MPT International 6/2014 (Dec)

Metallurgical Plant and Technology G 25074

6

ISSN 0935-7254

World Steel Association 2014 annual meeting held in Moscow, Russia

December 2014

A numerical modelling of non-recovery/heat-recovery coke ovens

Boost productivity.

Cut costs.

Modernizations for quality and reliability Excellent engineering services stand out from the crowd … especially when it comes to intelligent revamps. It’s about nothing less than upgrading existing plants to meet future market demands – one of today’s central challenges.

That’s where our whole wealth of experience comes in.

After all, our job is to help you increase your productivity while improving quality. Equally significant here is smart

planning, for instance taking advantage of scheduled maintenance stoppages and minimizing production losses.

Your bottom line: You save time and money.

Countless completed projects prove our quality and reliability as a global specialist in metallurgical plant and rolling mill technology.

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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Contributions to sustainable steel production Before the year 2014 ends, MPT does not want to miss remembering the 25th anniversary of a steel manufacturing technology that has dramatically influenced flat steel production during the last two and a half decades. 25 years ago, in 1989, not only the World Wide Web made history. In the same year, also the thin slab technology was first introduced.

Initially, the direct combination of slab casting and subsequent hot rolling had been developed as a cost-efficient production process for simple ordinary steel grades. However, since those days, the concept has developed into a leading process for the production of high-quality thin hot strip. The technology set a new benchmark in terms of energy efficiency. It immediately proved to be highly profitable and productive. Hundreds of metallurgists and plant engineers were involved in developing this plant concept and in the further development of metallurgical specifications. Only very few plant suppliers have succeeded in implementing the thin slab technology on a large-scale industrial basis. As an example, this issue features the CSP® technology which has been implemented – and is currently in operation – at 27 plants worldwide. Today, the CSP® concept provides a multitude of modular components facilitating a custom-made plant design.

Dipl.-Ing. Arnt Hannewald

Iron and steel production is definitely an energy-intensive industry. Whenever it comes to environmental issues and discussions about climate change, the iron and steel industry is more likely to be blamed for greenhouse gas emissions and the environmental impact, rather than commended for the beneficial resource efficiency of steel as a material and the sustainability indicators of the steel industry. On these grounds, it seems to be a permanent task to inform about the huge efforts and strong commitment of steel companies all over the world to enhancing energy efficiency and reducing their local environmental impact. MPT International regularly reports about investments in environmental protection measures. In this issue, the Russian steelmaker NLMK reports about the modernization of some of its key production facilities at the Lipetsk integrated iron and steel works, aiming to reduce both its environmental footprint and energy consumption. The NLMK group launched the third stage of its environmental programme covering the period 2014 to 2020. Investments in environmental initiatives and projects of the group will total approx. 227 million US$. This is a good example of how – at a local level – steel companies manage the environmental impacts of their operations. As quoted from the World Steel Association: the steel industry is taking action to minimize its environmental footprint. The industry continues to evolve and aims to make steel the most innovative and sustainable material of the 21st century.

MPT International 6 / 2014

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››› CONTENTS

International industry news 22

World Steel Association 2014 annual meeting This year’s worldsteel annual conference featured a discussion on how to address the positive image of the steel industry in the face of environmental challenges

Company profile 26

Danieli concludes a century of innovation, reliability and partnership Coverphoto: ECOmode, a patented and newly developed process for HCl acid regeneration plants, represents the next big step in a series of improvements and demonstrates enormous ONSDMSH@K HM Q@HRHMF DEÖBHDMBX %TDK BNMRTLOtion and emissions are reduced by 25%, alternatively production can be ramped up AX SGD R@LD @LNTMS $".LNCD B@M MNS NMKX be used for new installations, but also for DWHRSHMF OK@MSR Andritz AG, Vienna, Austria "NMS@BS VVV @MCQHSY BNL $ L@HK LDS@KR @S @MCQHSY BNL

Danieli is now resetting for the challenges of the future. The group has launched the “Metamorphosis 2” project to reshape its structure and operational methods over the next two years

Coke making 28

A numerical modelling of non-recovery/heatrecovery coke ovens Numerical calculations of the combustion process inside the coke oven were carried out in order to gain an improved understanding of the internal thermodynamic behaviour

Modernization 34 0 ./- GPJCPEGU GPGTI[ GHƂEKGPE[ CPF reduces environmental impact

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The Russian steelmaker has modernized some of the main production facilities. The air-blowing equipment used in BF operations was upgraded. A waste water treatment facility was installed at the coke and chemical operations

Enhanced process reliability and quality of special steel products Deutsche Edelstahlwerke is modernizing the cooling bed area of the special steel bar mill. The equipment is scheduled to be commissioned in autumn 2015.

Continuous casting 39

Siderar starts production with the highGHƂEKGPE[ EQPVKPWQWU UNCD ECUVGT

44

The evolution of the thin slab route The CSP® thin slab technology has developed into a leading process for the production of high-quality hot strips

Ternium Siderar, Argentina, has successfully commissioned the two-strand continuous slab caster at the San Nicolás location

Hot rolling

Automation

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53

Automation system for performance improvement in a four-strand wire rod mill An advanced automation system has recently been implemented at the Bhilai Steel Plant of the Steel Authority of India (SAIL)

MPT International 6 / 2014

Strip tension control technologies for continuous annealing lines Sophisticated control methods have been applied in annealing and heat-treating lines for electrical steel and for aluminium strip in the automotive industry

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44

34

28

Columns 8

International industry news

63

Literature service

56

Technical innovations

62

Imprint

61

Cartoon

Advertisers’ index ABB AB

27

AMETEK Inc.

17

Badische Stahl-Engineering GmbH

31

Castellini Officine Meccaniche S. p. A.

43

Danieli Automation Spa Danieli S. P. A.

64 6, 7

FC Technik AG

21

FRUTIGER Company AG

25

Johannes Hübner - Fabrik elektr. Maschinen GmbH Maschinenfabrik Köppern GmbH & Co. KG Loesche GmbH Messe Düsseldorf GmbH Morgardshammar AB Quaker Chemical Corporation Schuh Anlagentechnik GmbH

Siemens VAI Metals Technologies GmbH 51 42

SMS Siemag AG

55 33 59 15 16 12

ThyssenKrupp Industrial Solutions AG TML Technik GmbH Verlag Stahleisen GmbH

2 9 13 47

PAUL WURTH S. A.

37, 38

Z & J Technologies GmbH

19, 20

Zumbach Electronic AG

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MPT International 6 / 2014

Patented power mould and FastCast CubeTM (FCC) technologies integrated with state-of-the-art automation, breaking all productivity records, while continuing to meet the highest quality standards.

Four significant references out of total 1860 strands CMC STEEL AZ USA Up to 7.2 mpm speed (average 5.9) for 130-mm square billet: the fastest billet caster ever, thanks to FCC™ and Power Mould™.

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EMIRATES STEEL UAE 12-m-radius, 5-strand caster for billets and beam blanks up to 1050x460x120 mm, with a productivity up to 60 tph/strand, to feed their new-generation Danieli heavy section mill.

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››› INTERNATIONAL INDUSTRY NEWS

The Americas Mexico AHMSA expands capacity of planned heat treatment line. Altos Hornos de México (AHMSA) has commissioned Siemens Metals Technologies to expand the annual capacity of its planned normalizing line at its Monclova plant to 300,000 t of plate. The line, ordered from Siemens in October 2013, had originally been designed for 200,000 t/year with the provision for a future increase in capacity. The normalizing line is scheduled to become operational in the third quarter of 2015.

U. S. Steel has also decided not to proceed with additional investments into the carbon alloy facilities at Gary Works. This project, which began in 2011, contemplated the construction of two modules to provide a carbon alloy material used to replace traditionally manufactured coke to the Gary Works blast furnaces. One module, C module, has been built and will be permanently idled while a second, D module, will not be constructed.

In making these decisions, U. S. Steel considered its future raw materials needs for iron ore and coke, and found its current production capability sufficient. The previously announced examination of alternative iron and steelmaking technologies such as gas-based, direct-reduced iron and electric arc furnace steelmaking are not affected by these decisions.

USA USA Keystone modernizes cooling conveyors of wire rod mill. Keystone Steel and Wire has placed an order with Siemens Metals Technologies to upgrade the cooling conveyors of a two-strand wire rod mill in its Bartonville, Illinois production facility. The project includes the supply of five large blowers on each strand of the rolling mill, auxiliary systems as well as electric and automation equipment. The new equipment is expected to be commissioned in late 2014. With this upgrade, Keystone will produce wire rod of greater tensile strength and uniformity to meet the demands of the cable market. The upgrade is part of an ongoing modernization project undertaken by Keystone to expand into markets for higher value-added products.

USA U. S. Steel announces strategic actions. U. S. Steel has decided not to pursue an expansion of its iron ore pellet operations at Keetac in Keewatin, Minnesota. The expansion would have increased the facility’s production by 3.6 million t/ year and included upgrading and restarting an idled pelletizing line, as well as upgrading the mining, concentrating and agglomerating processes at Keetac. The permits required for this expansion expire this month and will not be renewed.

MPT International 6 / 2014

ArcelorMittal and NSSMC announce further investments in AM/NS Calvert. ArcelorMittal, in partnership with joint venture partner Nippon Steel & Sumitomo Metals Corporation, will invest in two projects that will further enhance the capabilities of the AM/NS steel finishing facility in Calvert, Alabama. While AM/NS Calvert is a state-of-the-art finishing operation capable of producing high-quality products for a variety of markets, additional improvements are needed to reach near-full capacity levels.

Currently, the hot mill is operating at around 75 to 80% of its design capacity.

A slab yard expansion project is underway to increase AM/NS Calvert’s slab staging capacity and efficiency to achieve the hot-mill capacity target of 5.3 million t.

It will include the addition of overhead cranes, along with foundation work and structural steel erection, to increase the staging and storage capacity in support of achieving the full capacity of the hot strip mill. The project is expected to be complete in the second quarter of 2016.

Additionally, a major investment will be dedicated to the facility’s existing No. 4 continuous coating line, which will significantly increase ArcelorMittal’s North American capacity to produce press hardenable steels, notably one of the strongest steels used in automotive applications, Usibor®, a type one Al-Si coated high-strength steel. AM/NS Calvert

will also be capable of producing Ductibor®, an energy-absorbing high-strength steel grade designed specifically to complement Usibor®. The modifications are expected to be complete by the end of the year and the first coil is targeted for production in January 2015.

USA Timken Steel to build heat treatment facilities. Timken Steel is building a quench-and-temper facility in Northeast Ohio to produce more value-added steel for demanding applications. The facility, which will be fully operational within two years, will perform heat-treat operations and have capacity for processing 50,000 t/year of 4” (100 mm) to 13” (330 mm) bars and tubes. It will be located in Perry Township on the site of Timken Steel’s Gambrinus steel plant near three existing thermal treatment facilities.

USA TMW to open processing centre at Big River Steel. The Material Works (TMW) will build an advanced flat rolled toll processing centre adjacent to the new Big River Steel mill in Osceola, Arkansas. Construction will begin in the second quarter of 2015 with the facility expected to be fully operational to coincide with Big River Steel’s opening in 2016. Phase 1 of the toll processing centre calls for a facility to house both cut-to-length and slitting lines capable of processing material from the lightest gauge the mill will produce up to 12.7 mm. The value-added services offered to Big River Steel customers will also include stretcher levelling. The property will allow TMW to double the building as volumes increase.

Asia China Voestalpine to build new special steel plant. Voestalpine is building a new special steel plant for long prod-

Innovative coke plant technologies Pioneering coke plant technologies are part of our daily CVTJOFTT 5IF FGĂ? DJFODZ BOE FOWJSPONFOUBM QFSGPSNBODF PG PVS QMBOUT BSF SFOPXOFE XPSMEXJEF 5BJMPS NBEF DPNQMFUF DPLF PWFO QMBOUT GSPN B TJOHMF TPVSDF ÂŽ UIBUÂłT PVS DPNNJUNFOU BOE ZPVS BEWBOUBHF HBJOFE GSPN B QBSUOFSTIJQ XJUI VT

500 coking plants worldwide

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››› INTERNATIONAL INDUSTRY NEWS

ucts in Yinchuan, Ningxia province, which at full capacity will produce between 50,000 and 70,000 t of tool steels and forged materials for the automotive, consumer goods and mechanical engineering industries. The production facilities of the new special steel plant will mainly consist of an ingot casting plant, two forging presses with manipulators and finishing facilities. The liquid steel will be supplied by the EAF meltshop with secondary metallurgy facilities operated by the existing JV between Kocel Machinery and Voestalpine Giesserei.

The new steel plant is scheduled for completion by the end of 2017.

China Daming to upgrade bar mill.

Taizhou Daming Stainless Steel is going to upgrade their existing bar mill with the implementation of a Kocks 3-roll reducing and sizing block, RSB®, of the latest design to increase the product quality. The heavy-duty reducing and sizing block will be implemented as finishing block in the existing 200,000 t/year stainless steel bar mill behind the 2-high reversing roughing mill and the intermediate and pre-finishing mill consisting of ten 2-high HV stands. The block will roll straight bars in the range from 16 to 100 mm diameter with tightest tolerances out of a one pass family in the upstream mill onto the cooling bed. It is dimensioned to operate with four 3-roll stands using rolls with a nominal diameter of 370 mm. The scope of supply comprises the 3-roll block with automatic quick stand changing system, the roll shop with quick roll change, the mill configuration programme Bamicon, and Capas, the computer-aided system for accurate adjustment of rolls and guides of the 3-roll stands. The start-up of the upgraded mill is expected for the end of 2015.

India Bhushan to build steel melt shops. Danieli has awarded UHT Uvån Hagfors Teknologi the order for the supply of an AOD as a part of Danieli’s project for Bhushan Power and Steel, Jharsuguda, Orissa, which comprises two new melt shops and one heavy MPT International 6 / 2014

bar mill for specialty and stainless steel products. The UHT scope includes the engineering and supply of equipment, such as a gas mixing station and the hydraulic converter tilting system, complete with automation and level-2 realtime UTCAS® process control.

India Durgapur to upgrade press line.

Durgapur Steel Plant, the only manufacturer of forged railway vehicle wheels in India, has placed an order with Siempelkamp to upgrade the three presses of the wheel line in the Durgapur plant. The project includes the new electrical and hydraulic controls for all presses, the supply of new mechanical components as well as a new press frame for the 20 MN dishing press.

After almost 20 years of operation, the available controls have become outdated. Siempelkamp will equip all three presses with new controls, replace individual components of the mechanical and hydraulic systems and supply the interface to the customer’s management information system (MIS). Production start of the upgraded line is scheduled for early summer 2015.

India SLR Metaliks to build bar rolling line. SLR Metaliks has awarded Siemens Metals Technologies an order to supply a bar rolling mill for its new steel plant near Hospet. The rolling mill will be designed for an annual production of 320,000 t of rebars and special bar quality (SBQ) grades, primarily for the automotive industry. Bars with smaller diameters will be rolled in multi-slit mode.

The plant is scheduled to be brought into operation in the first half of 2016.

Siemens will supply the complete process equipment for the new bar rolling mill, including the billet infeed with a hot charging option, descaling and the handling of the finished bars. The actual rolling line will consist of a roughing mill and an intermediate mill, each with six Red Ring stands in an HV arrangement, and a finishing mill with six Red Ring stands in an HVC arrangement. This will be followed downstream by a three-

stand sizing mill with CGA stands in an HVH arrangement. An inline system will be used for thermo-mechanically rolling the SBQ bars, as well as for quenching and tempering the rebars. The scope of delivery also includes the rolling guides and the fluid systems. Siemens will also supply the low-voltage transformers, motors, drives, mechatronic packages and measuring instruments, as well as the basic level-1 automation.

