ABS, and to major international contractors, such

Jindal Steel and Power Limited (JSPL) from India owns Oman’s first integrated DRI based steel mill – Jindal Shadeed – which has a production capacity of 7 million t/year. TES has signed a framework agreement with JSPL worth over 5 million euros covering the supply of seven industrial transformers for electric arc furnaces. Installation of the transformers has been taking place during 2013/2014 at Jindal Shadeed in Oman and at the three JSPL EAF steel mills in Raigarh and Angul in India.

Two of the transformers are rated to power a 220 MVA and a 240 MVA electric arc furnace. These EAF transformers rank among the five biggest EAF transformers in the world. JSPL opted for industrial transformers from TES to upgrade its plants and make them more reliable. It has set itself the ambitious target to triple steel production for the wealthy Middle-East market by 2015.

The 10-transformer project for Simec group The Mexican group Simec Corp. Inc. has a pressing need for equipment to power and upgrade its steel plants in

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52

››› STEELMAKING

the USA, Mexico and Brazil. TES was chosen to supply and upgrade a total of ten special transformers for the American plants of Simec during the years 2012 through 2014. Five of these transformers are newly built and five are upgraded on site. The contract – for a total transformer capacity of 671 MVA – is worth 7.5 million euros.

TES meets the technical requirements of the different plants, while complying with the specific standards in force in the various countries where the group operates. It offered a customized technological study and products based on international high-quality standards.

“Jolly” EAF transformer for two steel mills TES presented NLMK a winning technical solution in the form of a unique 138 MVA EAF transformer, the so-called “Jolly” transformer, to be used in two different steel plants.

The design took into account all relevant features and requirements of both production plants. The final technical solution proved to be fully safe and reliable. It is the result of the skilful use of exclusive technology leading to the production of high-power transformers which are fully interchangeable with existing ones.

The NLMK group purchased the 138 MVA EAF transformer with a 31 Mvar series reactor for its steel works in Ekaterinburg and its plant in Kaluga (both Russia) to increase steel output and build up stock wherever necessary. NLMK placed an order for the supply and installation of an innovative, reliable transformer and a series reactor to improve the performance of its steel mills. The project was implemented on a turnkey basis, including transport, unloading and installation.

TES designed both units in full compliance with the specific requirements.

Construction of both the transformer and reactor was completed according to schedule and all the tests were carried out successfully in accordance with IEC standards.

The design and construction stages for the transformer involved changes to the original design to meet the customer’s requirements. TES customized the design as required. This involved the positioning of the on-load MPT International 3 / 2014

“Jolly” 138 MVA transformer for NLMK group, Russia

Furnace transformer

Series reactor

Rated power

138 MVA

31.1 Mvar

Primary voltage

35 kV

35 kV

Secondary voltage

1,285-1,100-723 V

Max. sec. current

72.4 kA

Frequency

50 Hz

50 Hz

OLTC

MR Germany

MR Germany

Sec. connection

Internally closed delta

Cooling system

OFWF

OFWF

Weight

135 t

65 t

Technical data of the “Jolly” transformer and series reactor

tap changer and the cooling system in a specific fashion in order to fully comply with the needs of the two different plants. After completion of the work, TES organized the shipment and the installation of the transformers at the Revda plant, near Ekaterinburg.

Conclusion TES has always reinvested a large portion of its profit in research and

development activities conducted by a team of highly qualified experts.

This has enabled TES to grow with the challenge and develop its main strength, namely the ability to create customized products and provide an excellent standard of quality and safety. TES today provides ample proof of its ability to combine experience and research, making it a remarkable representative of Italian skill and expertise in developing tai쐍 lor-made solutions.

BSE Lance Manipulator Newly designed lance feeding unit for optimised operation N! G and less maintenance I S E D NEW Operation-driven Experiencebased design. enhancement.

Tangible advantages.

O The newly designed lance feeding unit for BSE Lance Manipulators is another convincing example for continuous product enhancement resulting from operational experience at BSW, the steel plant of the Badische group.

O Better view of the furnace door area for operators.

O Tested and proven in one of the worldâ&#x20AC;&#x2122;s most productive steel plants, this product will improve the performance in your steel

O The improvements in terms of reliability, availability and maintainability are based on the valuable hands-on feedback of plant operating and maintenance personnel.

O The new design of the lance feeding unit features a revised interior as well as exterior, e.g. modified shape of the lance head.

Badische Stahl-Engineering GmbH Robert-Koch-StraĂ&#x;e 13 D-77694 Kehl/Germany Phone (+49) 78 51/877- 0 Fax (+49) 78 51/877-133 eMail info@bse-kehl.de www.bse-kehl.de

O Less slag splashing on watercooled front and casing due to reduced contact surface.

O Less dust and slag particles in casing due to deflection through side openings.

O Less heat radiation on motor due to relocation to the rear area of the lance head.

plant, too!

The newly designed lance feeding unit...

O Less water-cooled parts further increase reliability and decrease need for maintenance.

...gives the operator a better view of the door area...

...and reduces slag accumulation thus need for maintenance.

54

››› STEELMAKING – SERVICE

Graphite electrodes and processoriented services for the distinct needs of meltshops around the world SGL Group’s new fully integrated graphite works in Banting, Malaysia, is an example of the company’s commitment to increasing customer value. By developing additional services around the electrode and the furnace, SGL Group continues on its way from an electrode supplier to a solution provider to the steel industry.

Electric steelmaking accounts for 42% of total crude steel production in Europe and 59% in the USA. In Asia, this share is presently 20% [1]. Against

SGL Group – The Carbon Company, Wiesbaden, Germany Contact: www.sglgroup.com E-mail: alexander.loscher@sglgroup.com

these figures, the Asian region still lags behind in terms of electric steelmaking.

This is primarily due to the generally low availability of local scrap in China and many other Asian countries, an essential factor for cost competitive EAF steelmaking.

In addition, EAF steel production in Asia is mainly characterized by DC furnaces which require super-size graphite electrodes. In the past, super-size electrodes were primarily used in DC ap-

SGL Group’s new graphite electrode and cathode plant in Banting, Malaysia

plications, but during the last few years super-size electrodes, especially those of 700 mm diameter, have become increasingly common in AC applications.

In response to this changing market environment, SGL Group decided to align its graphite electrode production to the market development by constructing a new manufacturing facility in Banting, Malaysia, following the objective of serving customers locally. Banting serves customers from

STEELMAKING – SERVICE India to Australia and from Korea to Indonesia. With an investment of more than EUR 200 million, Banting was the largest single investment project in the company’s 20-year history.

A shorter supply chain to the customer allows for reduced inventories as well as improved service levels – two important factors behind the decision to construct the works in Malaysia. With its state-of-the-art equipment, high degree of automation, and employee experience spanning more than 40 years, the Banting works set the foundation for increased steelmaking performance – especially in the large-diameter segment.

Therefore the individual manufacturing know-how for graphite electrodes and cathodes made by SGL Group was shared between the existing seven plants around the world and the new production hub in Asia. Being a works for both graphite electrodes and graphitized cathodes, Banting can switch manufacturing schedules based on market and individual industry needs.

Group’s portfolio and is therefore strategically positioned to supply Europe and the surrounding region. The most critical production step in the manufacture of graphite electrodes is extrusion, during which the needle coke and pitch are mixed and the electrode is given its specific shape. Based on internal and external benchmarks, SGL Group made the decision to upgrade the green shop in La Coruna in order to operate in line with best available technology and be fit for future environmental regulations. This will also enable the plant to enhance the quality of products, especially the super-size diameters. Best practices from all graphite electrode plants were shared and benchmarked. The new green shop was designed accordingly in order to

‹‹‹

55

further increase the quality step by step during the next few years. The total investment in the new green shop amounts to approximately EUR 25 million. Construction began in 2012.

“Super-size” and “superlong” electrodes In addition to the production of large diameters (“super size”) to cater to the demand of the Asian market, Banting also provides “super-long” electrodes to customers worldwide.

Whereas, previously, the maximum electrode length was 2,900 mm (114 inch), the new SGL works in Malaysia is now capable of producing electrodes of up to 3,800 mm (150 inch).

The first application tests with graph-

Modernization of electrode plants in Spain and the USA SGL Group’s Graphite and Carbon Electrodes business unit continuously modernizes all manufacturing facilities around the world to be up to date with the latest technology and operate ahead of future environmental regulations. Therefore modernizations in Ozark (USA) and La Coruna (Spain) have been initiated in parallel to the investment in Malaysia.

The Ozark (Arkansas) works is the only graphite electrode plant in SGL Group’s global network that produces the full range of electrodes from dia. 14 - 32 inch (dia. 350 - 800 mm). Due to the fact that the plant has been in operation since 1981, in 2012 the decision was made to close the old graphitization shop and construct a new one with the most advanced graphite production technology.

Capacity will remain similar to what it is now in order to maintain the high service level for the customers in North and South America. The total investment in the new graphitization shop amounts to approximately US$ 26 million and will yield significant quality improvement, cleaner technology and a reduction in energy consumption.

The La Coruna (Spain) works is the largest graphite electrode plant in SGL

5). )TQWRoU ƂTUV HQEWU KU QP VJG RGTHQTOCPEG QH VJG ITCRJKVG GNGEVTQFGU CPF VQ ƂPG VWPG VJGO HQT QRVKOWO URGEKƂE EQPUWORVKQP CV VJG EWUVQOGTU RNCPVU MPT International 3 / 2014

56

››› STEELMAKING – SERVICE

ite electrodes longer than 3,500 mm (dia. 700/800 mm) at steel works in Asia provided promising results. Performance improvements were already evident. Through the use of longer electrodes, the following advantages will be achieved: ▪ less jointing due to longer electrodes – therefore fewer joints, ▪ decrease in electrode jointing time due to fewer joints leading to increased productivity, ▪ less changes of electrode columns in parking position yielding less oxidation and graphite losses.

These advantages result in lower production costs. A trial at a customer site recently showed how savings can be achieved. In this example, an 800-mmdia. electrode was enlarged from 2,900 mm to 3,500 mm length. During the trial period it was observed that on average one more heat per month was achieved due to less jointing time. In addition, the specific consumption of the graphite electrode could be reduced by 2 to 5% due to less oxidation (off-furnace jointing). For this particular case, the productivity gain and the reduced graphite electrode consumption led to a total cost reduction of 300,000 euros/year.

Optimized meltshop performance supported by SGL’s service portfolio To further improve its customer service, SGL Group offers its full service portfolio through local technicians.

The complete service portfolio consists of 26 tools, from electrical measurements through to the optimization of the melting process in general by joint steel plant and SGL Group teams. The tools are reviewed on a continuous basis and enhanced based on global expertise as well as latest findings and technological developments. Especially SGL PRO (PROfessional PROjects), based on the Six Sigma methodology and coupled with many years of steelmaking experience, delivers added value to the meltshop, which goes far beyond the graphite electrode. Furthermore, it acts as a driver for innovation and new services to be later rolled out on a global scale.

The main targets of all service tools are increased melt shop performance and reduced total costs – from the delivery of the graphite electrodes through to the consumption of the MPT International 3 / 2014

dia. 550 mm

3%

dia. 600 mm

8%

dia. 700 mm

47%

dia. 750 mm

33%

dia. 800 mm

9%

$TGCMFQYP QH GNGEVTQFG FKCOGVGTU HQT &% HWTPCEG CRRNKECVKQP = ?

graphite electrodes in the furnace. A common “total cost of ownership” approach supports the commitment to decreasing total costs in a joint effort.

Being a graphite electrode supplier, SGL Group’s first focus is on the performance of the graphite electrodes and to fine tune them for optimum specific consumption at the customers’ plants.

Specific consumption is defined as the amount of electrode consumed per ton of steel produced. In order to optimize the specific consumption at the customer’s site, SGL Group works continuously to further develop internal production parameters and procedures in a structured way applying the Six Sigma methodology. In the meltshop, oxidation is a key influencing factor for specific consumption. The oxidized length has approx. 30% influence on the electrode consumption. Therefore customers frequently request information about spray cooling systems. SGL Group offers a wide range of expertise in this field from long-term trials in numerous steel plants and through recent innovations that are currently being rolled out.

Verified results from root cause analyses at steel plants comprise the following items: ▪ oxidation behaviour of graphite electrodes, ▪ cause and effect matrix for spray cooling systems, ▪ pipe diameter and bore diameter, ▪ use of nozzles/trials of different design, ▪ water flow rate and pressure.

Each change from existing parameters was individually calculated. A total reduction in graphite consumption of up to 0.15 kg per t of steel produced is possible, adding up to savings of 500,000 euros/year based on an annual steel production of 1,000,000 t.

A second focus is on the steelmaking process itself. Due to increasing energy prices and the growing importance of CO2 emissions, a major lever for the steel plants is the reduction of electrical energy needed to produce one tonne of steel.

A customer declared energy consumption as a target for improvement, setting the objective to reduce consumption significantly. The meltshop is modern and excellently operated. However, through internal benchmarks SGL was able to identify a potential for reduction by 25 kWh per tonne of good billet. Based on the good reputation of SGL PRO, the meltshop management agreed to cooperate with SGL Group to reduce energy consumption in a sustainable manner. The following root causes have been identified and the solutions implemented accordingly: ▪ EAF set-points in the melting programme, ▪ tapping temperature, ▪ slag foaming, ▪ power-off time, ▪ scrap handling and recipe.

The results obtained at the steel plant are: ▪ higher arc efficiency, ▪ decreased radiation onto the panels, ▪ shorter arc during the melt down, ▪ improvement of the early foaming slag, ▪ improvement of splash slag practice.

The project targeted an electrical energy reduction by 25 kWh per tonne of good billet. The steel plant objective was reached after a period of three months, and after the completion of the project at the end of the year total savings on energy costs amounted to 750,000 euros/year.

Conclusion SGL Group continues to invest in its global production infrastructure, including the modernization of equipment, in line with its commitment to provide the highest quality graphite electrodes to each customer. SGL Group supplies graphite electrodes to the majority of electric arc furnaces in operation globally and has one of the most experienced technical service teams in the industry. This experience along with that obtained from the cooperation with both furnace manufacturers and technology providers enables SGL Group to maximize value for its customers, thereby reducing total cost of ownership. 쐍 References [1] World steel in figures 2013. World Steel Association, Brussels, Belgium, 2014 [2] SGL Group internal data base

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58

››› MODERNIZATION – SERVICES

Building a new plant structure in almost no time In investment projects requiring new factory buildings, a main target is to minimize intervention and shutdown times. Shutdown time can be saved by having various project phases take place simultaneously, e.g. engineering planning, off-site pre-fabrication of foundation blocks and on-site work by highly specialized teams. The use of preassembled foundation blocks manufactured beforehand enables the reconstruction to be completed within an extremely small time window.

In investment projects requiring the revamp of a plant or a part of it, a minimized intervention time is a key target. The goal of reducing the usually required intervention time by 75% can be met by the Italian service provider Ferretti International, due to the fact that the company has the potential to take care of the entire revamping process from the initial feasibility study (phase 1), to carefully performed engineering planning and off-site assembly work prior to the plant shutdown (phase 2), up to the final on-site activities performed during the shut-down time (phase 3). The latter includes the dismantling and controlled demolition of existing plants and construction and installation of the new facilities (phase 3). A planning department links these three independent phases and develops an accurate schedule of the revamping process to achieve the target of saving 75% of the time normally required.

According to Alberto Ferretti, CEO of Ferretti International, the company offers a wide range of projects all over the world. “We provide the full range of engineering services, construction and electro-mechanical installations, piping and refractory lining installation as well as lump sum turn-key projects for which we have the full responsibility.”