South Korea Posco starts up modernized stainless steel caster. Siemens Metals Technologies has modernized and put into operation a single-strand continuous slab caster at Pohang Iron and Steel (Posco). The caster, which produces stainless steel slabs at the stainless steel mill 2, has been equipped with a number of technology packages from Siemens, enabling Posco to produce a wide range of different and advanced stainless steel grades, and to further enhance the quality of the slabs cast. From day one, the caster produced high-quality slabs in fully automatic mode.

The modernization project covered the replacement of the entire casting plant starting from the tundish car up to the slab discharge area. The original concept of a bow-type continuous casting machine with a straight mould, continuous bending and unbending, a machine radius of eight meters and a metallurgical length of around 20 meters remained unchanged. Siemens was responsible for the project management, the engineering for mechanics, fluid systems, electrics and automation, as well as the supply of mechanical key equipment. The caster produces slabs with thicknesses from 140 mm up to 200 mm and widths between 1,000 and 1,850 mm. Casting speed is up to 1.4 m/min.

Taiwan Walsin Lihwa orders cold-rolling mill for stainless steel. Andritz has received an order from Walsin Lihwa to supply a stretch-bend-levelling line, a rolling mill and a regeneration plant for the stainless steel cold-rolling mill in Taichung. Start-

INTERNATIONAL INDUSTRY NEWS up is scheduled for the third quarter of 2016. The levelling line with an integrated two-high skin-pass mill will process stainless steel grades AISI 200, 300 and 400. With the S6-high rolling mill it will be possible to roll hot strip with a width of 1,600 mm to a thickness of down to 0.5 mm without preliminary annealing. In addition to optimizing its production processes, Walsin Lihwa will also be setting new standards in terms of environmental protection in stainless steel production. The waste pickling liquor will be treated in a mixed-acid regeneration plant, the acids of the rinse water will be recovered in an additional plant and the water loop will be closed.

Thailand Posco to build continuous galvanizing line. Posco has broken ground for the construction of a continuous galvanizing line for steel sheet in the Amata City industrial complex in the Rayong province. The capacity

of the new facilities will be 450,000 t/ year. The line will be designed to produce GI (galvanized steel) and GA (galvannealed steel) products for automotive applications. The project is slated for completion by June 2016.

Australia Australia BHP Billiton to cut unit cost and increase capacity. BHP Billiton plans to cut unit costs at Western Australia Iron Ore (WAIO) by at least 25% and increase capacity there by 65 million t/year at a very low capital cost. The company continues to see healthy demand growth for iron ore in the mid-term. While high prices over the last decade created the incentives needed for new entrants to join the market and traditional producers to substantially increase supply, growth in seaborne supply is expected to exceed growth in demand

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News in brief Ternium Siderar,Argentina, has successfully commissioned the X-Cast® two-strand continuous slab caster supplied by SMS Siemag. The caster is in operation at the location in San Nicolás.

Outotec, Philippines, has opened a new office in Manila as part of the company’s expansion in the Asia Pacific region.

Tata Steel, the Netherlands, has opened a new finishing line at its IJmuiden steelworks. Finishing line 32 will process up to 400,000 t/year of galvanized steel coil.

Shanxi Taigang Stainless Steel, China, has successfully commissioned the 80 t Duplex RH-TOP unit No. 1 after a comprehensive revamp of the plant carried out by SMS Mevac.

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››› INTERNATIONAL INDUSTRY NEWS

over the short to medium term. In anticipation of this transition, BHP Billiton has turned its focus from major supply chain investment to productivity, cost reduction and capital efficient growth. The company has already cut the cost of production at WAIO and expects to increase the WAIO mine capacity to 275 million t/year without the need for additional fixed plant investment.

Australia BHP Billiton opens Caval Ridge coal mine. BMA, a 50-50 joint venture between BHP Billiton and Mitsubishi Development, has opened the Caval Ridge mine in central Queensland. The mine will initially produce up to 5.5 million t/year of premium quality metallurgical coal.

Europe Germany ArcelorMittal signs gas supply agreement. The Linde group is set to build a new air separation unit in Eisenhüttenstadt. The plant will supply the ArcelorMittal Eisenhüttenstadt steelworks with oxygen and nitrogen based on a long-term agreement. The new plant will also supply liquid gases to the regional market. By combining both gaseous and liquid production streams, the new plant will significantly increase the energy efficiency of oxygen generation at the integrated steelworks.

Eisenhüttenstadt is currently home to two oxygen generation units. The new plant will replace the older, less efficient facility. Linde’s Engineering Division will be responsible for delivering the turnkey plant. Linde Gas company LiGaPro will operate the plant once it goes on stream, currently planned for 2017.

Australia Bluescope restarts sinter plant.

Bluescope has restarted the sinter plant at the Port Kembla steelworks after obtaining necessary approvals from the New South Wales Environmental Protection Authority (EPA). This will enable the production of iron and steel at the steelworks to continue without interruption. The sinter plant will be operating under a temporary reconfiguration until the waste gas cleaning plant can be recommissioned, which is likely to take around six to eight weeks.

The company will monitor emissions and maintain close consultation with the EPA and the community.

Germany Saarstahl to revamp wire rod mill. Saarstahl is investing in the complete modernization of wire rod train 32 at its Neunkirchen location. On mill train 32, which has an annual capacity of almost 600,000 t, cold heading grades, spring steel and free cutting steels are rolled. It is planned to reconstruct the complete high-speed section. This will boost the productivity by increasing the final rolling speed and improve the quality in terms of strength and uniformity of the microstructure. By improving the

mechanical characteristics of the products, it will be possible to reduce the weight of the steel used and ultimately the weight of the vehicles made from it.

Commissioning of the new rolling mill train is planned for the middle of 2016.

Germany ArcelorMittal Bremen to upgrade hot strip mill. ArcelorMittal has chosen GE’s Power Conversion business to replace their existing DC drives control system with GE’s water-cooled Powersemi PW100 in an upgrade of their Bremen hot rolling mill.

The Bremen hot steel mill currently reaches a maximum strip speed of 1,300 m/min and has a production capacity of 4.5 million t/year. The new DC drives to be provided are employed with HPCi controller technology using PECe and PIBe. This results in a freely programmable, modular system with a real-time multi-tasking operating system. It is also used as the controller of GE’s low and medium voltage drives.

The project is expected to be complete by the beginning of 2017.

Germany Outokumpu Nirosta to revamp cold mill. Outokumpu Nirosta in Krefeld has awarded SMS Siemag an order to modernize the “SG3”20-roll cold mill. The mill had been supplied in 1969

by SMS Siemag (previously Demag). It was modernized in 1991. Following the closure of the Outokumpu works at the Düsseldorf-Benrath location, the pro-

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

Shavings suction plants Heat recovery systems Regenerative condensation

More than 550 plants for industrial processing worldwide since 2002.

Schuh Anlagentechnik GmbH Erinstraße 9 | 44575 Castrop-Rauxel | Germany | Telefon +49(0)2305.97 79-0 | www.schuh-anlagentechnik.de

MPT International 6 / 2014

INTERNATIONAL INDUSTRY NEWS duction previously carried out there is being transferred to the Krefeld works.

The mill will continue to be used for the production of high-grade special-steel strips made of austenitic, ferritic and martensitic materials, in particular including thin-gauge ferritic strips in high-gloss quality (2R bright-annealed).

The cold rolling mill needs to undergo a certain amount of conversion work in order to satisfy the preconditions for manufacturing mirror-finish material.

The SMS Siemag supply scope comprises changes to the entry and exit sides and on the millstand itself. Commissioning of the modernized mill is to take place already in July 2015, following a revamp shutdown of 21 days.

Russia

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News in brief

NLMK to implement environmental project. NLMK has concluded a contract with Siemens VAI for the main part of a large-scale upgrading project covering the gas exhaust, emission collection and cleaning systems at the Novolipetsk BOF operations. Siemens VAI will be responsible for engineering and the supply of the technological hardware required for the construction of a secondary emissions collection and cleaning system, as well as for the replacement of the gas exhaust ducts of two BOFs that have a joint capacity of 5.23 million t/year.

Construction and assembly activities related to the project are planned to begin in June 2016. The project is scheduled for completion in 2019.

Italy Ori Martin to revamp EAF feeding system. Ori Martin is replacing the feeding system of the electric arc furnace after 16 years of continuous and successful operation, with a new Consteel Evolution® system. The new system will be combined with Tenova iRecovery technology. This technology will recover thermal energy present in the dirty fume coming from the electric arc furnace and use this energy to generate steam. The iRecovery system will deliver thermal energy to the heat district grid of the city of Brescia during winter time and feed an ORC turbo-generator to produce electric energy for Ori Martin’s internal use. The steel plant’s savings on fuel thanks to the new equipment will result in approximately 10,000 t/year less CO2 emissions. The new system is planned to come on stream at the end of 2015/beginning of 2016.

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ThyssenKrupp Steel Europe, Germany, has started the second campaign of its blast furnace No. 2 in Duisburg-Schwelgern after having completed the relining and modernization work. In parallel with the work on Europe’s biggest blast furnace, continuous caster No. 1 in Beeckerwerth was revamped. The modernized caster is also back in operation.

Maanshan Iron and Steel, China, has issued the final acceptance certificate for the twostrand continuous slab caster No. 3 supplied by Siemens Metals Technologies. The caster has an annual capacity of 2.4 million t.

Russia Norilsk Nickel orders minerals processing technology and revamps smelter. Outotec has signed two contracts with Norilsk Nickel. The first contract is for the delivery of minerals processing technology and equipment to the Bystrinskoe copper concentrator in the Chita region. Outotec’s scope of delivery includes main process equipment for crushing and grinding as well as commissioning services and spare parts service for two years. Deliveries are scheduled to be completed in mid2015. Once fully operational in 2017, the Bystrinskoe concentrator complex will process over 10 million t/year of ore.

The second order is for the modernization and rebuilding of Norilsk Nickel’s nickel flash smelting furnace at the Na-

Symetal, Greece, producer of aluminium foil and part of the Elval group, will extend its Quintiq platform to cover sales and operations planning. With the new software, Symetal will gain full visibility and be able to easily compare strategic business options.

CSI Tubular Products, USA, has started production on its new electrical resistance welded (ERW) pipe mill at its site near Fontana, California. The pipe welding line was supplied by SMS Meer.

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MPT International 6 / 2014

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››› INTERNATIONAL INDUSTRY NEWS

dezhda smelter in Norilsk, where the company has licenses for two Outotec® flash smelting furnaces. Changes to the raw material base and the demand for a longer campaign life have led to the decision to modernize the nickel smelting furnace. Outotec’s order scope will include the engineering and supply of a new flash smelting furnace including modern proprietary equipment, advanced process control and cooling monitoring systems. A long-term technical service agreement will be separately negotiated during the delivery phase.

Russia NMLK to replace annealing facilities. NLMK has begun hot-testing of eight new bell-type annealing furnace stands at its rolling operations in Lipetsk. At the same time an additional 15 new stands are being installed, with hot testing planned to begin in the second half of 2015. The new equipment, which replaces obsolete furnaces, employs high-convection hydrogen annealing technology to ensure superior mechanical properties, for example better durability and ductility, than achievable by low-convection nitrogen annealing. The use of the new furnaces will enable the company to increase production of cold-rolled steel with premium quality surface finishing.

Spain ArcelorMittal Asturias to modernize pickling line. ArcelorMittal Asturias has awarded Siemens Metals Technologies an order to completely modernize the pickling line at its Avilés plant. The aims of the project are to increase the capacity of the pickling line from 1.5 to 1.8 million t/year, and to further improve working safety. It processes strips for end applications in the construction and automotive industries. For the modernization of the pickling line, Siemens will supply a charging section and new strip preparation and entry sections and will increase the capacity of the strip accumulators.

A new scale breaker will replace the existing skin-pass mill. The exit section will be equipped with an edge notchMPT International 6 / 2014

er. Siemens is responsible for the complete basic and detail engineering of the mechanical components and will supervise the installation and commissioning of the line. The revamp will be performed during short planned downtimes. The modernized line is scheduled to be operational by the end of 2015.

Sweden SSAB Borlänge to modernize tandem cold mill. SSAB has awarded SMS Siemag the order to modernize the tandem cold mill at its Borlänge works.

The five-stand tandem cold mill has an annual capacity of more than 1.2 million t. It produces carbon steel strips in widths ranging between 600 and 1,550 mm and with final gauges down to 0.32 mm. To be able to roll new materials cost efficiently and with better flatness on the tandem mill, SMS Siemag will supply new mechanical systems for mill stand No. 4. These will include systems for roll gap lubrication, roll cooling and an oil wiper system. The revamping work, which will take one week, is scheduled to take place during the regular shutdown in summer 2015. In mid-August 2015, SSAB will be able to resume production on the revamped tandem cold mill.

steelmaking plant. To this end, the cooling stacks of both converters will be modified in a first phase and provided with easy-to-maintain SMS Siemag Baumco adjustable skirts. These are lowered hydraulically onto the converter mouth during the blowing phase, enabling the primary gases to be extracted efficiently under suppressed combustion. The steam produced in the cooling stacks is used as process steam in the entire integrated iron and steel plant.

The complete conversion will be done during a scheduled shutdown in summer 2015.

Companies

Sweden

ArcelorMittal and Gerdau to sell Gallatin to Nucor. ArcelorMittal and Gerdau have entered into a definitive transaction agreement to sell their respective 50% interests in Gallatin Steel Company to Nucor Corporation. Gallatin is a flat rolled mini-mill located in Gallatin County, Kentucky, USA that melts scrap, pig iron and hot briquetted iron from various sources and processes the material to produce flat rolled steel.

Gallatin makes a wide range of steels from low to high carbon grades with an annual capacity of around 1.8 million t.

Both ArcelorMittal and Gerdau state that the divestment of Gallatin was made in order to focus on their core assets.

SSAB Luleå to revamp converter shop. SMS Siemag has received the contract for the revamp of the converter shop and related environmental technology at SSAB Luleå. SMS Siemag will supply lamella suspension systems and the converter tilt drive systems for both converters. The two-motor tilt drive systems to be supplied are easily accessible and very maintenance-friendly. The scope of supply also includes the converter trunnion bearings, the increase in height of the existing trunnion pedestals as well as installation of the vessels and trunnion rings. The new converter vessels will have a clearly greater volume. The additional capacity facilitates more environmentally friendly process control and efficient energy recovery.

The provided SMS Siemag Ecoplants solution comprises the revamp of the primary gas cooling system of the BOF

Restructuring of U. S. Steel Canada. U. S. Steel Canada has recorded a loss from operations in each of the last five years, with an aggregate operating loss of approximately US$ 2.4 billion. Additionally, U. S. Steel Canada represents approximately US$ 1 billion of U. S. Steel’s consolidated employee benefits liability as of 30 June 2014.

As a result of a Companies’ Creditors Arrangement Act (CCAA) filing, U. S. Steel has determined that U. S. Steel Canada and its subsidiaries will be deconsolidated from U. S. Steel’s financial statements on a prospective basis.

U. S. Steel has agreed to provide U. S. Steel Canada with approximately US$ 165 million of secured debtor-in-possession financing to support current operations through the end of 2015

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Outotec achieves improvement target. In October 2013, Outotec introduced an efficiency improvement programme, targeting up to 50 million euros annualized savings in operating costs by the end of 2014 compared to the Q3/2013 situation. The company achieved the targeted savings at the end of September 2014 and now closes the programme. To be prepared for a possible continuation of market sluggishness and uncertainty, Outotec proceeds with measures to enhance profitability and launches a new programme targeting approximately 45 million euros savings in operating costs during 2015, compared to 2014 full year cost level. The planned profitability enhancement measures include restructuring of Outotec’s operations in sales, delivery and global functions, as well as closing of some offices. To streamline the way of operating and improve efficiency, Outotec plans to centralize engineering work into engineering hubs, consolidate project implementation capabilities into fewer locations, centralize purchasing into supply hubs, as well as establish service centres and resource pools for administrative functions. The planned measures may include redundancies, early retirements and discontinuing fixedterm agreements in late 2014 and dur-

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AQM and ASM International form operating partnership.

Through a new collaboration agreement, AQM, a technical services centre with headquarters in Provaglio d’Iseo, Italy, has become an educational support location in Europe for ASM International. Multiple courses will be prepared using the metallurgical laboratories and the metallography and heat treatment schools of AQM. Topics of upcoming educational courses include metallurgy for non-metallurgists, corrosion, failure analysis in the oil and gas industry and metallographic interpretation.

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and allow U. S. Steel Canada to continue operating and serving its customers.

According to U. S. Steel president and CEO Mario Longhi, a planned restructuring will allow U. S. Steel Canada to operate and compete more effectively.

ing the first half of 2015. In addition, temporary lay-offs may be used to achieve the targeted savings, depending on capacity utilization.

NSSMC launches brand for bar and wire rod business. Nippon Steel & Sumitomo Metal Corporation (NSSMC) has decided to create a brand for its bar and wire rod business, together with processing companies. The recently launched business brand is called “SteeLinC™”. It covers the complete process chain from the base material to final processing.

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ExxonMobil to build new grease plant in Singapore. ExxonMobil will build a new grease plant at its Jurong facility in Singapore to meet the growing needs of its customers in the region. The new plant, to be built next to the existing lubricant plant, will integrate with the company’s existing chemical and refining activities in Singapore. Its completion is anticipated in 2016.

Tata Steel signs MoU regarding Long Products Europe business. Tata Steel has signed a memorandum of understanding with Klesch Group to undertake detailed due diligence and negotiations for the potential sale of its Long Products Europe business and associated distribution activities. The memorandum covers several UK-based assets including Tata Steel’s Scunthorpe steelworks, mills in Teesside as well as operations in France and Germany.

Explaining the context and rationale for this decision, Karl Koehler, chief executive of Tata Steel’s European operations, said: “We’ve improved the competitiveness of Tata Steel’s European operations, including Long Products Europe which now supplies more of the innovative steel rail, rod, plate, sections and special profile products demanded by customers. Accelerating the pace of innovation on advanced steel solutions, helping our customers succeed in their markets and creating a sustainable asset base requires significant capital and expertise. We have therefore decided to concentrate our resources mainly on our strip products activities, where we have greater cross-European production and technological synergies.”

Eurofer commenting on EU resolution on climate target. The EU heads of state and government have agreed on an ambitious European energy and climate policy framework for the period 2020 to 2030, including a CO2 emission reduction target of 43% by 2030 compared to 2005 levels for sectors covered by the EU Emissions Trading System (EU ETS). They also gave guidance that the EU ETS will – at the level of most efficient installations – not impose direct and indirect CO2 costs on globally competing European industries such as steel. According to Axel Eggert, acting director general of Eurofer, the European

INTERNATIONAL INDUSTRY NEWS

‹‹‹

17

Commission should now rapidly implement the safeguard measures and provide sectors at risk of carbon leakage with truly 100% free allocation at the level of the 10% most efficient installations, based on technically and economically achievable benchmarks, and based on real production instead of historic production levels. CO2 costs passedthrough in electricity prices must be fully off-set in all member states. “Those installations above the benchmark will have to buy additional allowances on the market. If they go beyond those benchmarks by developing and applying innovative, economically viable technologies, they may set new, more ambitious benchmarks,” Eggert says.

Personalities Harsco appoints chief financial officer. Harsco Corporation appointed Peter F. Minan as chief financial officer, effective 11 November 2014. Peter F. Minan joins Harsco with an extensive background in global financial management.

Changes to Ovako’s board of directors. Sakari Tamminen has been elected a new member of Ovako’s board of directors. Sakari Tamminen has extensive experience in managing and developing large international industrial companies. He also is vice president of Eurofer.

Change at the helm of ThyssenKrupp’s North American Operations. Torsten Gessner stepped down as CEO of ThyssenKrupp North America, as of 10 October 2014, to pursue other opportunities. Patrick Bass, currently senior vice president product lifecycle management/R&D at the ThyssenKrupp Elevator headquarter in Germany, will become CEO of ThyssenKrupp North America as of 1 January 2015. Kevin Backus, senior vice president and general counsel at ThyssenKrupp North America, has been responsible for the regional headquarter on an interim basis.

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Tenova with new leadership structure. Under Gianfelice Rocca as executive chairman, Tenova is now managed by a team of four managing directors leading the company’s business areas: Walter Kueng – Tenova Mining & Minerals; Mauro Medici – Tenova Pomini & I2S; Roberto Pancaldi – Tenova Thermprocesses; and Andrea Rocca – Tenova Steelmaking & Strip Processing. Alberto Iperti, former chief executive officer, will remain a Tenova board member.

Changes on Outotec executive board. Adel Hattab has joined Outotec as executive vice president and president of the EMEA region. He will also be a member of MPT International 6 / 2014

18

››› INTERNATIONAL INDUSTRY NEWS

Outotec’s executive board. Adel Hattab succeeds Dr. Peter Weber, who left the company after having been with the company since 1992.

Expanded management board team at Voestalpine. Voestalpine has expanded its management board from five to six members. The newest management board member is Peter Schwab, who has taken over the management of the Metal Forming Division. Earlier, this division was headed

by Herbert Eibensteiner, who is now head of the Steel Division. Herbert Eibensteiner began his career in the Voestalpine group in 1989 as a plant engineer at the steelmaking site in Linz. With his appointment as head of the Metal Forming Division in 2012, he became a member of the management board, where he has particularly dedicated himself to accelerating the process of internationalization in the automotive sector.

Herbert Eibensteiner

Executive officer resigns from Dillinger board. As of 31 December 2014, Dr. Norbert Bannenberg will step down from his position as executive officer, Technical Division, for personal reasons. He will be fully committed to the company until a successor has been assigned.

New board member at Cliffs Natural Resources. Cliffs Natural Resources has appointed Michael D. Siegal to its board of directors. Michael D. Siegal is chairman & CEO of Olympic Steel, which he has directed since 1984.

Change in Eurofer management. In the context of the appointMPT International 6 / 2014

ment of a new European Commission and the election of a new European Parliament, Eurofer has decided on a transition to a new leadership. Gordon Moffat, current director general is leaving the association. He has been with Eurofer for 27 years, eight of them as director general. Axel Eggert has been nominated as interim Eurofer director general. He has been director of public affairs at Eurofer in Brussels since 2007.

New CEO at ArcelorMittal Duisburg. Paul Tetteroo has been appointed as new chief executive officer of ArcelorMittal Duisburg. Paul Tetteroo, who took over from Thorsten Brand in early September, has 19 years of work experience for ArcelorMittal in different positions. Most recently he was responsible for purchasing as chief procurement officer at ArcelorMittal Europe, Long Products, in Luxembourg.

Promotion to executive vice president at Nucor. Nucor Corporation has promoted Dave Sumoski, vice president and general manager of Nucor Steel Memphis, to executive vice president of engineered bar products, which includes the special bar quality (SBQ) and cold finish businesses.

Jim Darsey, who has served as executive vice president of bar products since 2010, will continue to focus on merchant and rebar products.

Dismissal of executive officers at Usiminas. At a meeting held in September 2014, the board of directors of Usinas Siderurgicas de Minas Gerais (Usiminas) adopted the dismissal of the chief executive officer of the company, Julian Eguren, chief vice president of subsidiaries, Paolo Bassetti, and chief vice president industrial, Marcelo Chara. The board also voted to elect, on a temporary basis, Rômel Erwin de Souza for the posts of chief executive officer and chief vice president industrial and Ronald Seckelmann for the post of chief vice president of subsidiaries, until the board of directors elects new directors on a definitive basis.

Change of responsibilities of executive officers. Nippon Steel & Sumitomo Metal Corporation ( NSSMC) has resolved to change the division of business responsibilities of the executive vice president, managing director and managing executive officer.

Among others, Shinji Fujino, managing director, will take over the position of head of the Nagoya works from managing executive officer Yoshitsugu Sakamoto, who from now on will be advisor to the president.

Change at the head of Paul Wurth. Marc Solvi, chief executive officer of Paul Wurth since 1 January 1998, will resign from his function as of 31 December 2014, but remain member of the company’s board of directors. Georges Rassel, since 1988 active at Paul Wurth and since 2011 member of the management as chief operations officer, has been appointed by the board of directors as successor.

Georges Rassel

New technical manager at Lech-Stahlwerke. Knut Rummler is the new technical manager of Lech-Stahlwerke (LSW). He takes over the position from Dr. Michael Heußen.

In March 2014, Simon Zellberger had assumed the position of commercial manager.

Executive change on ArcelorMittal’s management board.

Sudhir Maheshwari, member of the group management board of ArcelorMittal, with responsibility for corporate finance, mergers, acquisitions and divestments, risk management, and India and China, is leaving the company to pursue other opportunities, effective 31 March 2015. His responsibilities will be shared between sen-

Professional Blast Furnace Equipment No-Bell Top The new compact charger ensures the simple exchange of a furnace-top double bell for a No-Bell Top system. The usual modification of the steel construction of the blast furnace necessary for such changes is no longer required, meaning no further modifications at the skip-or belt feeder system. This is due to the space-saving concept consisting of material storage, material control valves and gas shut-off valves. The combination of low investment costs and increased productivity ensures shortest repayment.

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INTERNATIONAL INDUSTRY NEWS ior ArcelorMittal executives. Sudhir Maheshwari first joined the company in 1989 in Trinidad & Tobago. After the merger to create ArcelorMittal he became a member of the management committee, before being appointed to the group management board in 2008.

New head of corporate communications at Voestalpine. Press spokesman Peter Felsbach will take over as head of corporate communications at the Voestalpine group. He succeeds Gerhard Kürner who is leaving Voestalpine of his own accord. As spokesman for the group, Felsbach remains the key contact person for external bodies as well as national and international media, in addition to his new management function.

MAN Diesel & Turbo appoints new CEO. Dr. Uwe Lauber will assume the function of CEO of MAN Diesel & Turbo. Uwe Lauber joined the company in 2000. On 1 October 2014, he took over the executive board position of global sales and after-sales.

New CEO and leadership changes at Aperam. Philippe Darmayan, who has been chief executive officer of Aperam since December 2011, will retire effective 31 December 2014.

The board of directors has appointed Timoteo Di Maulo, a member of Aperam’s management committee, as new chief executive officer. Di Maulo currently is chief commercial and sourcing officer and responsible for the services and solutions division and for research & development.

As a result of Timoteo Di Maulo’s appointment as chief executive officer the following appointments to the leadership team have been made: Nicolas Changeur has been appointed as chief marketing officer for stainless & electrical steel; Johanna Van Sevenant as chief executive officer for services & solutions; Bernard Hallemans as chief technical officer; and Frederico Ayres Lima as chief operating officer stainless & electrical steel South America.

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21

Events ›

19 – 21 May 2015 Düsseldorf, Germany Organizers: Steel Institute VDEh www.cetas2015.eu

Cetas 2015. The 9th International Conference on Progress in Analytical Chemistry & Materials Characterization in the Steel and Metals Industries will bring together scientists for an exchange of experience in analytical and characterization techniques. The subjects covered by the lectures will include sampling and sample preparation, cleanliness of steel and metals, characterization of surfaces and coatings, traceability of measurements, etc.

›

SIMPLE OPERATION 20 – 22 May 2015 Venice, Italy Organizers: AIM; IFHTSE www.aimnet.it/ht2015.htm

European Conference on Heat Treatment and IFHTSE Congress.

These jointly staged conferences will cover an extensive range of topics from heat treatment and surface engineering, with a focus on thermo-chemical treatment, surface hardening, coatings, quenching, residual stress and distortion, modelling and simulation, mechanical properties, etc.

›

ROBUST

13 – 15 September 2015 Mumbai, India Organizers: International Trade and Exhibitions India Pvt Ltd. www.wom-expo.com

World of Metal. This international exhibition and conference on metal production, processing and metal working will be an ideal business platform to consolidate opportunities in the Indian metals industry. It will provide a forum for face-to-face interaction with industry players and help identify equipment suppliers and opportunities for establishing manufacturing bases in India.

MPT International 6 / 2014

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World Steel Association 2014 annual meeting held in Moscow, Russia In October 2014, the World Steel Association met in Moscow for its 48th annual conference. Its theme was ‘Steel as the foundation of continued sustainable development’. This year’s annual conference heard from high-level speakers on topics including Russia’s economic prospects into the future and steel’s role in the energy sector, including recent developments in carbon capture and storage (CCS). The conference also featured a discussion on how to address the positive image of the steel industry in the face of environmental challenges.

The World Steel Association (worldsteel) is one of the largest and most dynamic industry associations in the world. It represents approximately

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

MPT International 6 / 2014

170 steel producers (including 9 of the world’s 10 largest steel companies), national and regional steel industry associations, and steel research institutes.

Members represent around 85% of world steel production. Every October, World Steel Association hosts the annual conference for its members, which usually begins with meetings of the executive committee and board. This is followed by a series of presentations and panel

sessions. This year the 48th worldsteel annual conference was staged in Moscow, the capital city of Russia.

Short range outlook for 2014 – 2015 worldsteel forecasts that global apparent steel use will increase by 2.0% to 1,562 million t in 2014 following growth of 3.8% in 2013. In 2015, it is

INTERNATIONAL INDUSTRY NEWS forecast that world steel demand will grow by another 2.0% and will reach 1,594 million t. Chairman of worldsteel Economics Committee, Hans Jürgen Kerkhoff said: “The positive momentum in global steel demand seen in the second half of 2013 abated in 2014 with weaker than expected performance in the emerging and developing economies. As a consequence we are issuing a lower steel demand growth figure than our forecast released in April this year. The slowdown in China’s steel demand reflecting the structural transformation of the economy has contributed significantly to our lower global growth projection. We have also seen major slowdown in South America and the CIS countries due to falling commodity prices, structural constraints and geopolitical tensions. In contrast, the developed economies fared well this year. Recoveries in the EU, United States and Japan are expected to be stronger than previously thought, but not strong enough to offset the slowdown in the emerging economies. In 2015 we expect steel demand growth in developed economies to moderate, while we project growth in the emerging and developing economies to pick up. In China rebalancing will continue to act as a drag on steel demand.

This outlook is prone to risks coming from various fronts. The US interest rates increase expected in 2015 is likely to impact global capital flows creating instability in the vulnerable emerging markets. At the same time the outlook in emerging markets is constrained both by the need for structural reforms and geopolitical tensions and as a result energy prices, globally, have emerged as a new risk factor. In China, the rebalancing and transition towards a consumption driven economy is not without challenges and uncertainties. Lastly, the recovery in the Euro-area is still constrained by household and government deleveraging.”

Apparent steel use in China is expected to slow to just 1.0% growth in 2014 to 748.3 million t with rapid cooling of the real estate sector as the government’s efforts to rebalance the economy curtails investment and weakens business sentiment. The weak growth momentum will continue into 2015 and China’s apparent steel use will grow by 0.8% to reach 754.3 in 2015. However, possible use of target-

ed stimuli and easing of restrictions on the real estate market in response to slower GDP growth could increase the forecast.

India’s outlook is improving following the election of a new government which is promising pro-business reforms. In 2014, India’s steel demand is expected to grow by 3.4% to 76.2 million t in 2014, following growth of 1.8% in 2013. In 2015 structural reforms and improving confidence will support a further 6% growth in steel demand but elevated inflation and fiscal consolidation remain key downside risks to the outlook.

In Japan following a 2.1% increase in apparent steel use in 2013, steel demand in 2014 is revised upward to increase by a further 2.3% to 66.8 million t aided by governmental economic policies. However, as the positive impact of “Abenomics” fades away and with another expected consumption tax hike steel demand is expected to decline by -1.5% in 2015.