Such projects demand a tremendous amount of planning, expertise and coordination. In so-called fasttrack revamping projects, Ferretti International uses its own professional resources and suitable means to meet

Ferretti International, Dalmine, Italy Contact: www.ferretti-group.com E-mail: info@ferretti-group.com

Off-site prefabricated blocks assembly before shutdown at ABS (2007)

Replacement of the cooling bed at the rolling mill (2007) Customer: Acciaierie Bertoli Safau (ABS) Location: Cargnacco, Udine, Italy Pre-shutdown works:

Civil engineering

Pre-assembled blocks:

150,000 kg

Rebar positioning:

100,000 Kg

Formworks:

2,000 m²

Shut down period:

7 calendar days

Demolition:

2.200 m³

Excavations:

3,000 m³

Lean concrete pouring:

250 m³

Foundation slab blocks positioning

100,000 kg

Foundation slab pouring:

1,500 m³

Wall block positioning:

150,000 kg

Wall formworks completion:

2,000 m²

Walls pouring:

1,500 m³

Formworks removal and cleaning:

2,000 m²

Fast track revamp of the cooling bed at Acciaierie Bertoli Safau (ABS) MPT International 3 / 2014

60

››› MODERNIZATION – SERVICES

Prefabricated blocks positioned on-site before pouring the

Formworks completion at the Ferriere Nord meltshop

concrete at the Ferriere Nord roughing mill (2007)

(2011)

the customers’ expectations in terms of time and budget. The company relies on Oracle’s “Primavera” as the main project portfolio management tool. It provides a good overview of

the project planning and control activities. Alberto Ferretti: “Of course, steel producers keep a close eye on time schedules and are concerned about not being able to start produc-

Revamp of a roughing mill (2007) Customer: Ferriere Nord S.p.A. Location: Osoppo, Udine, Italy Pre-shutdown works:

Civil engineering

Pre-assembled blocks:

9,600 kg

Rebar positioning:

144,000 kg

Formworks:

3,600 m²

Embedded steel:

12,000 kg

Shut down period:

6 calendar days

Demolition and cuts by diamond wire:

450 m²

Structural blocks positioning:

9,600 kg

Structural pouring:

1,200 m³

Rebar completion:

1,400 kg

Formworks completion:

400 m²

Fast track revamp of the roughing mill at Ferriere Nord

Replacement of the EAF and ladle car (2011) Customer: Ferriere Nord S.p.A. Location: Osoppo, Udine, Italy Pre-shutdown works:

Civil engineering

Rebar positioning:

111,000 kg

Pre-assembled blocks:

40,000 Kg

Formworks:

1,600 m²

Shut down period:

7 calendar days

Demolition:

1.200 m³

Excavations:

400 m³

Structural blocks positioning:

40,000 kg

Rebar completion:

5,000 kg

Formworks completion:

100 m²

Structural pouring:

850 m³

Fast track revamp of the EAF and ladle car at Ferriere Nord MPT International 3 / 2014

tion on time, that is by the agreed deadline. If the agreed deadlines and budgets are not met, we assume part of the risk and costs of the potentially lost production. This is a challenging and non-standard approach which proves our teams’ outstanding performance.” Ferretti International has a proven record of successfully executed fast-track revamping projects from all over the world. Alberto Ferretti: “I am really proud to say that in many years we have never failed to meet the agreed deadlines or paid any penalty.”

Being on time, on budget and working according to specifications are crucial factors and should be in any project manager’s DNA. Communication, advising and assisting customers in successfully meeting their targets are other very important elements of the project management, along with focusing on the quality of work. Quality is an essential element and the reason why customers keep coming back.

Safety is another key factor. It is to be addressed at a very early stage of the project. All people involved need to have the necessary knowledge and expertise. It is of common interest to ensure safety as a top priority.

After concluding any project, a structured review should be an integral part of it. Some customers may give direct feedback, others may be more reluctant. In any case, it is important to review and explain how a project developed and why it developed the way it did. More than anything, it is a matter of good personal relationships with the customers and valuing their know쐍 how.

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62

››› MODERNIZATION

JSW Steel to upgrade 2-strand thin slab plant at Dolvi works JSW Steel Ltd., one of India’s largest steel producers, has placed two orders with SMS Siemag for a comprehensive revamp of the CSP® thin slab caster and the downstream hot strip mill at the Dolvi location in the federal state of Maharashtra. The most important aim is to boost the annual capacity and to enable production of high-quality strip of low and medium carbon steels and HSLA grades as well.

JSW Steel pioneered the CSP® technology in India when installing the first plant of this type at the Dolvi site in 1998. In 2003 a second continuous casting machine was added to double the production capacity. With an average casting speed of eight meters per minute – maintained for a whole month – JSW Dolvi holds the CSP® world record in fast casting.

Now the plant will undergo a major revamp to achieve the aim of economical production of 3.3 million tons per year. Various changes will be made to the continuous caster. At the hot strip mill the electrical and automation system will be modernized extensively. Commissioning of the modernized plant is scheduled for the spring of 2015.

Modernization of the thin slab continuous caster The revamp of the continuous caster focuses on the capability to primarily cast high-quality slabs of low and medium carbon steels and HSLA grades.

With slab thicknesses of 65 to 50 millimeters, the plant is designed for a casting speed of up to seven meters per minute.

The casting floor of CCM No. 1 will be elevated to the level of the casting floor No. 2. At CCM No. 1, the electromechanical oscillation system will be replaced by a hydraulic oscillator with the same design and the same functions as at CCM No. 2. The capacity in-

SMS Siemag AG, Düsseldorf, Germany Contact: www.sms-siemag.com E-mail: communications@sms-siemag.com

MPT International 3 / 2014

crease will be achieved by a new strand guiding system at CCM No. 1 and by the extension of casting strand No. 1 from the current 6,970 mm to 9,420 mm. The new strand guiding system will be equipped with liquid core reduction (LCR1) and thus also be capable of flexibly adjusting the strand thickness. The mold level control is to be modernized and provided with new hydraulics and the corresponding hardware.

For the conversion of the mechanical system and for the revamping of the electrical and automation system, SMS Siemag has developed a customer-specific concept which can also be transferred to other casters. The modernization of the electrical and automation system comprises adaptations and additions to the control systems as well as integration of the technological X-Pact® systems such as mold level control, hydraulic mold oscillation and adjustment of the pinch-roll bending unit and withdrawal straightener.

The cost efficiency of maintenance and the stocking of spare parts will be increased significantly by the modernization, since the two continuous casters will be identical after the revamp.

New electrical and automation systems for the rolling mill The existing electrical and automation system will be renewed completely. The modernization work, commencing with the descaler, then the six stand finishing train and the cooling section, and continuing to the two downcoilers including the coil conveyor system, will be carried out during a downtime of only 23 days.

The supply scope of the X-Pact® electrical and automation package in-

cludes the Level 2 control systems with pass schedule calculation, profile, contour and flatness control and cooling section control and the replacement of the complete Level 1 systems inclusive of the technological control systems and basic automation. The implementation of the innovative HMI concept from SMS Siemag with new control desks ensures an ergonomic operating process.

Plug & work tests and operator training before commissioning To enable the rolling mill to be shut down for a short time, use is made of the plug & work procedure developed

by SMS Siemag. Here, the entire automation system with the original control units is tested and optimized at SMS Siemag by means of comparison with a real-time simulation of the process technology. This unique procedure enables defects to be detected and eliminated right in the preliminary stages. As part of the plug & work test, the operating staff is trained beforehand on the modernized plant operation system with a view to enabling the customer’s personnel to become familiarized quickly with the new operating concepts and to participate actively in performing the commissioning work.

Besides the complete replacement of the plant automation, SMS Siemag will replace the main drive control system while retaining the existing power sections. This will also include the incorporation of new auxiliary systems and the revamping of the low-voltage drives through replacement of the converter systems. In addition to increasing the plant availability, the simplicity of maintenance will be decisively enhanced. 쐍

64

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş MATERIAL FLOW LOGISTICS

Storage logistics system optiOK\GU YQTMĆ&#x192;QY KP VJG UNCD [CTF ArcelorMittal EisenhĂźttenstadt in Germany has implemented a new storage logistics V\VWHP IURP 6LHPHQV 7KH 6LPHWDO 6LORF VROXWLRQ RSWLPL]HV ZRUNĆ&#x192;RZV VLPSOLĆ&#x201A;HV VWRFN control and shortens cycle times. Automated transport orders optimize composition of slab stacks. The system automatically registers manual restacking operations.

The Simetal Siloc logistics system provides the company with a precise picture of its stock at all times and the over 40,000 slabs that pass through the slab storage each year. It not only enhances the composition of the stacks of slabs, but also automates logging of manual restacking operations. Simetal Siloc thus improves workflows and simplifies stock control. Cycle times have also been reduced because the slabs can be fed to the rolling mills at a higher temperature.