In the United States, after a decrease of -0.4% in apparent steel use in 2013, steel demand is seen increasing by 6.7% to 102.2 million t in 2014, a large upward revision, helped by strong growth in the automotive and energy sectors. Steel demand is expected to increase by 1.9% in 2015. In Mexico steel demand is expected to grow by 6.9% in 2014 and moderate to 3.5% growth in 2015.

In Central and South America, apparent steel use forecasts have been revised down with most countries registering a negative growth and is expected to decline by -2.4% to 48 million t in 2014 from 4.2% growth in 2013. The combination of falling commodity prices and the delayed structural reforms is hurting steel demand across the region. Steel demand is expected to increase by 3.4% in 2015. In Brazil, apparent steel use will contract by -4.1% in 2014 to 25.3 million t and will rebound only by 1.5% in 2015 as problems such as high inflation, overvalued currency, high labour costs and infrastructure bottlenecks are curtailing investment activities.

The recovery in the EU (28) has gained further momentum in 2014 and steel demand outlook has improved considerably to grow by 4% to 145.9 million t after increasing by 0.8% in 2013. The improvement reflects a

‹‹‹

23

pickup in steel using sectors in most countries, but notably the UK and Poland and those countries that underwent structural reforms. Apparent steel use in 2015 is projected to grow by 2.9%. However, the EU is facing new challenges with disinflation and geopolitical tensions threatening the continued recovery. Apparent steel use in Germany is expected to show 3.2% growth to reach 39.1 million t in 2014 and 2.3% in 2015.

The outlook for apparent steel use in CIS has been revised down significantly in 2014 by -3.8% to 56.9 million t following a 2.8% growth in 2013 due to the crisis in Ukraine. In Russia, the weak trend in steel using sectors in the second half of 2013 continued, and in 2014 weak infrastructure investments combined with the impact of the geopolitical tensions constrained steel demand, leading to -0.5% growth to reach 43.2 million t. In 2015 it will recover by 1.1% to reach 43.7 million t.

In Ukraine, the conflict in the eastern part of the country is a severe blow to its economic activities and apparent steel use is expected to decline by -19% in 2014. In 2015, assuming a stabilization of the political situation, CIS steel demand will grow by 1.9%.

In the MENA region, steel demand in 2014 has been revised down due to the political instability in some countries in the region, but is still expected to grow by 3.3% to 67.6 million t aided by strength in the oil producing countries and again by 6.6% in 2015.

Overall apparent steel use in the developed economies will register over 4% growth in 2014, but then slows to 1.7% in 2015. On the other hand the emerging and developing economies excluding China will grow by 1.7% in 2014, followed by a rebound of 4.7% growth in 2015.

New officers. On the occasion of the annual meeting, the board of directors of worldsteel has elected Wolfgang Eder, chairman and CEO of Voestalpine, as chairman for 2013/2014.

The board elected as vice chairmen: Alexey Mordashov, CEO, Severstal JSC, and André Gerdau Johannpeter, president and CEO Gerdau; as treasurer: Eiji Hayashida, president and CEO, JFE Steel Corporation. The new officers are elected for one year, until October 2015.

The board of directors of worldsteel also elected the 2014/15 execMPT International 6 / 2014

24

››› INTERNATIONAL INDUSTRY NEWS

utive committee: Wolfgang Eder, Voestalpine; John Ferriola, Nucor Corporation; Eiji Hayashida, JFE Steel Corporation; Heinrich Hiesinger, ThyssenKrupp AG; Sajjan Jindal, JSW Steel Ltd; Oh-joon Kwon, Posco; André Gerdau Johannpeter, Gerdau; Mario Longhi, US Steel Corporation; Lakshmi Mittal, ArcelorMittal; Alexey Mordashov, Severstal JSC; Paolo Rocca, Techint Group; Kosei Shindo, Nippon Steel & Sumitomo Metal Corporation; Lejiang Xu, Baosteel Group Corporation; Xiaogang Zhang, Anshan Iron & Steel Group Corporation; Edwin Basson, World Steel Association.

A decade of collective commitment to sustainability World Steel Association has published its 2014 Sustainability Indicators, presenting the steel industry’s progress in sustainability performance over the past decade. Edwin Basson, director general of worldsteel, said: “Measuring performance is the first step in making progress, and having defined indicators allows companies to benchmark themselves and encourages further improvement. Sustainability reporting at a global level is a major effort that the steel industry undertakes to manage its performance and demonstrate its commitment to sustainability. In 2004, 42 steel companies participated with a rise to 149 companies in 2014. We are pleased that the steel industry has made steady improvements in most indicators over the past decade.

The steel industry believes that sustainable development must meet the needs of the present without compromising the ability of future generations to meet their own needs. Members of worldsteel are committed to a vision in which steel is recognized as a key element of a sustainable world.

This is achieved by a financially sound industry that takes leadership in environmental, social and economic sustainability.

We recognize that continued engagement and collaboration with our stakeholders is essential as we strive to become a fully sustainable industry in a sustainable world. We encourage both our members and non-members to join us in the reporting programme and to implement the seven princiMPT International 6 / 2014

ples outlined in our sustainable development policy in order to monitor and improve their sustainability performance.”

The 2014 Sustainability Indicators publication presents the latest 2013 results for eight sustainability indicators reported on by the steel industry. For environmental performance, in 2013, average greenhouse gas emissions was at 1.8 tonnes of CO2 per tonne of crude steel cast and energy intensity was at 20.0 GJ per tonne of crude steel cast.

Material efficiency indicator results showed that 96.4% of materials used on-site to make crude steel are con-

Regions

Safety and health excellence World Steel Association has recognized six excellent safety and health programmes from ArcelorMittal, Celsa, Essar Steel, Gerdau, Tata Steel and Ternium. Joon-Yang Chung, worldsteel’s chairman for 2013/2014, said: “Communication is vital to create a safer working environment which is the main purpose of this recognition. The companies recognized this year not only have shown a continued commitment to leadership in safety and health by demanding uncompromising safety standards but have also helped the industry get a step closer to

2014

2015

146

150

+2.9%

Other Europe

38

39

+3.8%

CIS

57

58

+1.9%

138

141

+2.2%

Central and South America

48

50

+3.4%

Africa

35

37

+8.0%

Middle East

52

55

+6.0%

1,050

1,064

+1.4%

1,562

1,594

405

411

+1.7%

1,157

1,182

+2.2%

814

840

+3.2%

European Union (28)

NAFTA

Asia and Oceania

World Developed economies Emerging and developing Economies World excluding China

change

+2.0%

Short range outlook for apparent steel use (million tons)

verted to products and by-products.

The environmental management systems (EMS) indicator demonstrated that 90.2% of steel industry employees and contractors worked in EMS registered production facilities. For social performance, the lost time injury frequency rate (LTIFR) was at 1.6 injuries per million hours worked in 2013 while the employee training indicator showed that employees (at both production & non-production facilities) received an average of 7.8 training days during the year. For economic performance, investment in new processes and products in 2013 was at 8.6% of revenue while economic value distributed (EVD) reached 582.7 billion US$ or 97.3% of revenue.

the goal of an injury-free and healthy workplace by sharing their knowledge and experiences”.

ArcelorMittal Tubarao Brazil introduced ‘Quality of Life Programme’ aimed at a healthier life and a zero accident environment. One activity launched in 2000, a health campaign focused at reducing smoking amongst its employees and reached the goal in 2010 with no employees smoking during working hours.

The set of actions from the programme resulted in the improvement of employees’ health indicators, which reflected on productivity. The company currently has 92% of its employees on its ‘best health profile’. The programme can be perfectly applied to other companies with minor adjustments.

INTERNATIONAL INDUSTRY NEWS Celsa Huta Ostrowiec Poland implemented a safety programme ‘Brother’s keeper’. It involves employees volunteering to go into groups of two where they then complete their tasks on a daily basis to ensure neither gets hurt. Each participant accepts the commitment to safeguard their ‘brother’ at all times to ensure that they do not have an accident or become exposed to risks. The programme resulted in a rapid acceptance of safety feedback at all levels and helped reduce injury rates by more than 60% in one year.

Essar Steel Hazira India has built a sustainable health, safety and environment management system. The company appointed safety marshals to oversee safety practices and introduced a competency assessment for all contractors working in the facility. In order to establish a behaviour based safety culture, the company organized a series of events including ‘Safety and Fire Week’ celebrations, safety skits, mass safety rallies, ‘Safety Month’ and ‘Environment Day’ celebrations. These initiatives have greatly contributed to improve the safety and health standards in the company.

Gerdau Brazil developed safety behaviour management assessment. It is comprised of six evaluation points which are focused on people’s behaviour. The company’s safety corporate team assesses each plant twice

a year and produces a specific report with details on the areas for improvements as well as recommendations.

Thanks to the programme, the company’s special steel plants in Brazil were able to increase the average level of the check points from 1.0 in 2011 to 3.1 in 2013.

Tata Steel Europe Netherlands in 2012, launched ‘Time out for hand injuries’ programme, specifically aiming at reducing hand and finger injuries which accounted for 60% of all injuries in the past two years. An innovative and interactive workshop and discussion were held to raise awareness and bring attention to personal consequences of hand injuries. The programme helped to reduce hand and finger injuries by 42 % and all injuries by 30% in the first year. This led to a cost saving of 100,000 euros per annum. It has been transferred to other parts of Tata Steel.

Ternium Argentina/Mexico implemented a ‘Logistics Safety Preventive Action Plan’ to prevent accidents in the supply chain department. An analysis identified four main areas of concern: securing loads, working on the platform, loading and unloading, and warehouse and coil yard personnel access. The company implemented safety practices designed to address each area and it resulted in 90% reduction on the LTIFR since its launch in 2009.

‹‹‹

25

Steelie awards The 5th Steelie awards winners were announced at the annual dinner to close the 48th worldsteel conference.

The trophies, known as Steelies, were awarded in seven categories this year.

The categories and winners were: ▪ Steel industry website of the year: ArcelorMittal, ▪ Innovation of the year: ArcelorMittal Dofasco for spreader beam use, ▪ Excellence in sustainability: Gerdau for improving the sustainability of their scrap supply chain, ▪ Excellence in life cycle assessment: Tata Steel Europe for the use of LCA to demonstrate the benefits of steel in bridge designs versus alternative materials, ▪ Excellence in education and training: Tenaris for development of online learning courses with The University of Sheffield and edX, ▪ Journalist of the year: John Miller, Wall Street Journal, ▪ Industry communicator of the year: Alexey Mordashov, Severstal.

The selection process for nominations varies between awards. In most cases nominations are requested via the appropriate membership committee and the worldsteel extranet. Entries are then judged by selected expert panels using agreed performance criteria.

Journalist of the year and communicator of the year are selected by direct vote.

26

››› COMPANY PROFILE

Danieli concludes a century of innovation, reliability and partnership ,Q WKH Ć‚QDQFLDO \HDU WKH 'DQLHOL JURXS DFKLHYHG UHYHQXHV RI PLOOLRQ HXURV DQG D QHW SURĆ‚W RI PLOOLRQ HXURV 7KH JURXSĹ’V RUGHU ERRN DV RI -XQH DPRXQWHG WR PLOOLRQ HXURV :KLOH LQ WKH SODQWPDNLQJ VHJPHQW HQJLQHHULQJ DQG PDQXIDFWXUH RI PHWDO SURGXFLQJ SODQWV WKH JURXS UHYHQXHV VOLJKWO\ LQFUHDVHG WKH $%6 JURXS VWHHOPDNLQJ VHJPHQW Ĺ? PDGH XS RI $FFLDLHULH %HUWROL 6DIDX DQG $%6 6LVDN Ĺ? VDZ D VXEVWDQWLDO ULVH LQ UHYHQXHV 2014 marks the first century since Mario and Timo Danieli established the Angelini Steelworks in Brescia, Italy, in 1914. Danieli looks back on such a successful past and is now resetting for the challenges of the future. To this end, the Danieli group has launched the “Metamorphosis 2â€? project to reshape its structure and operational methods over the next two years. The project is intended to make the company more responsive to current needs and to increase its turnover.

The Danieli group designs, builds and sells plant and equipment for the iron and steel industry, offering a complete range of machines for primary processes and the complete production chain down to the manufacture of finished goods (essentially from ore to the finished product). It also produces and sells special steels for the long products market through its subsidiaries Acciaierie Bertoli Safau S.p.A. (Italy) and ABS Sisak D.o.o. (Croatia).

In spite of the global turmoil that forced the group to temporarily shut down some of the sites in the MENA region, Danieli met its own targets in financial year 2013/2014. New orders acquired in the period were in line with the budgeted amount, in a market that continues to be receptive. While in the plantmaking segment the group’s revenue performance remained substantially stable, there was a significant increase in the steelmaking segment,

Danieli & C. S.p.A., Buttrio, Italy Contact: www.danieli.com E-mail: info@danieli.com

MPT International 6 / 2014

without appreciable changes in the scope of consolidation. The operating profit for the period was solid, thanks in part to the release of some provisions made in prior years, and it was positively affected by the strong contribution from the steelmaking sector.

to expand the latter’s business in the USA and to improve service.

The internationalization process of the Danieli plantmaking segment has rounded out with the progress taking place at the workshops in India and Russia. The new production facil-

Plantmaking

Steelmaking

Total

vs. 2012/13

Sales

2,149

795.1

2,944.1

EBITDA

218.1

90.7

308.8

+11%

Net profit

125.3

28.2

153.5

-6%

Order book

2,862

217

3,079

-4%

Employees

10,067

1,357

11,424

+4%

+6%

Forecast for 2014/15 Sales

2,050 / 2,100

700 / 800

2,750 / 2,900

EBITDA

190 / 200

70 / 80

260 / 280

Order book

2,950 / 3,100

150 / 200

3,100 / 3,300

(million euros) (KIWTGU QH VJG &CPKGNK ITQWR HQT VJG Ć‚PCPEKCN [GCT CPF HQTGECUV HQT VJG EWTTGPV RGTKQF

Two major events occurred for Danieli during the financial year 2013/2014. The first one was the acquisition of the remaining 50% shares of Danieli Corus from Tata Steel. Now the company has full ownership and the ability to strengthen the scope of technologies in the field of integrated steelworks, i.e. blast furnaces and converter shops. Further, the Danieli Taranis joint venture was established. It links the expertise of the American company Taranis in the field of steelmaking automation with Danieli Automation

ities in China and Thailand are up and running. Altogether, the Danieli group has transformed into an international force that can assure production quality and punctuality.

As for the steelmaking segment represented by Acciaierie Bertoli Safau, Danieli has been investing in the steelworks located in Italy and Croatia according to the 350-million-euro investment programme, which will be concluded by the end of October 2015.

Activities took place at ABS Cargnacco to streamline production and fur-

COMPANY PROFILE ther expand the steel brands produced, and at ABS Sisak to complete the facility upgrades and boost operating capacity and manufacturing efficiency.

Outlook The world’s steel market is expected to grow by 2.5 – 3.0% per annum, with installed production overcapacity remaining at around 15 – 20%.

This means fewer investments in new plants, an effect which may influence the Danieli group’s growth targets for the next two/three years. There are

three main reasons shaping the outlook for global steel consumption: the loss of formerly significant markets due to regional unrest, the effects of a sluggish European economy, and the slower growth of steel consumption in China.

For the plantmaking market, Danieli expects that for the next two or three years (a longer period than previously expected), worldwide fewer investments will be made in new plants.

This will be taken into account in the group’s strategic planning for the next five years. As a consequence, Danieli

‹‹‹

27

will focus on plant upgrades. Technological packages can improve the competitiveness of existing plants and take them to the level of new plants. For the steelmaking segment, Danieli predicts that turnover and EBITDA will grow thanks to the new investments and hopefully a market recovery.

For the next year, the Danieli group expects that it will be able to improve its financial position, consolidating available net cash with greater profitability of short term financial assets, while always retaining the short-term nature of its investments.

Stressometer® Systems. Extended actuator teamwork.

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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.

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MPT International 6 / 2014

28

››› COKE MAKING

A numerical modelling of nonrecovery/heat-recovery coke ovens Numerical calculations of the combustion process inside the coke oven were carried out in order to gain an improved understanding of the internal thermodynamic behaviour. In GRLQJ VR VFLHQWLĆ‚F HQJLQHHULQJ WRROV DUH FUHDWHG ZKLFK KHOS ERWK LPSURYH WKH RYHQ GHVLJQ and optimize the coking process.

In the heat-recovery/non-recovery (HR/NR) coke ovens the coal/coke bed is located in the large oven chamber in the upper part of the oven. The coal/coke fixed bed is of a parallelepiped shape, the typical dimensions being approx. 1 m in height, 4 m in width and 15 m in length.

The carbonization process of the coal begins at the top and at the bottom of the fixed bed. Then the carbonization front will move continuously through the bed.

The heat required for thermal decomposition and carbonization is generated by combustion of volatiles released from the coal bed. The volatile matter is partially combusted in the free space above the fixed bed using air entrained through the various ports/openings (channels) located in both side doors and the oven roof.

The gas formed in the upper oven is transported through “downcomer� passages to the sole flue (bottom part of the oven). Additional channels in the sole flue provide the required amount of air to complete the combustion process [1 – 4].

In the course of a coking process (which proceeds under negative pressure) the amount of air provided to the spaces above and below the coal bed is controlled by under-pressure (suction) generated using either a fan or through natural draft caused by a stack. The entire coke making process can be controlled just by varying the suction at the outlet of the oven. This is usually not enough to obtain the same high quality product (coke) in the entire coke bed.

Dr. Ronald Kim, Dr. Patrick SchwĂśppe; ThyssenKrupp Industrial Solutions AG, Dortmund, Germany; &T 4CHCV $WE\[ÄžUMK 6GEJPKECN 7PKXGTsity Clausthal, Clausthal, Germany Contact: www.thyssenkruppindustrial-solutions.com E-mail: ronald.kim@thyssenkrupp.com

MPT International 6 / 2014

Primary air openings: Oven door

Downcomer AF?LLCJ SNNCP

Side air inlets

Downcomer channel (lower)

to fan 1MJC kSC Secondary air channels

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Geometry of a heat-recovery/non-recovery coke oven

To improve the homogeneity of the coke product, a uniform heating rate of the fixed bed has to be ensured. In the upper part of the oven (above coal bed), heat is transferred to the bed mainly through radiation from the oven walls and from hot gases, which are products of partial combustion of volatiles. The heat produced in the sole flue is transferred to the coal charge through the sole flue brick ceiling. The uniform heating rate of coke charge through the sole flue ceiling can be obtained if the temperature profile in the sole flues is uniform. This can be achieved by changing the size and position of the gas and air channels.

3D numerical model of the coke oven Numerical simulations using computational fluid dynamics (CFD) are considered a perfect method for engineering and optimizing the design of the NR/HR-coke ovens. CFD-simulations of processes occurring in both the upper and the lower part of the oven, allow

both identify the reasons for uneven heating and propose remedies.

The coke making process is transient and requires typically around 48 to 72 hours until the coal has been completely transformed to coke. Performing time-dependent CFD-simulations of the entire process would require an unreasonable amount of CPU time. Consequently, the CFD is used to simulate the furnace performance at selected, characteristic coking phases, assuming pseudo steady state conditions. Such an approach produces useful results in a reasonable time.

In the numerical simulations, only half of the entire oven has been considered, due to its symmetrical design. It is imperative to include a large chamber volume above the coal/coke bed as well as a sole flue. A coke making oven is in fact a hydraulic network where the driving force is the under-pressure generated by a fan and, therefore, while performing CFD simulations the oven cannot be divided into segments.

A non-structural mesh consisting of around 10 million hexa/tetrahedral elements has been generated. Only CH4,

COKE MAKING CO2, CO, O2, H2, H2O and N2 have been considered as components relevant in the gas phase reactions. In order to save computation time, three characteristic instants of the coking process have been selected, corresponding to 10%, 50% and 90% of the total coking time.

This article is limited to the discussion of results obtained for 10% of the coking time. The numerical calculations are performed by means of the commercial CFD software package FLUENT. The amount of air entrained through ports (air channels) into the analyzed oven depends on: ▪ the applied suction (at the outlet), ▪ external conditions (mainly air temperature), ▪ mass flow rate, gas composition, temperature of the raw gas released during the carbonization process.

The pressure inlet boundary condition was provided by the air inlets and the pressure outlet boundary condition by the oven outlet. At the top of coke charge a mass flow inlet is provided. The suction (negative pressure) at the outlet, gas composition, temperature and mass flow rates of raw gas released from the coal bed were taken from measurements.

It is important to note that above the fixed bed, combustion of volatiles takes place under a deficiency of oxygen (excess air ratio is in the range of 0.3 to 0.6).

In the outer sole flue, the air excess ratio is in the range of 0.9 to 1.3. In the inner sole flue the ratio is equal to 1.5 to 1.8. In the simulations, the oxidation of methane (CH4), carbon monoxide (CO) and hydrogen (H2) has been modelled.

Methane is mainly consumed in the upper part of the oven under under-stoichiometric conditions. The carbon monoxide and hydrogen is oxidized in the sole flue (air excess ratio > 1).

Results of the 3D calculations Reflecting about the calculated temperature distribution in the sole flues for the HR/NR design at 10% coking time, the non-uniformity in the temperature distribution is apparent. Moreover, the temperature near the U-tube is close to the safety limit (< 1,500°C). The sole flue ceiling temperature should be lower than 1,500°C since excessive temperatures damage the silica-based refractory.

Three characteristic temperature regions are apparent in the results. The “dead zone” (zone 1) appears in the

Ta = 298 K pa = 101325 Pa

‹‹‹

29

.PCQQSPC GLJCR dp = 0 Pa .PCQQSPC GLJCRQ dp = 0 Pa

Symmetry

.PCQQSPC GLJCRQ dp = 0 Pa

.PCQQSPC GLJCR dp = 0 Pa

.PCQQSPC GLJCRQ dp = 0 Pa .PCQQSPC MSRJCR dp = 150 Pa General conditions

'LLCP 5?JJ 2CKNCP?RSPC

DC 5 DC 4 DC 3

the hottest region

DC 2 DC 1

“dead zone“ the coldest zone

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outer sole flue near the first downcomer (DC1). The region called “dead zone” is colder than other regions of the outer sole flue and this is due to deficiency of air in this region. The deficiency occurs because air is introduced to the sole flue downstream of the first downcomer. Thus, little combustion occurs in this part of the flue which is located upstream of the first air inlet.

In the hottest region (zone 2) located near the U-tube, very high temperatures close to the safety limit (> 1,500°C) occur.

In this region damage to the silica refractory may occur. The problem is caused by: ▪ the combustion conditions – excess air ratio in this region reaches a value of around 1.0,

▪ the design of the sole flue – all the gas which flows into the outer sole flue accumulates in the region near the U-tube. The U-tube intensifies the mixing so the remaining fuel burns rapidly leading to an intensive heat transfer to the ceiling.

The “coldest region” (zone 3), where the problems have been noticed, is the region in the inner sole flue near the outflow. The gas in the inner sole flue is gradually cooled down by the entering cold air. The excess air ratio increases from 1.0 near the U-tube to the value of 1.5 to 1.8 at the end of the sole flue.

Temperature non-uniformity of the sole flue ceiling may also be caused by the air supply installation above the coal MPT International 6 / 2014

30

››› COKE MAKING

deposit (in the upper oven). The gas containing combustible compounds such as CO and H2 is transported to the sole flue through five downcomers per wall. The gaseous fuel is produced by partial combustion of volatile matter released from the coal bed located in the upper oven.

Primary air required for partial combustion flows through the top (primary) air channels and side air channels. The side air channels may disturb the uniformity of the air supply. Gas transported in downcomers DC 1 and DC 5 has a different composition than gas flowing through the other downcomers DC 2, DC 3 and DC 4. Differences in flow rates, temperatures and composition of the gas in downcomers may worsen the uniformity of the sole flue temperature.

The gas-flow in the downcomers and in the sole flue is generated by the suction fan located at the plant exit duct.

The secondary air is entrained via eight air inlets. There is marked non-uniformity in the distribution of the gas flowing through the downcomers; the largest amount is transported through the 5th downcomer whilst the smallest amount flows in the 1st downcomer. Different amounts of air are entrained through the air inlets so that different, highly non-uniform, combustion conditions (stoichiometry and mixing) occur. Consequently, the ceiling of the sole flue is exposed to non-uniform heat transfer rates, which invoke non-uniformity of ceiling temperatures.

To improve the temperature distribution in the sole flue, one has to understand how the gas produced in the upper oven behaves when entering the sole flue.

It is also necessary to understand the air behaviour. After igniting, the gas leaving the downcomer is heated up, it then hits the side wall (sole flue partition) and flows upwards to the sole flue ceiling. The calculation clearly shows that the gas recirculates in the sole flue. The behaviour is similar for all downcomers.

The secondary air flows differently.

The air entrained from the surroundings enters the sole flue using ports (channels) placed at the sole flue bottom. The air flows upwards and hits the sole flue ceiling near the downcomers 1 and 2. In the vicinity of the downcomers 3, 4 and 5 the air streams are entrained by the main flow and do not hit the ceiling.

The existence of the hottest region of the sole flue can be explained by the above-described behaviour of the gas MPT International 6 / 2014

entering the sole flue. The hot combustion products of gas leaving downcomer 5 (and other downcomers) pass by the U-tube and flow upwards to the region near the sole flue ceiling. The gas stream impinges on the ceiling in the “hottest area” of the sole flue ceiling. The main flow and the sole flue ceiling near the oven outlet are cooled by the air entering the oven through air channels located at the bottom of the sole flue.

DC 5

DC 4

one-dimensional (1D) network model, which would provide simplified simulations of the whole coking process (about 70 hours) in two to three days. Such a model, described below, is currently under development.

The one-dimensional model consists of four main parts: ▪ hydraulic network – for calculation of the downcomer flow rates and the amount of entrained combustion air,

DC 3

DC 2

DC 1

Gas path lines coloured by temperature

DC 1 DC 2 DC 3 DC 4 DC 5

Gas path lines coloured by carbon monoxide mass fraction

1D numerical model of the coke oven FLUENT is a useful software tool which helps to understand processes inside the oven. The knowledge gathered from the FLUENT calculations is very helpful when the oven design and construction have to be optimized. When it comes to controlling the coking process, a one-dimensional model may be a better choice since results are obtained (significantly) faster compared to FLUENT. A single CFD calculation takes about three weeks. It is possible to develop a

▪ gas combustion sub-model – to simulate gas combustion inside the branches of the hydraulic network.

The sub-model is coupled with the hydraulic network, ▪ chamber sub-model – equilibrium calculations to predict gas composition in the upper oven, above the coal/coke bed, ▪ coke sub-model – to simulate heat conduction through the coal bed, evaporation, condensation phenomena and the devolatilization process using “Merrick’s model” [5].

Tiltable Virtual Lance Burner VLB with innovative tilting function ensures maximum efficiency with flexible input

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Lancing mode: Efficient oxygen injection due to steep lancing angle at sufficient distance between refractory and lancing jet.

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32

››› COKE MAKING +PPGT UQNG ƃWG RCVJ NKPGU EQNQWTGF D[ temperature

DC 1

DC 2

DC 3

DC 4

DC 5

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Relatively quick calculations allow for the determination of a number of parameters necessary for improved oven performance. The 1D model may provide information concerning parameters such as “required oven (under-pressure) suction”, “end of coking process” or “required channel diameter”.

The hydraulic network model and gas combustion model are coupled. Mass flow rates, gas composition and temperature in each branch are exchanged between both the hydraulic network model and the combustion model.

The raw gas (volatiles) composition comes from the Merrick sub-model [5].

The comparison of the mass flow rates entrained (sucked) through the primary air inlets and the secondary air inlets shows that both models (one-dimensional and FLUENT calculations) produce very similar results. The temperatures in the upper oven and in the sole flue are also in good agreement.

MPT International 6 / 2014

Because the adjustment of the primary and secondary air flow quantities at the correct points in time is of great significance with respect to the temperature regime within the oven, an optimized instruction schedule was prepared based on the above investigation, meeting various operational conditions. Its multiple benefits are permanently validated during operation of a HR-plant in Brazil, where the adjustment schedule is part of an automatic installation. One of these benefits is the avoidance of melting processes of sole or wall refractories caused by any incorrect adjustment of the cross section of the secondary air inlet devices below the oven sole.

Based on the investigations described above, ThyssenKrupp Industrial Solutions has optimized the overall design and process control of its NR/HR-oven, resulting in a uniform heat flux distribution both above and below the oven charge. It is associated with short gross coking times of less than 58 hours using compacted coal charges with a density of d = 1,100 kg/m³, thus guaranteeing high process efficiency and low invest쐍 ment costs at the same time.

Conclusions The 3D flow simulation model developed for NR/HR-ovens, corresponding to state-of-the-art design of TKIS-PT, enables the mixing and combustion process within the oven chamber and sole flues to be observed through graphical animation and lead to an evolutionary improvement in the understanding of mixing and combustion laws within all combustion chambers of the oven. Moreover, the model allows the application limits of this coking technology to be determined with respect to important process parameters like characteristic temperature and pressure profiles in the upper and lower parts of the oven. It is also possible to illustrate any geometric point with differently adjusted primary and secondary air fractions, taking into account all aspects of process and geometric coupling between the upper and lower parts of the oven.

References [1] Kim, R., Ein Prozessmodell zur Kokserzeugung mit direkter Beheizung, Dissertation, TU Clausthal, 2010 [2] Quanci, J., Recent Trends in Heat Recovery Coke making Processes, SunCoke Energy, ABM Brasil, 2011 [3] Zheng, Q., and Wei, H., Three-Dimensional Numerical Simulations and Analysis of a Heat-Recovery Coke Oven, School of Chemical Engineering and Technology, Energy Fuels, 27 (6), pp 3570 – 3577, 2013 [4] Austin, G.T., “Coal Chemicals” Shreve’s Chemical Process Industries Fifth Edition edited by George T. Austin McGraw Hill International editions, p. 70, 1984 [5] Merrick, D., and Atkinson, B., Mathematical models of the thermal decomposition of coal. National Coal Board, Coal Research Establishment, Stoke Orchard, Cheltenham, Glos., GL52 4RZ, UK, 1982

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High-performance turbo compressors have substituted obsolete equipment at the heat and power plant

0./- GPJCPEGU GPGTI[ GHƂEKGPE[ CPF TGFWEGU GPXKTQPOGPVCN KORCEV The Russian steelmaker NLMK has modernized some of the main production facilities at the Lipetsk site aiming to reduce both its environmental footprint and energy consumption. The company has upgraded air-blowing equipment used in blast furnace operations at the Lipetsk site. A biochemical waste water treatment facility was installed at the coke and chemical operations here.

Novolipetsk is the main production site of NLMK group, Russia’s leading manufacturer of steel and high value added rolled products. The integrated iron and steel works at Novolipetsk is MPT International 6 / 2014

the nucleus of NLMK group’s production chain, with assets in Russia, the EU and the USA. Here, the company celebrated the 80th anniversary of the production of its first pig iron with a

formal jubilee heat ceremony on 7 November 2014. The ceremony was held at blast furnace #7, that today is one of the most modern and efficient ironmaking plants in the world.