ArcelorMittal is the worldâ&#x20AC;&#x2122;s largest steel producer and a global supplier of high-quality steel products. In EisenhĂźttenstadt, in the German state of Brandenburg, the main products are high-quality, coated flat steels for the automotive industry, together with steel products for domestic appliances and the construction industry. Dr. Ralf BĂśsler, Primary CEO at ArcelorMittal EisenhĂźttenstadt GmbH, explained, â&#x20AC;&#x153;The new Siemens system, above all, meets future requirements for the planned modification and optimization of the technological and logistic processes in our company. The advanced strategies for storing and retrieving the slabs provide a good basis in particular.â&#x20AC;?

The new Simetal Siloc storage logistics system from Siemens is part of a programme to modernize the automation, and thereby increase the efficiency of hot strip production. In the finishing department of the continuous casting plant of ArcelorMittal EisenhĂźttenstadt, slabs and blooms are accepted, inspected, transported,

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

MPT International 3/ 2014

The bar icons in the centre indicate the current location of the crane supporting the crane operator

stored, processed according to scheduling and quality specifications, prepared for further processing in the hot rolling mill, and finally finished for dispatch. The plant personnel have to constantly coordinate the movements of twelve cranes, various storage areas, a number of roller tables, trolleys, inspection tables, heat recovery, and the slitting and cross-cutting stations.

Planning in the finishing department was previously done manually and independently of the higher-level planning processes. This resulted in a large number of restacking operations in all storage areas.

The new storage logistics system takes its instructions from the higherlevel production planning system (PPS), the material tracking system (MVS), and the dispatch system. Simetal Siloc coordinates the work of the individual systems in the finishing department in line with the instructions of the material accepted. For example,

the crane operator receives automatically generated transport orders on the terminal in his cab, which ensure optimum composition of the stacks of slabs. Simetal Siloc applies its own safety rules to ensure the stability of the stacks and protect the slabs from damage. The crane operator can also perform unscheduled restacking operations manually. These are then automatically registered by the system and entered in the database which is always up to date, allowing all material movements to be visualized.

The expandable, modular system is based on the Simatic IT and Simetal Siloc product platform. It provides a large number of organizational and commercial metrics in the form of clear graphics and tabular evaluations.

For example, it can show how many crane movements have been made per shift for any category of slab, so that the time and cost for each operation can be calculated exactly. ě??

Michael Degner 2013. 16,0 x 24,0 cm. 256 pages.

ISBN 978-3 514-00808-3

Modern Hot Strip Production This book is a handbook for engineers in the hot rolling technology field. It features the techniques of the whole process chain of a hot strip mill starting from the slab down the line to the finished hot strip coil. Mill

components are entirely explained.

The empirical operational results are described in detail. In general, not theory but the reproducible operation in reality is in the focus of the book.

Verlag Stahleisen GmbH P.O. Box 10 51 64 ¡ 40042 Dßsseldorf ¡ Germany Phone: +49 211 69936-264 ¡ Fax: +49 211 69936-266 Email: annette.engels@stahleisen.de ¡ www.stahleisen.de

66

››› MATERIALS

New high-strength microalloyed special steel wire rod to substitute quenched and tempered steels Swiss Steel has introduced a high-strength micro-alloyed, wire rod product. Swissbain7MnB8 is an alternative to quenched and tempered steels that saves resources in the production of high strength parts, particularly for the automotive and construction industries. Specially developed for cold forging application, it has a high tensile strength but is still excellent for cold forming without requiring separate heat treatment.

Steels for conventional use must generally be annealed and quenched and tempered to meet the requirements of “good workability” and simultaneously “high strength”. Finding the right balance of these aims has now been mastered by the new bainitic steel Swissbain-7MnB8 (material number 1.5519) from Swiss Steel AG. The new high-strength special steel product makes downstream cold forging manufacturing even more efficient compared to conventional quenched and tempered steels. Developed by Swiss Steel AG (Schmolz + Bickenbach Group), Swissbain-7MnB8 is produced as standard dia. 7 to 40 mm wire rod.

Conventional quenched and tempered steels, e.g. 23MnB4, 41Cr4 or even 42CrMo4, have the disadvantage that they must be annealed prior to cold forging and must then be hardened by means of quenching and tempering. Long parts in particular can deform during heat treatment.

If any distortion occurs, the parts must undergo additional straightening. Swissbain-7MnB8 steel, however, was designed to provide already a higher degree of strength as-rolled.

The strength can be increased during cold forging to 800 to 1000 MPa on

Cementite-free, micro-alloyed (granular) bainite structure of Swissbain-7MnB8 wire rod

the finished part, depending on how the wire is withdrawn and the design of the forming steps selected. Costly separate heat treatment and straightening processes are eliminated.

Product development Swiss Steel AG, a company of Schmolz + Bickenbach Group, Emmenbrücke, Switzerland Contact: www.swiss-steel.com www.schmolz-bickenbach.com

MPT International 3 / 2014

The Swissbain-7MnB8 product was developed as part of the “Coheadbain” project funded by the European Research Fund for Coal and Steel. The aim was to produce a bainitic steel ideal for cold forging

from which high-strength parts can be manufactured without additional annealing, quenching and tempering processes. One focus of the task was to reduce the costs of producing cold-forged parts. In three years time, a suitable material concept was developed in cooperation with research institutes and project partners from industry, and extensive laboratory and large-scale tests were conducted.

The initial product was based on the bainitic steel concepts al-

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ready used in the flat steel segment which were transferred to the long product segment. To achieve the required strengths despite a low carbon content, the steel specialists relied on micro-alloyed elements such as titanium, vanadium, and niobium. With this material concept the use of expensive alloying additions such as chromium, molybdenum, and nickel was also able to be reduced.

C O N V E Y

Q U A L I T Y

Hot DRI Conveyor

Production and rolling technology The basis for the product is separated scrap iron that Swiss Steel melts in an 80t electric arc furnace. The micro-alloying elements are added to the heat in the ladle furnace. The molten steel is then cast as billets from which wire is manufactured in the rolling mill. In addition to chemical analysis, control of the temperature and cooling process during rolling plays a decisive role when the cementite-free bainitic structure is to be regulated specifically for cold forging and with the desired mechanical properties.

In cooperation with cold formers, Swiss Steel tested the final product successfully for its suitability for practical application and took it to market-readiness. The steel producer is currently pursuing the standardization of Swissbain-7MnB8 (material number 1.5519).

AUMUND Hot DRI Transport in Inert Atmosphere s %NCLOSED AND SEALED CONVEYORS WITH HEAT INSULATION s ,OW POWER CONSUMPTION

Application The new special steel Swissbain-7MnB8 is ideally suited to cost efficient production of a number of articles for the automotive and construction industry for which no quenched structure is stipulated: short- and long-shaft ball studs, various screws, nuts, hollow parts, step-mounting pins, stud bolts, and plug bolts. Cold formers and component manufacturers profit from shorter cycle times specifically for components, lower processing costs and an optimized energy balance. Hence, the new special steel product Swissbain-7MnB8 from Swiss Steel AG lowě?? ers manufacturing costs.

s ,ESS HEAT LOSS OPTIMIZED METALLISATION

DRI. HBI. HCI.

AUMUND Foerdertechnik GmbH 3AALHOFFER 3TR s 2HEINBERG s 'ERMANY METALLURGY AUMUND DE q WWW AUMUND COM

68

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

Simulation of inductive high-frequency tube welding TUBEMAKING It used to be extremely difficult to simulate the high-frequency welding process as three different simulations need to be combined: electro-magnetic, thermal and mechanical. The companies Data M and MSC.Software have now found a way to solve this problem. The new HF welding capabilities of the CopraÂŽ FEA RF analysis software allow combining the simulation of three physical steps. The user-defined harmonic coil current leads to a magnetic field, which induces an electric current in the tube. This current field initiates a heat source distribution due to the electric resistance of the tube material. In this electro-magnetic simulation step, both the tube and the ambient air are described by an appropriate FE mesh. The distributed heat sources lead to a temperature field in the tube.

The maximum temperature is reached at the tip of the Vee-angle due to a high energy density at this location.