PCI equipment installed at the blast furnace operations

Over the 80 years of its history, NLMK has come an enormous way from a single blast furnace to becoming a global steelmaker. Currently, steel output at the Lipetsk site exceeds 12 million tonnes per year, which accounts for approximately 18% of Russia’s total steel output and approximately 80% of NLMK group’s total steel output. Novolipetsk’s high-quality steel products are used in various strategically important industries, from construction and machine-building to the production of energy equipment and large-diameter pipes. Over the last three years, NLMK

NLMK Novolipetsk Metallurgical Complex, Lipetsk, Russia Contact: www.nlmk.com E-mail: babichenko_sy@nlmk.com

group has implemented a number of large investment projects aimed at increasing the energy efficiency of operations and increasing the share of electric energy generated using by-products.

Modernization of the airblowing equipment used in blast furnace operations An example is the new 150 MW energy recovery co-generation plant, installed at the Lipetsk site. It was built together with a modern electric air-blowing station installed to meet the needs of blast furnaces #6 and #7. NLMK also built a modern air separation unit that produces 34,000m³ of oxygen per hour.

Recently, three modern turbo compressors were launched at the heat and power plant. They will supply air under high pressure first to the hot-blast stoves

and then to the blast furnaces #3, #4 and #5. Hot testing of the third and final turbo compressor began in September 2014.

Alexander Starchenko, NLMK vice president for energy, said: “Substituting obsolete equipment with high-performance modern equivalents increases operational stability and reduces energy consumption. Savings for each of the three units will exceed RUB 70 million (approx. 1.5 million US$) per year.” Investment in the project of installing the three modern turbo compressors totals RUB 1.86 billion (approx. 40 million US$).

NLMK is making continuous efforts to increase productivity and energy efficiency. In 2013, specific energy consumption per tonne of steel totaled 5.67 Gcal, a 20% improvement compared to 2000. This brought NLMK closer to the level of best available technologies.

MPT International 6 / 2014

36

››› MODERNIZATION

Additional PCI equipment installed

Unique environmental facility

try leaders in environmental efficiency.

This project is yet another step towards achieving this goal.”

The facility employs a custom technology developed by Russian scientists for deep biochemical water purification from phenols, rhodanides, ammoniacal nitrogen and its oxides (nitrites and nitrates) in one stage, whilst the previous technology required several stages. Elimination of these obsolete stages allows for up to 95% waste water purification from nitrites and nitrates.

All infrastructure and utilities were installed above ground on an isolated concrete area equipped with a rain, melt and drain water collector, preventing any chance of groundwater pollution in the event of a containment failure.

Earlier this year, NLMK has started hot A biochemical waste water treatment testing the second pulverized coal injec- facility was commissioned at the coke tion (PCI) unit in its blast furnace opera- and chemical operations. Total investtions. The company has started installing ment into the project which was imthis resource-saving technology, which plemented as part of NLMK’s Environhas only recently been introduced in Rus- mental Programme 2020 exceed RUB 2 sia, at its blast furnace #4 with a capacity of billion (approx. 43 million US$). approximately 2.1 million tonnes of hot From 2009, all industrial storm and metal per year. In 2013, a similar unit was waste water at the Lipetsk production successfully installed at blast furnace #5 site has been contained in a closed-loop with a capacity of 3 million tonnes of hot water cycle with multistage treatment metal per year. As a result, over a third of to enable it to be reused in technologiNovolipetsk hot metal production capaci- cal production processes. The new 160 ties will be equipped with resource-saving m³/hour facility was designed using the PCI systems. NLMK managing director best available technologies, and will Sergey Filatov said: “Installing pulverized provide a twenty-fold improvement coal injection technology at the Lipetsk in the quality of treatment of coke and site is one of the key elements of our gener- chemical operations waste water for real programme to boost efficiency and cut use in the closed-loop water cycle. unit costs, which is one of the key priorities of NLMK’s Strategy 2017. Expanded use of this technology was made possible through the experience of working with PCI acquired by our blast furnace operators, and the radical change in the quality of coke brought about by new technologies and approaches to coke and chemical operations.”

PCI technology involves co-injecting natural gas and fine coal particles into the blast furnace. Using pulver- Biochemical waste water treatment facility at the coke and chemical operations ized coal fuel made Sergey Filatov, NLMK managing diIn May 2014, NLMK group anfrom steam coals reduces gas consumption by 70 – 80% and coke consump- rector, said: “NLMK group’s Lipetsk nounced the launch of the third stage tion by 20 – 30%. Replacing expensive production site has achieved unprece- of its environmental programme, raw materials with cheaper alterna- dented results in the course of imple- covering the period up to 2020 (Entives (coking coals with steam coals) menting the previous stages of its en- vironmental Programme 2020). This will reduce the cost of producing pig vironmental programme: specific air programme is aimed at further miniron. Moreover, the use of new technol- emissions have been halved since 2000, imizing the group’s environmental ogies in coke and chemical operations while steel production has increased footprint and achieving the best poshas already allowed NLMK to obtain by 51%; and waste water discharge has sible environmental standards in globhigh-quality coke from domestical- been completely halted. But we are not al steel production. Investment in enly sourced inputs. Approximately RUB going to stop at that and are continuing vironmental initiatives and projects at 3.7 billion (approx. 80 million US$) have our ongoing efforts to reduce the com- NLMK group companies will total RUB been invested in the project, which in- pany’s environmental footprint as part 10.6 billion (approx. 227 million US$). volves equipping blast furnaces #4 and of NLMK’s Environmental Programme Most of the funds will be invested at #5 with PCI systems.

2020. Our goal is to become the indus- NLMK’s Lipetsk production site.

MPT International 6 / 2014

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Siderar starts production with VJG JKIJ GHĆ&#x201A;EKGPE[ EQPVKPWQWU slab caster Ternium Siderar, Argentina, has successfully commissioned the two-strand continuous slab caster, which was supplied by SMS Siemag, at the San NicolĂĄs location.

At its San NicolĂĄs, Argentina, location, Ternium Siderar operates a BOF steelworks comprising three converter shops and a two-strand continuous slab casting plant. The slab casting plant was initially supplied by SMS Siemag 30 years ago. It has since been revamped by the German company.

Thanks to the high-efficiency continuous caster, Siderar is now able to fully utilize the production capacity of the upstream BOF shops and increase its production of low to medium-carbon steels and peritectic grades.

SebastiĂĄn Capote LĂłpes, head of the continuous casting and second-

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

ary metallurgy department at Ternium Siderar, said: â&#x20AC;&#x153;The continuous caster went into operation on schedule and trouble-free. We were immediately able to cast an entire ladle and are very satisfied.â&#x20AC;?

Designed for casting speeds of up to 2.15 meters per minute, the plant achieves a production capacity of 2.5 million t of slab per year. The strand guide with twelve segments is prepared for the addition of two further segments. With this, the casting speed and, as a result, the plantâ&#x20AC;&#x2122;s productivity can be further increased in the future.

The plant is designed for 200 and 250 millimeter thick slabs with widths between 750 and 1,900 millimeters. The technological equipment of the caster includes several Intelligent Slab Casting (ISCÂŽ) modules which determine

quality and production. Among these are the hydraulically powered resonance oscillation system, remote-controlled mold narrow faces for width change during casting and the position-controlled Cyberlink segments to perform Dynamic Soft ReductionÂŽ.

The production of slabs of a high internal quality is thus guaranteed through the above in combination with the width-dependent air-mist secondary cooling and the technological Dynamic Solidification Control (DSC) process model.

The plant is fully equipped with the X-PactÂŽ electrical and automation system from SMS Siemag. This comprises process automation (Level 1) and technological process models (Level 2) as well as commissioning. The personnel of Ternium Siderar received intensive and true-to-life training.

MPT International 6 / 2014

Enhanced process reliability and quality of special steel products Deutsche Edelstahlwerke is modernizing the cooling bed area of the special steel bar mill at the Siegen, Germany, site. After commissioning in 2015, the 14-million-euro investment project will guarantee enhanced process reliability and product quality.

Deutsche Edelstahlwerke, a company of the Schmolz + Bickenbach group, is investing 14 million euros in modernizing its Siegen, Germany, steel mill. The cooling bed of the bar mill is MPT International 6 / 2014

undergoing an extensive revamp. The international manufacturer of special steel long products is thereby reacting to the constantly growing market demands regarding process reliability

and the surface quality of rolled products. The equipment is scheduled to be commissioned in autumn 2015.

The first part of the overall construction activities, for which no more than

Construction site at the Siegen special steel bar mill in the summer of 2014

rolled products to be raised from a transfer carriage onto the rake-type bed in a continuous, uninterrupted procedure. On the cooling bed, the bars will cool down evenly across their whole width. The synchronized movement of the bars and the homogeneous temperature distribution will ensure much improved and reproducible length tolerances after cutting to size.

“Depending on the grade, the rolled material shrinks by one to two percent when cooling down from temperatures ranging between 1,000 and 20°C. Consequently, the bars will have different lengths after cutting to size, depending on the shrinking ratio across the width of the roller bed.

When we start up the revamped equipment in 2015, this problem will be significantly reduced,” Thomas Helsper explains.

The modern design of the alignment grids has the additional effect that the bars will in future leave the cooling bed in a straight condition. Consequently, it will no longer be necessary to straighten them in an additional processing step in the finishing area, as has been a standard, though time-consuming practice till now. Hence, the production process will be even more efficient in the future.

Better surface quality through gentle handling

seven weeks are scheduled, has already been completed.

“The design of the cooling bed ideally suits our product range of bars with diameters from 20 to 90 mm. Among our main customers are construction companies, automotive suppliers and cold forming companies. They will in

Deutsche Edelstahlwerke GmbH, Siegen, Germany Contact: www.dew-stahl.com E-mail: melanie.biskup@dew-stahl.com

particular benefit from the modernization in terms of quality and process technology improvements. In applications, such as complex power train and transmission components in cars, the steel surface often remains visible.

Score marks are therefore not acceptable,” explains Thomas Helsper, manager of the rolling mill.

Accurate and straight bars without additional straightening The 66-meter-long cooling bed from plant maker SMS Meer will enable the

In addition, the qualitative benefits of the modernization will show as soon as the rolled bars arrive at the cooling bed. Currently, the bars are slowed down by friction in a concealed channel. In the future, this task will be accomplished by a roller bed with braking slides. As a result, friction marks on the bar surfaces will be significantly reduced.

“Apart from the effects of increased quality and improved processes, also the average throughput rate in the Siegen rolling mill will go up by at least 10%,” forecasts Thoma Helsper. “At the moment our two cutting systems are arranged in a line, one behind the other. Simultaneous operation is not possible. Therefore it sometimes MPT International 6 / 2014

42

››› MODERNIZATION

happens during automatic operation that one machine must stop and wait for the other to complete its operation. After the modernization, the two cutting systems will be decoupled and connected to each other via a cross-transfer system. This will reduce the non-productive times.” As from autumn 2015, the whole continuously synchronized process in the Siegen rolling mill will also significantly simplify material traceability, further minimizing the already low risk of mixing up material.

Only seven weeks scheduled for onsite construction A time frame of only seven weeks has been scheduled for the onsite construction activities. During this period, the construction team, coordinated by SMS Meer, performs activities such as the dismantling of the old cooling bed, the temporary removal of components as required for the installation of the new equipment, the laying of extensive foundations, and the construction and commissioning of the new cooling bed. This is a huge challenge for all in-

Installation of the new pulpit of the rolling mill has already been completed

volved. “By no means shall the processing of our customers’ orders be disrupted due to the implementation of the modernization project. Therefore all work will be performed during regular annual plant shutdowns,” explains Thomas Helsper.

In early August 2014, already approx. 80% of all the foundations and

cable channels were built. Also all the equipment which had to be temporarily removed for this purpose was dismantled and reinstalled during the three-week summer shutdown. The installation of the new plant components will take place during next year’s summer shutdown, including the dismantling of the old equipment.

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44

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş CONTINUOUS CASTING

The evolution of the thin slab route The CSPÂŽ thin slab technology was originally introduced as a plant concept for the FRVW HIĆ&#x201A;FLHQW SURGXFWLRQ RI VLPSOH RUGLQDU\ VWHHO 6LQFH WKDW WLPH WKH GLUHFW FRPELQDWLRQ of the casting and the rolling process has developed into a leading process for the SURGXFWLRQ RI KLJK TXDOLW\ KRW VWULSV 1RZDGD\V WKLV WHFKQRORJ\ LV FDSDEOH RI SURGXFLQJ DOPRVW DOO VWHHO JUDGHV UHTXLUHG E\ WKH PDUNHWV 7KH HIIHFWLYHQHVV RI WKLV FRQFHSW LV DOVR SURYHG E\ WKH HQHUJ\ HIĆ&#x201A;FLHQF\ SURĆ&#x201A;WDELOLW\ DQG SURGXFWLYLW\ 7RGD\ SODQWV RI WKLV NLQG DUH LQ RSHUDWLRQ ZRUOGZLGH 7KDQNV WR WKH SHUPDQHQW IXUWKHU GHYHORSPHQW DQG D PXOWLWXGH RI PRGXODU FRQFHSW FRPSRQHQWV IRU D PDUNHW RULHQWHG GHVLJQ WKH &63ÂŽ FRQFHSW FRQWLQXHV WR EH FRQVLGHUHG D OHDGLQJ WHFKQRORJ\ LQ WKH VWHHO LQGXVWU\

CSP ÂŽ rolling mills can consist of four to seven mill stands

With the World Wide Web (WWW) and compact strip production (CSPÂŽ technology), two technical innovations at a time made history in 1989.

They revolutionized processes which were common practice at that time and they are still up-to-date today after 25 years. The Hypertext Markup Language (HTML) introduced a new technical standard in programming of websites

Stephan Krämer, Christoph Klein, SMS Siemag AG, Dßsseldorf, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com

MPT International 6 / 2014

which still characterizes the worldwide exchange of information today.

The CSPÂŽ concept also laid the focus on the continuity of the processes. Its thin slab technology permits the production of almost all steel grades required by the market. The core elements of the compact plant concept are the thin slab casting plant with the CSPÂŽ mould with the funnel-shaped expansion in the middle, the tunnel furnace and the rolling mill. The reason for the outstanding performance of the CSPÂŽ plants is the combination of the production steps â&#x20AC;&#x153;Castingâ&#x20AC;?, â&#x20AC;&#x153;Heatingâ&#x20AC;? and â&#x20AC;&#x153;Rollingâ&#x20AC;? in one manufacturing line. By coupling the rolling mill to the caster by means of a

continuous furnace, it is not necessary to heat up the slabs with thicknesses ranging from 50 to 90 mm from ambient to rolling temperature anymore. In this way, gas consumption is reduced by approx. 45% as compared with conventional hot rolling technology. The CO2 emissions are reduced to the same extent. As, compared with the conventional continuous casting technology, the slab thickness is reduced by a factor of 3 to 5, no roughing mill is required for the slabs in the rolling process. The deformation required for obtaining the final rolling thickness can be attained by the hot rolling finishing mill alone. This results in a comparatively lower rolling effort, which

CONTINUOUS CASTING means that less energy is required. The production of a hot strip starting with casting of the liquid steel in the casting mould up to the finished hot strip at the coiler lasts approx. 20 minutes, which is considerably faster and much more efficient than the conventional process, which partly takes up to several hours. The overall CSPÂŽ process is regulated and controlled by a particular automation system. The mould design in combination with a process automation system specifically designed for a faultless operation at high casting speed, reliably prevent breakouts thus ensuring high availability of the casting machine. The constant pro-

Institute standard (API) as well as dual and multiphase steels. CSPÂŽ hot strip of silicon-based steel is further processed into non grain-oriented (NGO) and grain-oriented (GO) hot strip for the production of electrical motors, generators and transformers. By means of this wide production range in combination with the modular plant concept various forms of application are created. Thus it has proved its worth as regards the cost-efficient introduction on the market for flat products. Moreover, the CSPÂŽ technology also offers tailor-made solutions for the expansion of an existing product portfolio or for the increase of total yield.