This is simulated in the thermal step. The temperature field results in a thermal expansion of the heated tube material. The temperature-dependent material description in the mechanical simulation step leads to a change in strength, even up to the molten condition. Simultaneously the material is deformed by the squeezing rolls in the weld station. Also backwards coupling is taken into account. Both the geometrical change of the tube as well as any temperature-dependent material properties result in a changed response to the electromagnetic field initi-

Simulation of high-frequency tube welding

ated by the coil current. The described simulation allows to investigate in detail the relevant roll forming phenomena like temperature field and squeeze-out of the material in the weld.

Contact: www.datam.de

6@SDQ FKXBNK GXCQ@TKHB Ă&#x2014;THCR @MC FQD@RDR LUBRICATION TECHNOLOGY In order to help customers hydraulic fluid support water hydraulic equipment by prein the steel industry adjust to the latest industry challeng- venting corrosion in components and piping, inhibiting es and bring value to their processes, the Quaker portfolio bacterial growth in the fluid and extending component life. of Quakertekâ&#x201E;˘ specialty greases includes Key benefits include excellent fire-rea range of aluminium complex, lithium sistance, minimal foaming, high viscomplex, polyurea and calcium sulphocosity index and extended pump life nate thickened greases that can be used in systems operating under high pressure or in overloaded hydraulic systems. for coke making, casting, the blast and basic oxygen furnace, melt shop, hot To illustrate the benefits of fire-resistmill, cold mill temper mill, pickle line ant hydraulic fluids over mineral oils, mobile equipment, motor bearings, as Quaker has developed a series of videos well as other extreme temperature apshowing a lab test comparison of both plications. fluid types. The videos explain why Quaker has expanded its line of fire-resistant hydraulic fluids are critfire-resistant hydraulic fluids with the ical to improving safety and reducing addition of the QuintolubricÂŽ 702-46 Watch the video risk in hot environments and applications close to open flames and show the UJQYKPI VJG DGPGĆ&#x201A;VU QH RD water glycol hydraulic fluid. The increased risk of flame propagation, fast Ć&#x201A;TG TGUKUVCPV J[FTCWNKE new fluid, which is FM approved as a less hazardous fluid, is designed to proaggressive ignition, waterfall of fire, and Ć&#x192;WKFU QXGT OKPGTCN QKNU instant fireball when using mineral-oil vide optimum performance in hydrauby scanning this lic systems where fire-resistant fluids based hydraulic fluids.

QR code (http://www. are required. Specific additives formuyoutube.com/watch?v= lated into the fire-resistant water glycol Contact: www.quakerchem.com bEtlikCMRWM) MPT International 3 / 2014

THE

"NRS R@UHMFR SGQNTFG introduction of highODQENQL@MBD FQD@RD

Edition 1/1

TECHNOLOGIST CONTINUOUS CASTING

ROLLING MILLS EZDK, Egyptâ&#x20AC;&#x2122;s largest steel producer, reviewed its grease portfolio during a planned engineering service as it looked to reduce grease consumption and increase the protection of the chock bearings in its flat and rod mills. The company decided to switch from a multi-purpose,

INTECO TBR offers continuous casting machines for long products as well as special solutions for the production of special steels. Our portfoOLR FRYHUV FRPSOHWH JUHHQ ÂżHOG SURMHFWV DQG UHYDPSV RI H[LVWLQJ FDVWHUV %DVHG RQ RXU ORQJ WHUP H[SHULHQFH LQ HQJLQHHULQJ DQG GHVLJQ RI LQGLYLdual bloom casters, we offer tailor-made solutions for all kinds of steel producers.

Lubricated bearings

lithium-based grease to the high-performance grease Mobilith SHC 460 from Mobil Industrial Lubricants. Mobilith SHC 460 is an extreme pressure grease with ISO VG 460 synthetic base fluid. It provides outstanding high temperature bearing protection under heavy loads at low-to-moderate speeds and in applications where water resistance is a critical factor. Mobilith SHC 460 has a constant operating temperature range from -30ÂşC to 150ÂşC. The introduction of the new grease at EZDK proved successful in both trials. In the rod mill, the chock bearings were greased manually, using a pneumatic pump for a set time equal to 360 g of Mobilith SHC 460 every 48 h. Temperatures of the chock bearings were taken using thermograph imaging before and after re-greasing. During each of the three passes of the 42-day trial, the consumption of Mobilith SHC 460 was measured at 5.5 kg per pass, compared to the 37.2 kg previously consumed. In the second trial, which took place in the flat mill, the test focused on the cohesive properties.

The grease was put through a water washout test where each bearing is rotated at 600 rpm in a water spray chamber at 80°C for an hour to test for water resistance. The trials showed that compared to a multi-purpose, lithium-based grease, Mobilith SHC 460 provided greater resistance to water washout, enabling re-greasing intervals to be significantly increased while maintaining bearing protection. The new grease has enabled EZDK to make significant cost savings in the rod mill by reducing grease consumption, while increasing productivity and reducing maintenance downtime in the flat mill.

Contact: www.mobilindustrial.com

Bloom and Billet Casters The continuous casting of blooms has become a well-established technology for the production of semis for high-quality applications. Similarly, continuous casting of billets is the basis for highly productive steelmaking.

INTECO TBR supplies robust continuous casting machines with higKHVW TXDOLW\ RI WKH ÂżQDO SURGXFW ORZ PDLQWHQDQFH UHTXLUHPHQWV DQG KLJK operator friendliness.

Design Criteria â&#x20AC;˘ Bow-type or vertical-bending machines â&#x20AC;˘ Modular design with the provisions for upgrading features of the caster at a later stage Â&#x2021; 2SHUDWRU IULHQGO\ FDVWLQJ Ă&#x20AC;RRU â&#x20AC;˘ Advanced mould level control solution â&#x20AC;˘ Quick change of mould and segments â&#x20AC;˘ High-precision, robust mould oscillator Â&#x2021; 0RXOG DQG ÂżQDO VWLUUHU â&#x20AC;˘ Dynamic secondary cooling (water and air-mist) Â&#x2021; &XVWRPL]HG UXQ RXW DUHD FRQÂżJXUDWLRQ â&#x20AC;˘ Rigid cooling bed â&#x20AC;˘ Performance assurance by integrated automation system Â&#x2021; +LJKHVW ÂżQDO SURGXFW TXDOLW\ E\ TXDOLW\ PRGXOHV RI WKH /HYHO automation Special Casting Applications Continuous casting machines for special techniques, such as horizonWDO RU YHUWLFDO FDVWLQJ URXQG XS WKH SURGXFW SRUWIROLR LQ WKH ÂżHOG RI WKH SURGXFWLRQ RI VSHFLDO VWHHOV $ Ă&#x20AC;H[LEOH DQG LQWHOOLJHQW GHVLJQ DQG WKH implementation of customer demands emphasize our competence in this product segment.

/Ed K d Z Ä?Ä&#x201A;Ć?Ć&#x;ĹśĹ? Ć&#x161;Ä&#x17E;Ä?Ĺ&#x161;ŜŽůŽĹ?Ĺ?Ä&#x17E;Ć? 'ĹľÄ?, WĆ&#x152;Ä&#x17E;ĆŠÄ&#x201A;Ä?Ĺ&#x161;Ć?Ć&#x161;Ć&#x152;Ä&#x201A;Ć&#x2DC;Ä&#x17E; Ϲϭ ϴϳϏϏ >Ä&#x17E;Ĺ˝Ä?Ä&#x17E;Ĺś ĆľĆ?Ć&#x161;Ć&#x152;Ĺ?Ä&#x201A; WĹ&#x161;ŽŜÄ&#x17E;Í&#x2014; нϰϯ ͞ϏͿ ĎŻĎ´Ď°ĎŽ ώϹϴϯϲͲϏ &Ä&#x201A;Ç&#x2020;Í&#x2014; нϰϯ ͞ϏͿ ĎŻĎ´Ď°ĎŽ ώϹϴϯϲͲϭϲ ŽĸÄ?Ä&#x17E;Î&#x203A;Ć&#x161;Ä?Ć&#x152;ͲÄ?Ä&#x201A;Ć?Ć&#x;ĹśĹ?Í&#x2DC;Ä?Žž Ç Ç Ç Í&#x2DC;Ć&#x161;Ä?Ć&#x152;ͲÄ?Ä&#x201A;Ć?Ć&#x;ĹśĹ?Í&#x2DC;Ä?Žž

70

››› TECHNICAL INNOVATIONS

'XCQ@TKHB OQDRR ENQ O@QSR TRDC HM OHODKHMD BNMRSQTBSHNM FORGING The press line in operation at the new facility of the Russian company Oil and Gas Systems close to the city of Aleksin in the Tula region features a press force of 140 MN and a height of 22 m. This is the largest hydraulic forging press in the history of Schuler, the press supplier. The press is used to forge parts of 0.6 to 20 t weight from round blanks and sheet metal. A speciality is the forging of large shells for valve bodies in oil and gas pipelines.

The spectrum of products ranges from rings automatically forged in three stages, open die forged parts and forged pipe sections, bends and tees through to extrusion parts. With thicknesses from 10 to 150 mm and made from a wide variety of metals and alloys, the blanks for the forging press must be heated just once for the three-stage forming process. The furnaces to heat the parts were

Forging of valve bodies (photo by courtesy of Oil and Gas Systems)

supplied by Andritz Maerz, which – like Schuler – belongs to the Andritz group.

ONLINE AUCTION due to BANKRUTCY by order of Mrs. R. Maes and L. Favoreel,

RSB Transmissions Belgium nv Havenlaan 5 - 3980 Tessenderlo (Belgium) CNC DOUBLE MILLING MACHINE “Anayak” HVM-11.000PC (‘06); 4x CNC lathes “Haas” (‘07), “Yang” and “Doosan” (‘07); 5x CNC MACHINING CENTRES “Haas” VF-11/50 HE (‘08), “Daewoo” ACE-H100, “Mazak” VS-20, “Mori Seiki” SH-63 and “Deckel Maho” DMF 360 Linear (‘04); CNC GANTRY MACHINING CENTRE “Duplo Standard” CTF; CNC double column machining centre “Kao Ming”; CNC PLASMA CUTTING LINE “Hypertherm” (‘12); CNC vertical lathes “Intermato”(‘06); cnc milling machine “Maut”; 4x CNC CAROUSEL LATHES “Fremtas” 32FR3 (‘09), “Yu Shine” VL-1600 ATC (‘08), “Berthiez” TFF 160N and TFM 125; 3-rolling mill “Lisse”; cnc press “LVD”, cap. 320t x 4000 mm; CNC oxy-cutting table “Messer Griesheim” Stratosec KSP 5600; OVERHEAD CRANE “Demag”, cap. 16t; etc.

Contact: www.schulergroup.com

INJECTION SYSTEMS Manufacturer of : Carbon Lime FeSi Dust…. pneumatic transport Systems for EAF, LF …….

BIDDING ONLY ON THE INTERNET CLOSING: Tuesday 8

PHOTOS / CATALOGUE / INFO available on our website

www.TroostwijkAuctions.com

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JULY from 14h00

VISITING: Thursday 3 July from 9h00 till 16h00 Monday 7 July from 9h00 till 16h00

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KOLL ANLAGENBAU GMBH & Co KG Schachtstr. 21 59379 Selm GERMANY Tel. 0049 (0) 2592 978578 Fax. 0049 (0) 2592 978682 E-mail: koll @ eaf - carbon.de

We are exhibitors: METEC 2015, Düsseldorf MPT International 3 / 2014

OUR EXPERTISE MAKES YOUR OPERATION MOST 9 PRODUCTIVE 9 ECOLOGICAL & 9 ENERGY-EFFICIENT PAUL WURTH is one of the world leaders in the design and supply of the full-range of technological solutions for the primary stage of integrated steelmaking:

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Blast furnace technology and the entire equipment range Coke oven plants Agglomeration plants Direct reduction plants Environmental, energy-saving & recycling technologies

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Subsidiaries: Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Taiwan, Ukraine, U.S.A., Vietnam

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ISO 9001 ISO 14001

BUREAU VERITAS Certification

Blast Furnace Plants engineering & construction of complete blast furnace plants, modernisations, rebuilds and relines.

BF Technology & Equipment cooling & lining concepts and systems, automation, top charging technology, special equipment.

*>Ă&#x2022;Â?Ă&#x160;7Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;]Ă&#x160;Ă&#x152;Â&#x2026;iĂ&#x160;*>Ă&#x2022;Â?Ă&#x160;7Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;Ă&#x160; Â&#x153;}Â&#x153;]Ă&#x160;*, 1-]Ă&#x160;,i` Ă&#x20AC;Â&#x153;Â&#x2DC;Ă&#x160;>Â&#x2DC;`Ă&#x160;,i`-Â&#x201C;iÂ?Ă&#x152;Ă&#x160;>Ă&#x20AC;iĂ&#x160;Ă&#x152;Ă&#x20AC;>`iÂ&#x201C;>Ă&#x20AC;Â&#x17D;Ă&#x192;Ă&#x160;Â&#x153;vĂ&#x160;*>Ă&#x2022;Â?Ă&#x160;7Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;Ă&#x160;-° °Ă&#x160;>Â&#x2DC;`Ă&#x160;Â&#x201C;>Ă&#x17E;Ă&#x160;LiĂ&#x160;Ă&#x20AC;i}Â&#x2C6;Ă&#x192;Ă&#x152;iĂ&#x20AC;i`Ă&#x160;Â&#x2C6;Â&#x2DC;Ă&#x160;Ă&#x17E;Â&#x153;Ă&#x2022;Ă&#x20AC;Ă&#x160;Â?Ă&#x2022;Ă&#x20AC;Â&#x2C6;Ă&#x192;`Â&#x2C6;VĂ&#x152;Â&#x2C6;Â&#x153;Â&#x2DC;°

Auxiliary Plants sintering plants, hot blast stoves, stockhouse, pulverized coal injection, slag granulation and dewatering.

Coke Making Plants complete plants and batteries, coke oven gas by-products recovery systems and auxiliary plants, centralised supervision and process control.

Recycling Technologies multiple hearth based technology: PRIMUSÂŽ, rotary hearth based technology: RedIronâ&#x201E;˘, RedSmeltâ&#x201E;˘.

Environmental Protection BF top gas cleaning, aspiration systems, hot blast stove heat recovery, coke oven gas treatment, sinterplant off-gas cleaning.

PAUL WURTH â&#x20AC;&#x201C; LEADING IN IRONMAKING TECHNOLOGY VCA**

ISO 9001 ISO 14001

BUREAU VERITAS Certification

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CERT IF

Paul Wurth S.A.Ă&#x160;UĂ&#x160;Ă&#x17D;Ă&#x201C;]Ă&#x160;Ă&#x20AC;Ă&#x2022;iĂ&#x160;`½ Â?Ă&#x192;>ViĂ&#x160;UĂ&#x160;*°"°Ă&#x160; Â&#x153;Ă?Ă&#x160;Ă&#x201C;Ă&#x201C;Ă&#x17D;Ă&#x17D;Ă&#x160;UĂ&#x160; Â&#x2021;£äĂ&#x201C;Ă&#x201C;Ă&#x160; Ă&#x2022;Ă?iÂ&#x201C;LÂ&#x153;Ă&#x2022;Ă&#x20AC;} /iÂ?°\Ă&#x160;­³Ă&#x17D;xĂ&#x201C;ÂŽĂ&#x160;{Â&#x2122;Ă&#x2021;äÂ&#x2021;ÂŁĂ&#x160;UĂ&#x160; >Ă?\Ă&#x160;­³Ă&#x17D;xĂ&#x201C;ÂŽĂ&#x160;{Â&#x2122;Ă&#x2021;äÂ&#x2021;Ă&#x201C;Ă&#x201C;äÂ&#x2122;Ă&#x160;UĂ&#x160;ÂŤ>Ă&#x2022;Â?Ă&#x153;Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;JÂŤ>Ă&#x2022;Â?Ă&#x153;Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;°VÂ&#x153;Â&#x201C;Ă&#x160;UĂ&#x160;Ă&#x153;Ă&#x153;Ă&#x153;°>Ă&#x2022;Â?Ă&#x153;Ă&#x2022;Ă&#x20AC;Ă&#x152;Â&#x2026;°VÂ&#x153;Â&#x201C;Ă&#x160;

TECHNICAL INNOVATIONS

‹‹‹

73

$ % RBQ@O OTRGDQ @MC RK@F CNNQ BKD@MHMF QNANS STEELMAKING In electric arc furnace operations, tapto-tap times and workforce safety are key factors for an effective melt shop managing process. To achieve these

Scrap pusher for electric arc furnaces

objectives, C.M.P. Officine Meccaniche offers an EAF scrap pusher and slag door cleaning robot complete with sampling manipulator. Keeping the slag door of the EAF clean and taking samplings by remotely controlled operations contribute to shorter tap-to-tap times and increased safety. The sturdy and simple design of the equipment ensures easy maintenance and low operating costs.