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

45

casting machines are suitable for production volumes of up to 1.5 million t/year. In case of higher production volumes and accordingly higher casting thicknesses, bow-type casters with the vertical CSPÂŽ funnel-shaped mould and vertical segment 1 are used. By means of these so-called VLBÂŽ casting machines (vertical liquid bending) it is possible to attain production volumes of up to 2.5 million t/ year.

Up-to-date energy concept In order to considerably decrease the energy requirements of the CSPÂŽ plants even further while keeping the

2TQĆ&#x201A;NG EQPVQWT CPF Ć&#x192;CVPGUU EQPVTQN 2%(%ÂŽ) ensures constant qualities up to the strip edges

cess conditions of the CSPÂŽ technology guarantee the excellent quality of the produced hot strip: The characteristic features are the excellent mechanical and geometrical properties with constant minimum tolerances over the overall strip length and width. Moreover, the CSPÂŽ process guarantees a reliably reproducible homogeneous microstructure, thus qualifying the CSPÂŽ technology for the production of all types of flat steel required on the market. Apart from thin and ultra-thin hot strip of IF steel and soft steel with lowest carbon content, this also includes thick hot strip with high-strength micro-alloyed tube steel types up to X80 according to the American Petroleum

Market-oriented modular principle The modular design principle of the concept is adapted to the changed market conditions in a flexible manner and, thanks to a multitude of customer-specific adaptation solutions, it allows the plant to grow along with the requirements. Thus, the casting machine can for example be extended by two strands up to a total of three casting strands. The number of segments varies from two segments with a metallurgical length of 5.7 m up to five segments with a metallurgical length of 10.3 m.

Casting thicknesses between 40 and 90 mm are possible as a standard. These so-called VSBÂŽ (vertical solid bending)

wide product range unchanged, a combination of a gas-heated tunnel furnace and an inductive heating plant might be suitable. For this variant, inductive heaters are installed between the soaking furnace and the CSPÂŽ rolling mill in order to adjust the thin slab temperature in accordance with the requirements. Strips which require a higher inlet temperature are directly inductively heated upstream of the rolling mill. By means of this specific increase it is possible to attain higher reductions in the millstand and it is therefore suitable for the production of ultra-thin strip. At the same time, the normal furnace temperature can be reduced to a level required for the maMPT International 6 / 2014

The Edge Masking® U[UVGO KORTQXGU VJG EQNF UVTKR ƃCVPGUU D[ RTGXGPVKPI VJG UVTKR GFIGU HTQO WPFGTEQQNKPI KP VJG NCOKPCT cooling system

jor part of steel types and strip dimensions, thus saving energy.

Homogeneous microstructure CSP® rolling mills consist of four to seven mill stands. A substantial deformation of the slab in the first stands is of decisive importance in particular for the production of tube steel in order to be able to transform the uneven casting microstructure into an even re-crystallized microstructure.

In older CSP® plants, the thickness and width of the slabs which can be used is limited by the rolling torque.

The rolling torque can be considerably increased by exchanging the motors and gear units. The CSP® Vario rolling mill is in particular suitable for the production of high-strength thick strip for tube steel grades. Here, a strong millstand M1 is installed upstream of the first finishing stand. Depending on the focus of production, further modules, such as an induction heater between the two stands M1 and F1 are used. A plant concept, combining endless and batch-type of operation offers particular flexibility.

MPT International 6 / 2014

Perfect co-operation By means of their holistic system solutions, SMS Siemag makes a decisive contribution to safety, quality and efficiency of the processes. The interaction of the mechanical, electrical and automation systems which is perfectly matched to the customer-specific process is the basis for a stable and also flexible and trouble-free production. A wide-range of demand-oriented modules from the level 1 basic control as well as the integrated level 2 process control are available for this purpose. In the casting process, the material composition can be exactly calculated and controlled by modules of the X-Pact® solution. The mold level control (MLC®) and/or the hydraulic mold oscillator (HMO®) ensure the high internal and surface quality of the material. Monitoring of the temperature and of strand shell stickers (MMS®), the calculation of the solidification process and the cooling water requirement (DSC®) as well as the slab gauge control (LCR®) through X-Pact® contribute to the required safety and flexibility of the casting process. An integrated solution consisting of pro-

cess models, control systems, drives and sequence controls ensures the rolling stability required for the production of high-strength steel types and thin strip. Thus, the pass schedule calculation (PSC®) determines the optimum load distribution and roll gap thickness based on the material data base (MDB®) as well as on the models of the stand and the deformation process.

The profile, contour and flatness control (PCFC®) ensures constant qualities up to the strip edges. The gauge control “Observer-based automatic gauge control” (AGC) adapts the mill stand and the adjustment systems to the material during rolling so that the required strip thickness is precisely observed.

By means of control systems for strip flow control such as RAC® or ALC® and tension distribution measuring devices, SMS Siemag moreover contributes to a maximum yield. In order to specifically attain the required strip qualities of multiphase steel during the cooling process, a complex thermo-physical process model is combined with sophisticated control technology. The Edge Masking® system improves the cold strip flatness by preventing the

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strip edges from undercooling in the laminar cooling system. In the coiler, the Step ControlÂŽ system controls carefully winding of the strip.

Tried and tested system modules As inventor of the CSPÂŽ concept, SMS Siemag has been fully engaged in this technology and its continuous further development in close cooperation with the users for more than 25 years. With every new challenge, the

modular concept is extended by one system module which can also be easily adapted to other CSPÂŽ plants. The specific design and the transferability to the concrete process is tested based on simulations and is exactly matched.

This results in an integrated growth of existing plants, and market and demand-oriented adaptation solutions.

The holistic optimally adapted system consisting of electrical, automation and mechanical equipment ensures maximum security of investment. The system supplier which is well acquaint-

ed with the individual userâ&#x20AC;&#x2122;s process, the plantâ&#x20AC;&#x2122;s mechanical equipment and the automation systems due to maintenance and/or modification work combines customer-specific knowhow accumulated by SMS Siemag and the tried and tested concepts with future-oriented solutions. These are optimum conditions for steelworks to expand their product range in a market-oriented way with the required flexibility, to increase their efficiency and to further reduce the energy consumption of the CSPÂŽ plants.

MPT International

â&#x20AC;&#x201C; the leading technical journal for the global iron and steel industry Metallurgical Plant and Technology

Metalurgia, Processos e Tecnologias

MetalĂźrji Prosesleri ve Tesisleri

Also available as

e-journal 10 years PQFÂŽ technology: international symposium on tube and pipe production technology

MPT International 6 / 2014

48

››› HOT ROLLING – AUTOMATION

Automation system for performance improvement in a four-strand wire rod mill An advanced automation system has recently been implemented at the Bhilai Steel Plant of the Steel Authority of India (SAIL). The integration of the new systems in critical parts of the mill has provided substantial improvement in the reliability of the controls, resulting in a decrease in downtime and the consequent increase in mill productivity.

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Layout scheme of the wire rod mill at the Bhilai Steel Plant, SAIL

The wire rod mill (WRM) at the Bhilai Steel Plant of Steel Authority of India Limited (SAIL) is a continuous high-capacity plant comprising the charging area, a common reheating furnace, a common roughing group and a common first intermediate group for all four strands as well as four separate finishing strands followed by the coil handling

Archana Sharan, Vikash Kumar, Usha Rani, S. Ilangovan, Deepak Kumar, Ramanuj Prasad, Susanta Majumdar and Binod Kumar Prasad, R & D Centre for Iron & Steel, SAIL, Ranchi, India; Anupama Kumari, Mukesh Kumar Gupta and K. G. Muralidharan, Bhilai Steel Plant, SAIL, Bhilai, India Contact: http://tinyurl.com/nk9cd5k E-mail: archana@sail-rdcis.com

MPT International 6 / 2014

area. Finishing strands B, C and D of the mill have been modernized earlier and are equipped with modern controls capable of delivering quality finished products at high speed and with high productivity. However, breakdowns in the charging area, the furnace, and the common roughing and intermediate stands, which represent an arterial part of the mill, have led to complete stops of the wire rod mill.

Several strategic interventions have been made in the automation system of this primary area of the mill to reduce the controllable delays and to improve the overall automation performance of the shop.

For rolling, the billets are discharged from the furnace through an ejector ram and fed into the strands through a billet feeding system. First, combined rolling of the billets takes place in the roughing group comprising stands 1 – 9 and in the first intermediate group

comprising stands 10 – 15. This is followed by separate processing of the four strands in the finishing blocks.

Upon discharge from the furnace, billet feeding into the four strands is accomplished with the help of a drawout roller, a distribution table and pinch rolls. The draw-out roller is a single roller at the bottom of the roller table. There are four pinch rolls (A, B, C, D), one for each strand. They press the billet from the top and pull it into the corresponding strand in stand 1.

The billet is positioned into a strand by the distribution table. All these operations, including billet charging coordination, are carried out from the operator desk (PP2).

The DC drive-based rolling stands of the roughing group and of the first intermediate group are individually and manually set for rolling, based on the desired pass schedule. For setting the stands, each stand is equipped with one

HOT ROLLING â&#x20AC;&#x201C; AUTOMATION screw-down mechanism at top left and one at the top right of the stand as well as one stand displacement mechanism at the bottom. The AC motors are operated from local operator desk. There are three operator desks (LP1, LP2 and LP3) for carrying out the mill setting operations for stands 1 â&#x20AC;&#x201C; 3, stands 4 â&#x20AC;&#x201C; 9 and stands 10 â&#x20AC;&#x201C; 15, respectively.

Drawbacks of the existing mill automation

process and largely contributed to mill downtimes. Mal-operation of the distribution table, the stand displacement mechanism and improper screw down controls also resulted in operational problems such as cobbles and roll breakages.

The absence of a proper monitoring system and on-line fault diagnostics resulted in tedious maintenance and delays required for the elimination of the faults, again reducing mill efficiency.

Also reliable inter-pulpit coordination for the smooth discharge, feeding and rolling of the billets could not be always ensured. The above problems necessitated that the control system for this critical section of the mill was to be completely refurbished with stateof-art measurement and level-1 automation systems.

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mill comprises extensive equipment and facilities operated and controlled from several pulpits and machine halls spread over a wide area. For the design of an integrated automation and control system, an architecture with PLC and I/Os distributed over an industrial network backbone was chosen. Distributed I/Os â&#x20AC;&#x201C; herein referred to as remote I/O (RIO) nodes â&#x20AC;&#x201C; were strategically installed near the operator pulpits for billet feeding and mill stand setting. The system is based on GEâ&#x20AC;&#x201C;IP Make Rx3i processor and VersaMax Remote I/Os platform on Ethernet TCP/IP through fibre-optic cable and CAT6. Seven RIO nodes facilitated the design of a streamlined interface of more than 500 I/Os from field desks, machine hall electrics and interface panels using only a single line of industrial, armoured communication cable. The implementation of a reliable network-based PLC system drastically reduced the problem of cable damage in congested cable galleries, cable faults and frequent mal-oper-

The mill had been designed for an 80 mm² billet cross-section. However, the billet size has been gradually increased to a cross-section of 105 mm². Numerous modifications to the furnace charging and discharging ends have been carried out to meet this requirement, including changing the pass design in the roughing group stands, installation of entry and delivery tackles, changes to operational practices, just Architecture of the new to name a few. But the continuous automation system and reliable operation also necessitatA new automation was conceived, ed a very accurate alignment of the designed and implemented for the bildistribution table with respect to the entry guide of stand + 0 , 1 to prevent cobbles and mis-feeds due to 3/& the very small gap left on the sides. In 999) 5,2 ² ,QWHUIDFH 5,2 5,2 ,QWHUIDFH the existing system, GULYH 3DQHO SDQHO GLVWULEX positioning of the WLRQ WDEOH distribution table was performed by an outdated system which did not provide the desired ac ĹśÄ? curacy and repeatability in positioning ^ Ͳ>Ä&#x17E;ĨĆ&#x161; ^ ͲĆ&#x152;Ĺ?Ĺ?Ĺ&#x161;Ć&#x161; Ĺ?Ć?Ć&#x2030; 3LQFK UROO 'LVWULEXWLRQ 'UDZ RXW ^ Ͳ>Ä&#x17E;ĨĆ&#x161; ^ ͲĆ&#x152;Ĺ?Ĺ?Ĺ&#x161;Ć&#x161; Ĺ?Ć?Ć&#x2030; and had required freWDEOH UROOHU VROHQRLGV 6WDQG 6WDQG quent maintenance ĹśÄ? and adjustments for proper positioning.

The existing con5,2 ² 5,2 ² 5,2 ² 5,2 ² trol system for the ÍžWWĎŽ Ä&#x161;Ä&#x17E;Ć?ĹŹĆ?Íż Íž ŽŜĆ&#x161;Ć&#x152;Žů Ä&#x161;Ä&#x17E;Ć?ĹŹ Ρϭ Ͳ ΡϯͿ Íž ŽŜĆ&#x161;Ć&#x152;Žů Ä&#x161;Ä&#x17E;Ć?ĹŹ Ρϰ Ͳ ΡϾͿ Íž ŽŜĆ&#x161;Ć&#x152;Žů Ä&#x161;Ä&#x17E;Ć?ĹŹ ΡϭϏ Ͳ ΡϭϹͿ equipment was based on hardwired 2.% DCUGF NGXGN EQPĆ&#x201A;IWTCVKQP FKCITCO relay logic circuits, which are prone to failure, and a large number of power and control cables let feeding system and the mill setting ation of equipment due to hardwired running from the operator desks to mechanisms of the roughing and in- connections.

In terms of measurement and conthe control panels in the machine termediate group stands along with an hall, with the consequence of fire MIS and maintenance management trol requirements, the distribution tahazards in the congested cable galler- system. Technological considerations ble is the most complex mechanism of ies, earth faults and so on. This result- in designing the system architecture the billet feeding system. The mechaed in disruptions to the production included the following: The wire rod nism performs almost 120 operations MPT International 6 / 2014

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per hour. The travelling distance from one position to the next is very short and the movements take place at a high speed. The outdated hardwired control system comprised a CAM limit switch, used for obtaining feedback about the table reaching any of the four positions, and a slip ring AC motor for driving the table. This mechanism operates in conjunction with the AC motor-driven draw-out roller, the DC solenoid operated pinch rolls and an electromechanical DC operated brake. The desk for operating the table, draw-out roller, pinch rolls, strand bypass, other auxiliary controls for the furnace door operation, permission for billet pushing etc. was hardwired to relay panels in the machine halls. This system was completely revamped to PLC-based controls and industrially proven speed and position feedback sensors. Also a new control desk was installed.

The existing slip ring motor driving the table was replaced with a new Siemens heavy-duty squirrel cage induction motor driven by a Siemens Micromaster MM440 V/F drive. To measure the actual position of the distribution table at any point of time, an absolute encoder (make HĂźbner Giessen) with SSI interface was installed to sense the table position in real time. Speed feedback to the VFD is via a hollow incremental encoder. The VFD-PLC stations are networked via Profibus protocol. The basic equipment and power switchgear of the draw-out roller, pinch rolls and brake have been retained but the controls were switched over to the PLC, integrated with the distribution table. The billet feeding operation involves a very complex algorithm, taking into consideration the billet status in the furnace, the readiness of the billet ejector and billet pusher, readiness of downline equipment in each strand, permission for rolling as well as operator inputs. Based on this, the strand into which the billet is to be fed is automatically selected and the table accurately positioned.

The strands not ready for rolling will be automatically bypassed. All these operations are very fast owing to the high rolling speed. The logic for interlocks is implemented in the PLC and set points and commands for the drive are provided by the PLC via Profibus network.