We agglomerate your valuable dusts and fines

Contact: www.cmpofficinemeccaniche.it

1DRS@QS NE LNCDQMHYDC AK@RS ETQM@BD IRONMAKING After having been taken out of service in spring 2012 for relining and replacement of parts of the cooling system, ThyssenKrupp Steel Europe has recently fired up blast furnace 9 in Duisburg-Hamborn, Germany, for a new campaign. The previous campaign lasted 25 years. Originally built in 1962 and revamped and enlarged to its current size in 1987, blast furnace 9 produced altogether around 40 million t of hot metal in this period. Around 2,400 t of refractory material was required for the 2012 reline. Hot metal production in blast furnace 9 has been restarted in preparation for a planned reline of blast furnace 2 in Duisburg-Schwelgern.

In the metallurgical industry we briquette e. g. steel mill residues, sponge iron (hot and cold), chrome ore, nickel powder, copper concentrate, and other fines.

Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units.

Köppern – Quality made in Germany.

• State of the art technology • Process technology know-how • High plant availability • Quick roller replacement

www.koeppern.de

Contact: www.thyssenkrupp-steel-europe.com MPT International 3 / 2014

74

››› TECHNICAL INNOVATIONS

Incremental looper encoder STRIP ROLLING A looper encoder with incremental output for the specific requirements of steelworks and rolling mills has been developed by Johannes Hübner Giessen.

The encoder of the FGL 40 type captures the rotating angle of the looper and feeds the collected data back to the control system in real time in order to optimize tension control of the metal strip between the rolling stands. A new incremental interface optimizes tension control of the metal strip between the rolling stands. The precision electronics enable up to one million pulses per revolution. In this way, even the smallest changes in rotational speed and angle of movement can be captured. The high load rating of the ball bearings and encoder shaft, and the shock resistance of up to 450 g allow the FGL 40 to reach a long useful life.

The FGL 40 is available in flange or flange/foot design. Its special ball bearings are set in an additional steel bushing.

A markedly higher dynamic load rating than standard ball bearings, the special grease filling and an additional radial shaft sealing ring with protective lip ensure a long useful life even in extreme operating conditions. The looper encoder is in compliance with protection classes IP 66 and IP 67. The device has a reinforced shaft with a maximum load

Robust looper encoder

of 140 N in axial design and 170 N in radial design. It can be used in a temperature range of between -25°C to +85°C. Contact: www.huebner-giessen.com

Advanced metallic coating weight LD@RTQDLDMS Recalibration samples Spectrometer check samples Certified check samples

Customs specifically sample production Moulds and machine accescoires

Production and distribution:

SURFACE COATING Zinc, aluminium, tin and other metallic coatings can be measured on-line by a coating gauge offered by NDC Infrared Engineering. The gauge uses the fluorescence emitted by the strip when exposed to X-ray radiation. The scanning frames and sensor heads of the FVXR-1 coating weight gauge are designed for continuous duty in high ambient temperatures normally found on a coating line, especially when mounted in the cooling tower. The sensor and its electronics provide fast, accurate measurement across a wide coating range and provide straightforward integration into third party closed-loop control platforms. A unique ridge detection option is available for the detection of longitudinal narrow overweight streaks anywhere in the zinc coating profile. There is also an advanced iron content measurement option for galvanneal applications. The FVXR-1 gauge is available with an O-frame with separate drives for the top and bottom heads or as a split frame for installation near bridle rolls.

Contact: www.ndc.com

MPT International 3 / 2014

TECHNICAL INNOVATIONS

‹‹‹

75

+@XHMF GD@C SDBGMNKNFX TOFQ@CD DWSDMCR OHOD KHED ROD ROLLING Laying head pipes are a crucial element of laying heads in long rolling mills. A new laying head technology upgrade developed by Siemens Metals Technologies extends pipe life to new levels. As part of a broader redesign of the Morgan high-speed laying head, the upgrade of the SR series, with its new regenerating wear zones, eliminates vibration challenges, improves laying patterns and offers a more consistent formation of head and tail ends. It can be easily retrofitted to existing arrangements.

Typical mill configurations for rolling 4.5 to 8.0 mm rods require frequent laying head pipe changes after just a few thousand t of production. The new field-tested technology has extended pipe life to as much as 130,000 t. This reduces maintenance requirements, production interruptions and spare parts storage. The SR series includes various options, from basic pipe to treated and composite choices. The top performer of the SR series is the DM2, which features the proprietary material, Revotech, exclusively designed by Sandvik Materials Technology and only available for the Morgan high-speed laying head.

Contact: www.siemens.com/metals

Pipes for laying head upgrades

CAN-ENG FURNACES

Continuous Tube, Bar and Plate Heat Treatment Systems

QUENCH AND TEMPER, ANNEALING / NORMALIZING FOR TUBE, BAR AND PLATE Contact us to find out why many of the world’s largest steel companies choose to work with CAN-ENG FURNACES INTERNATIONAL LIMITED. To learn more about Can-Eng Furnaces’ engineering, design and manufacturing capabilities visit www.can-eng.com or e-mail Greg Stanley at gstanley@can-eng.com

6800 Montrose Road, Niagara Falls, ON, Canada L2E 6V5 www.can-eng.com T : + 1 905 356 1327 F : + 1 905 356 1817

MPT International 3 / 2014

76

››› TECHNICAL INNOVATIONS

2XRSDL@SHB LD@RTQDLDMS NE ×@S OQNÖKDR @MC RG@ODC VHQD QUALITY ASSURANCE Manufacturing tolerances for shaped wire and flat profiles are extremely tight. The majority of optical systems used to check the profile are equipped with laser or CCD cameras that measure the shadow height of a product. This, however, like the human eye, is subject to heavy fluctuation if the product is not precisely aligned with the laser beam. A deviation of a twist angle of 1 degree may already lie outside the permissible tolerance range.

Zumbach solves this problem by offering in-line height and width measurement solutions which are able to provide the required high precision, regardless of position and twist. The robust and compact measuring systems can be easily integrated into existing production lines. Measurements are performed using either laser technology or the light-cut method with image processing. The ODAC® laser measuring heads measure the height and width of any profile without contact and at 1,200 measurements/s. The extremely dirt-resistant scanners ensure maximum error detection and permanent calibration. The pivoting mechanism of the DVW 1 support rotates the ODAC® laser measuring heads mounted on it continuously around the measuring axis within +/-2.5° , +/-5°, +/-7.5° or +/-10°. With the DVO 2 oscillating device for ODAC®, the angle can be increased to +/-50°, thereby ensuring maximum possible measurements of profile dimensions. The values acquired from the DVW 1/ DVO 2 and ODAC® are processed via a connected USYS system and used for automated production monitoring.

When measuring with the light-cut method, product quality can be assured using image processing profile measuring systems. The Profilemaster® PMM 30/50/80 are non-contact in-line and off-line high-tech systems for measuring profiles. The used CCD megapixel gigabit Ethernet cameras measure fields with diameters of within 30, 50

Laser dimension measuring head with pivoting support

or 80 mm. One to six laser/camera modules continuously measure the cross-section of the moving profile. A PC-based processor combines the cameras’ partial images, consisting of straight lines and curves, yielding the momentary cross-section of the profile. All relevant dimensions such as width, height, thickness, angle and radii are added together to form the full cross-sectional picture.

Contact: www.zumbach.com

#HFHS@K VDKCHMF ENQ ROHQ@K OHOD OQNCTBSHNM PIPEMAKING Perfect Arc® is a precision-controlled solution for arc and submerged arc welding used in the production of spiral pipes. The solution was developed

by PWS, part of the SMS Meer business area. A digitized current source generates the “perfect arc”, which uses 30 to 40% less energy. In spite of the high speeds of up to 12 m/min, the solution achieves a significant reduction in product rejects and plant wear. Perfect Arc® has been included in the group of ecoplants solutions from SMS Meer.

Contact: www.sms-meer.com

Unit for spiral pipe welding MPT International 3 / 2014

TECHNICAL INNOVATIONS

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-DWS FDMDQ@SHNM QDCTBHMF RHYHMF AKNBJ HOT ROLLING The new RSB SCS technology is the latest milestone in reducing and sizing technology for SBQ products recently launched by Friedrich Kocks GmbH Co. KG, Hilden, Germany. The new generation of the well-established reducing & sizing block provides improvements in bar quality, productivity, mill availability and economy as well as simplified, safe and environmentally friendly operation. It combines the real-time closed-loop control system – called size control system (SCS) – with 3-roll stands adjustable under load (AUL) and/or tension control. These features further improve the rolled tolerances and their reproducibility, and at the same time simplify the operation by means of an automated optimization of the process parameters for the rolled bars either by roll gap adjustment or control of the tension between the stands.

Another integral part of the RSB SCS is an innovative stand changing concept, which allows automatic stand changing within three minutes together with a fast remote control (FRC). It enables immediate adjustment of the roll gap against the rolling force (under load) within milliseconds.

Size changes along the free-size range can also be made within the traditional billet gaps in less than five seconds.

The new generation RSB integrates the real-time closed-loop control system – called size control system SCS

A newly developed modular drive concept of the RSB SCS provides a smaller foot print in the layout, a drastically reduced oil-lubrication volume and a simplified maintenance schedule. Furthermore, intelligent engineering reduces the number of necessary hydraulic functions of the RSB SCS, which ensures a safe and environmentally friendly rolling process.

Contact: www.kocks.de

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››› LITERATURE SERVICE Sustainable induction furnace technology 10 pages, English A brochure highlighting sustainability aspects of thermal plant technology designed by ABP Induction Systems for melting, holding, casting, forging and heating ferrous and non-ferrous metals. The plants outlined include coreless induction furnaces, crucible- and channel-type induction furnaces as well as pouring systems.

Contact: E-mail:

www.abpinduction.com info@abpinduction.com

Refractory bricks 20 pages, English, German A catalogue of refractory bricks offered by EKW. Detailed technical information is provided on each product in clearly structured lists. The bricks come as light-weight firebricks, rectangular bricks, ladle bricks and ladle bottom bricks. Also mortar products are included in the catalogue.

Contact: E-mail:

www.ekw-feuerfest.de ekw@ekw-feuerfest.de

Chains and sprockets for the steel and aluminium industries 20 pages, English This brochure provides a comprehensive overview of chains designed by KettenWulf for conveyor applications, including sinter, scrap, coal and iron ore transport, coil transport and looping towers, chains for continuous casting applications, sheet, beam and pipe transport, cooling conveyors, etc.

Contact: E-mail:

SlabProfiler™ - Slab measurement system

SlabProfiler™ Slab measurement system

s

True 2D dimensional measurement of slabs

s

Width, edge profile, length, camber, thickness

s

Gives information about caster performance

s

Improve edge scrap yield at hot strip mill

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Non contact – low maintenance

s

World wide references

www.kettenwulf.com service@kettenwulf.com

Slab measurement system 4 pages, English, German A product brochure on the SlabProfilerTM offered by Limab for inline control of slab dimensions. Laser distance and profile sensors provide information that can be used to calculate the slab width. The integrated software provides the possibility of real-time control of slab data.

Contact: E-mail:

www.limab.com sales@limab.de

Slag formers for secondary and tertiary metallurgy 4 pages, English, German A brochure describing the production process and the properties of the Refraflux® series of slag formers developed by Refratechnik. Included are technical and performance data as well as information on the grain size of the slag formers for secondary and tertiary metallurgy treatments.

Contact: E-mail:

MPT International 3 / 2014

www.refra.com casting@refra.com

LITERATURE SERVICE

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Furnace and offgas cooling for ferroalloy EAFs 4 pages, English A brochure featuring an energy recovery project in Norway implemented by Reining HeisskĂźhlung, a subsidiary company of the Oschatz group. The project encompassed an offgas and furnace cooling system for three ferroalloy electric arc furnaces, involving the installation of new high-pressure steam sections and relining of the furnace pots.

Contact: E-mail:

www.reining-heisskuehlung.de office@reining-heisskuehlung.de

'ZJCWUV RNCPVU HQT Ć&#x192;COG EWVVKPI UOQMG 8 pages, English A brochure describing a smoke filter solution implemented by Venti Oelde at a recycling operation for slag blocks. To capture and filter the smoke during flame cutting, mobile exhaust hoods travel along a track until they are positioned above the scrap to be cut. The cutting process does not start until the doors of the hood have been closed.

Contact: E-mail:

www.venti-oelde.de info@venti-oelde.de

Anchoring systems for refractory products 8 pages, English, German, French, Spanish A technical brochure featuring the MVP 3-D anchoring system available from vhi. This universal 3-D anchor is used to anchor gunning mixes and castables on boiler tube walls. The brochure includes photos and drawings to illustrate this anchor system and compares it with other anchoring solutions.

Contact: E-mail:

www.vhi-gmbh.com office@vhi-gmbh.com

Thickness and shape measurement 8 pages, English In this brochure, Vollmer summarizes its portfolio of instruments for measuring and controlling thickness and shape in rolling mills. Aspects covered include tactile and optical measurements, X-ray and isotope based measurements, automatic gauge control and strip shape control systems.

Contact: E-mail:

www.vollmergmbh.de contact@vollmer.de

Single oven pressure control in cokemaking plants 4 pages, English Driven by the challenge to reduce gas emissions and air suction during coke distillation, Paul Wurth developed the SoprecoÂŽ (single oven pressure control) system, which is able to separately control the pressure in each oven of the coke battery. The main advantages of the system are dramatic reduction of emissions through doors, lids and stand pipes and minimized stack emissions.

Contact: E-mail:

www.paulwurth.com paulwurth@paulwurth.com

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››› IN THE NEXT ISSUE…

Steelmaking Start-up of the new integrated works of Fujian Fuxin Stainless Steel, China Fujian Fuxin Stainless Steel is the name of a 1.3 billion US$ investment project – a completely new integrated stainless steel works built on an area of about 88 hectares in Zhangzhou, Fujian province, China. Commissioned in 2013, the first phase comprises a steelmaking plant, hot strip mill and hot annealing and pickling line with an annual production capacity of 720,000 t of ultra-pure ferritic stainless steel, high-nitrogen and nitrogen-containing austenitic stainless steel and super austenitic corrosion-resistant stainless steel. The steelplant is pioneering to utilize the waste heat from the AOD converter and from the EAF, hence reducing CO2 emissions by 60,000 t/year.

Continuous casting Innovative modernization concept for the upgrade of continuous caster No. 2 at Salzgitter Flachstahl, Germany German flat steel producer Salzgitter Flachstahl is modernizing the mould and oscillator equipment on continuous caster No. 2 in order to make the casting process safer and hence increase plant availability. The company will implement the newly developed “Delta Speed Adjustment” process in the plant, by way of which slab widths can be adjusted efficiently and with a high degree of flexibility. The taper of the narrow faces is adjusted simultaneously with the width change itself. This saves time and shortens the transition length. Furthermore, the casting speed does not have to be reduced for the adjustment process, and the planned production is hence not impaired.

Hot rolling Enhanced accuracy of descaling nozzle arrangements with new, complementary measurement methods Hydro-mechanical descaling systems need to be designed in such way that the typically high safety margins resulting in excessive spray overlaps must be eliminated. Latest technologies have been applied to new measurements of all the variables that form the basis for the new edition of the DESCALE 7.5 software. This software is an indispensable tool for the design of descaling headers. In order to verify the digital values in a more practical approach, two additional and complementary methods have been utilized: the aluminium erosion method and the new hot descaling test, the latter representing real conditions.

This preview may be subject to change.

Published by: Verlag Stahleisen GmbH P.O. Box 10 51 64, 40042 Düsseldorf, Germany

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MPT International 3 / 2014

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Metallurgical Plant and Technology

Metalurgia, Processos e Tecnologias

also Metalürji Prosesleri ve Tesisleri

10 years P PQF® technology: international symposium m on tube and pipe production technology g

MPT International the leading technical journal for the global iron & steel industry

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