The complete logic for the operation MPT International 6 / 2014

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of the distribution table including the calculation of the instantaneous table position, calculation of the speed set point for the motor, the logic for operation in case of a bypass of strands and other appropriate interlocks have been incorporated for highly reliable operation of the system. A drive changeover scheme has been provided in the event of failure of the primary drive to ensure highest availability of the equipment. A new operator desk with enhanced facilities for annunciation has also been installed. While for the mill setting mechanisms the reliable motors, power circuits and power cables were retained, the hardwired interlocks of the existing system were replaced with control logic via PLC. The power schemes were also improved by installing new protection devices for all the screw down and displacement motors.

Due to the critical role of the system, a reliable management information system with user friendly diagnostic facility for quick trouble shooting and on-line monitoring was implemented.

An HMI station built on a Cimplicity platform and communicating on-line with the PLC and drive system was specially designed for the purpose. Features of the system include node and equipment diagnostics, mill operation information, event alarms, historical trends for vital parameters and so on. The HMI screen provides an online overview of the billet feeding operation and a facility for centralized calibration of the distribution table.

The status of the complete integrated billet feeding process is available to monitor the inter-pulpit coordination for billet feeding. Appropriate in-

terlocks have been built into the programme to prevent wrong feeding of billets. Also the distribution table can now be easily calibrated for positioning from a centralized location. Apart from the newly designed HMI system for billet feeding and mill setting, an innovative display system commissioned earlier provides instantaneous information about all the charging, furnace and feeding equipment, the primary rolling stands and other auxiliaries. Equipment healthiness, stand overload alarms, information on rolling permission and production data are displayed in improvised mimics at strategic locations. These measures have helped to provide an efficient maintenance and operation management system, reducing downtime in this critical section of the mill.

Implementation challenges Implementing such systems successfully in an existing operational mill is not an easy task. It requires an innovative and multi-pronged approach to interface the data and to design a tailor-made control, display and reporting system. A lot of ingenious design and engineering efforts were required to achieve proper interfacing with the existing and heterogeneous field components and a successful execution and changeover. The major challenges faced during the design, implementation and changeover of the operation to the new systems included, among others, the extreme site conditions (in terms of temperature and dust) due to the proximity to the furnace. The billet feeding equipment and its electrical equipment is located directly at the

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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››› HOT ROLLING – AUTOMATION

exit of the furnace. The arduous site conditions due to the high temperatures and conductive dust necessitated a very careful selection of electronic equipment suitable for installation under such conditions (e.g. IP67 sensors and motors, temperature-resistant signal cables, FO networks). Specially designed field RIO panels (IP66) and enclosures (with cooling) were designed and fabricated for long-term sustainability.

Another challenge was the limited installation space available for the new field control equipment. The space constraints affected the design of the new motors and encoders. They required measures such as the use of hollow-type speed encoders, careful engineering in order to match the foundation of the existing motors and the brakes, retrofitting the position encoder above the existing shaft of the CAM limit switch etc.

Emphasis was placed on achieving a changeover with minimum mill downtime. The mill is a very important asset of the steel plant, which produces close to 2,000 t/day of finished steel products. A long shutdown of the shop to carry out the installation and commissioning of the new system was not acceptable. Therefore, installation and commissioning were meticulously planned. As far as the mill setting control was concerned, all changeover activities that would require a shutdown, e.g. modifications to the three operator desks, adaptation of the existing circuitry, incorporation of new protection devices and control system changeover for all 39 motors, were carried out during regular scheduled maintenance activities. The critical billet feeding control system was commissioned stage-wise in order to allow the operators to gradually familiarize with the new system. First, only the new desk and the PLC were introduced and interfaced with the existing electrics. Replacing the old PP2 control

MPT International 6 / 2014

desks with the new control desk posed a major challenge since it involved tagging all the old cables, replacing the desks, connecting new cables and reconnecting the few retained cables required for operating the mechanisms at the charging side and for existing annunciations. Finally, the challenging task of installing, testing and commissioning the new motors and encoders was carried out during capital repair shutdown of the shop.

First results after implementing the new system The new control system was fully commissioned in April 2014 and has been in continuous use ever since.

The system is expected to reduce the downtime caused by the electrical system in the area concerned by more than 50% annually. The system has also reduced the downtime in the area concerned due to operational and mechanical issues. The monthly trend after implementation of the system shows a reduction in annual controllable delays on account of electrical, mechanical and operation-related issues by 10%.

One of the prime purposes of implementing the improved billet feeding control system was to enhance the positioning accuracy of the distribution table and the repeatability of operation without frequent adjustments. To this end, extensive trials were performed and the positioning accuracy of the distribution table was measured and calculated with respect to the set value. The positioning accuracy achieved was within ± 2 mm.

Precise positioning of the distribution table prevents downtimes due to operation and equipment-related issues such as cobbles or breakage of the mechanical equipment. Further, the drive-based system has helped to optimize the billet feeding speed which in turn contributes to an enhancement

of the mill’s throughput. The system has been designed such that future expansion and modification can be easily implemented, thus providing a backbone for the future installation of an integrated automation and shopwide management information system for further improved shop productivity and performance.

Conclusion Long-product rolling mills such as the multi-strand wire rod mill at the Bhilai Steel Plant are characterized by high-speed, high-productivity operations. The billet feeding system, the roughing group and the first intermediate groups are very critical to the operation of the mill since these equipment units are common for all four strands. Therefore, 100% availability of these equipment units has to be ensured. Further, accurate positioning of the table for billet feeding is essential as any sideways deviation of the billet may result in cobbles at the mill entry and therefore stoppage of production. In wire rod mills, the control systems and their electrics are spread over a large area. A centralized control system based on a PLC and a distributed architecture based on remote I/O, as implemented in the above described project, is an important asset to improve the overall performance of the mill by reducing the mean time for repairs and extending the mean times between failures as well as improving the coordination between the various operation pulpits. Replacing the outdated combination of a CAM limit switch and a slip ring motor (but avoiding the use of costly servo-based systems) with state-of-the-art positioning and feedback systems coupled with modern AC drive technology ensures highly accurate positioning of the distribution table with excellent repeatability. The system has also enabled higher billet feeding speed, facilitating an increase in productivity.

AUTOMATION

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53

Entry section of a levelling and coating line for high-grade grain oriented silicon steel

Strip tension control technologies for continuous annealing lines This article provides a comprehensive overview of recent developments in and experiences with automation and control technologies applied in the most sophisticated FRQWLQXRXV DQQHDOLQJ OLQHV IRU PHWDO VWULSV 6SHFLĆ&#x201A;FDOO\ VWULS WHQVLRQ FRQWURO PHWKRGV applied in annealing and heat-treating lines for electrical steel and for aluminium strip in WKH DXWRPRWLYH LQGXVWU\ DUH GHVFULEHG In annealing furnaces, the accuracy of strip tension control is of paramount importance to obtain the best metallurgical and physical properties in the production of easily damageable products, such as aluminium for automotive applications, bright stainless steel and silicon steel for electrical transformers. Modern lines often treat different strip sizes with a wide range between the minimum and maximum strip dimension. This increases the need for

Enrico Dellepiane, Pierluigi Curletto, Tenova Strip Processing, Genova, Italy Contact: www.tenova.com E-mail: enrico.dellepiane@tenova.com

high-performance process control.

Tenova designed dedicated electromechanical solutions and developed specific software and control strategies to perform high-accuracy strip tension control inside the annealing furnaces.

Tight accuracy and high mechanical stability The strip tension in the annealing furnace must be maintained within a certain range from a set value, in the steady state with tolerances of about 3% and during speed transients with tolerances of 5 to 10% . To reach this accuracy, a sophisticated mechanical design is necessary, including correct machine sizing, i.e. without any oversizing, which could reduce the precision of performance in

terms of torque control. The control of the strip tension inside the furnace is important in order to avoid damage to the strip shape or the deterioration of the physical properties, above all when producing electrical steel strips.

Outside the furnace, mainly in accumulators, the strip tension must be adequately maintained at high values to ensure good strip guiding; here the tension value is higher than in the furnace.

The large tension gradient between the accumulator and the furnace sections is performed by multi-roll tension bridles; a specific software function ensures torque sharing between the various rolls perfectly adjusted to the mechanical sizing. This has the aim to keep the friction factor distribution in function of the strip tension for every roll.

MPT International 6 / 2014

54

››› AUTOMATION

At the entry side of the annealing furnace the tension closed-loop control is performed based on a strip tension value measured by load cells fixed under a tensiometer roll bearing. This instrument ensures that the necessary control is performed with the required high precision. If the tension ratio between maximum and minimum is more than 20, a special device is installed in order to activate the tension sensor within a smaller range. Setting smaller ranges achieves better accuracy.

To achieve good strip tension control inside the furnace, it is necessary to minimize uncontrolled tension variations.

The major strip tension variations are generated as a result of entry and exit section speed alterations; to minimize this disturbance, the coil changing operations must be carefully managed in order to be fast and smooth at the same time.

The looper carriage control has been designed taking into account the tensioning function, inertia, frictions between the car and the rails, and the movement of the swinging arms of horizontal accumulators. These movements are carefully measured during cold commissioning and tuned for optimum compensation during the final commissioning stage. The “soft tensioning function” is applied to all strip accumulator systems.

The bridles before and after the annealing furnace are torque controlled with a very fast speed regulator which quickly compensates possible speed pulses due to disturbances. This control strategy forms a kind of barrier between the furnace and the other line sections in order to insulate the furnace from strip tension perturbations.

Bridle torque control diagram

Entry section of a continuous annealing and surface heating line for aluminium to be used in automotive applications

Furnace tension control Two independent controls are provided at the entry and at the exit, usually with the same tension values. However, it is also possible to have a small difference to achieve the correct outgoing tension for the downstream process requirements.

This differential control is achieved by very fine tuning of the roller torque inside the furnace, compatible with the tension transfer of the roller itself. The main principles for a good tension control inside the furnace are the following: ▪ Each furnace roll is continuously and independently speed controlled through its inverter.

MPT International 6 / 2014

Furnace tension control diagram

AUTOMATION ▪ Over the entire furnace length, each roll is provided with a speed reference according to the thermal cycle of the furnace, the roll diameter and the furnace speed master.

▪ An entry bridle sets the tension at the furnace entry based on the tensiometer at the entry side of the furnace.

▪ In each roll the applied torque is set taking into account the inertia and friction, and limited to a tight range to avoid skidding between the roller and the strip and any resulting skid marks.

▪ Any difference of the strip tension at the furnace exit (measured by the relevant tensiometer) with respect to the value at the furnace entry is used to adjust the speed of the furnace rollers in order to achieve the desired strip tension at the exit of the furnace.

The furnace tension data (as recorded with the ibaAnalyzer) show the strip tension in the furnace during filling and emptying of the strip accumulator car, during the complete operation from stopping and restarting of the exit section for a coil change. The final results of the control technologies applied in this line show that the strip tension in the furnace is by no means perturbed by the exit speed variation.

During slowing down, stopping, restarting and accelerating to synchronous speed, the furnace tension is perfectly stable. The schemes and graphs show the behaviour of the inlet and outlet furnace tension during both entry and exit speed variations.

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55

We agglomerate your valuable dusts and fines

Conclusions Consumers today demand high-quality products, such as light-weight cars, low-energy devices or attractive furniture. To make these products, raw materials like delicate metal strips made of aluminium, electrical steel and bright stainless steel play an important role.

To reach the required high strip quality, a constant strip tension and speed control is necessary during the thermal treatments. During the past years, Tenova has developed specific dedicated software to comply with this goal.

The development involved very close cooperation between the mechanical and automation engineers with the aim to supply strip processing lines capable of producing high quality products on a constant basis.

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

MPT International 6 / 2014

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››› TECHNICAL INNOVATIONS

Wheel washing system in operation

Wheel washing systems and dust control ENVIRONMENTAL PROTECTION Dirty public roads and dust-contaminated air are tolerated less and less by legislators and by the public. For more than 25 years, the wheel washing systems from Frutiger have been at work in over 3,500 operations worldwide. Whenever contaminated trucks from construction sites, mines or industrial areas drive out directly onto the public roads, the systems, traded under the brand name “MobyDick” wheel washing systems, can prevent dangerous contamination from getting onto the roads and highways.

Another rapidly expanding area of application for wheel washing systems are steel plants. For this reason, in the past years, Frutiger has successfully increased production of more and more wheel washing systems for steel plants for customers including ThyssenKrupp, Tata Steel or ArcelorMittal all over the world. As an example, a few months ago, a MobyDick Quick System was installed in Port Talbot (UK).

There, the UK Environment Agency had identified significant levels of particulate matter at the site of Tata Steel, Port Talbot, which was caused by the large number of trucks moving between dirty areas and roads. The solution to this problem was to clean the trucks when they moved between different areas. To handle the large trucks and all other vehicles a special wheel washing system was needed. After an

MPT International 6 / 2014

on-site inspection, the Frutiger engineers developed and manufactured a tailored solution for the customer. In response to the difficult site conditions, a fully-galvanized, tailor-made wheel washing system with six washing pumps and over 10,000 liters of washing power per minute was needed to ultimately solve the problem. Because of the sustainable MobyDick water recycling technology, most of the wash water can be recycled through the system to be reused again and again. Since the installation, the streets and the air are much cleaner around the area, and the wheel washing system has also helped to keep the truck scales clean, resulting in lower maintenance costs.

Not only the trucks are producing dust. Handling huge amounts of slag in steel mills, pile-up the dumpsites, and the influence of local wind turbulences cause a general dust cloud above the entire plant which can become a serious environmental and political problem. Together with their Belgian partner Savic, Frutiger offers a wide range of MobyDick dust control cannons and complete dust control concepts for the steel, mining, bulk handling, recycling and construction industry, in addition to the wheel washing systems.

Contact: www.mobydick.com

TECHNICAL INNOVATIONS

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Measurement system for hot strip mills HOT ROLLING Designed for operation in harsh steel mill environments, the DigiScan XD4000 system developed by Delta measures the width of strip and plate products by stereoscopic measurements using two digital high-resolution CCD cameras. The system permits high on-line accuracy and overcomes the inherent problems due to tilting, lifting and bouncing of the strip. Wherever the self-emitted radiation of the product provides enough contrast for the width measurement, the gauge is installed above the rolls.

For installation at the coiler entry or when the rolling temperatures are below 600°C, the system can be operated in a backlight or frontlight mode. The DigiScan XD4000 width gauge sensor captures all the edge data and computes the width and centreline. This information along with other I/O and alarm data is transmitted to the PLC via Ethernet.

The highly user-friendly Delta client software provides a colour graphic display, which shows the coil number, statistical product width data and a graph of the width and centreline deviations of the product versus time.

Delta delivers the gauge systems in the calibrated condition ready to be installed. The equipment is enclosed in a compact and robust sealed aluminium housing, weighing only 44 kg and designed to resist the severe environmental conditions of hot rolling mills.

Measurements by a stereoscopic width gauge

Contact: www.deltasensor.eu

Granulation of BOF and EAF slag STEELMAKING In the Baosteel Slag Short Flow (BSSF) process, a granulation process developed by Baosteel, liquid slag is transferred to a granulation drum where it is treated with injected water with a dwell time between three and five minutes. This significantly reduces the amount of unreacted free lime. The hermetically sealed vessel and central vapour extraction system ensure that all emissions of dust and hazardous substances are avoided. The process is already in use at Baosteel and several other Chinese steel producers, the Korean Posco group and the Indian JSW company. The batch-wise operating BSSF plants have short process times and a compact design. They achieve a high level of slag and crude steel metal separation, uniform granulation and a consistently high quality in the end products.

Within the framework of a cooperation in the granulation of slag produced in BOF converters and electric arc furnaces, Siemens Metals Technologies and Baosteel Engineering & Technology will focus on the joint marketing and implementation of the Baosteel Slag Short Flow (BSSF) technology in steel mills worldwide, with the exception of China and Korea. The agreement is exclusive for its agreed term.

Siemens already offers solutions for slag granulation from pig iron production in blast furnaces.

Slag granulation at the Baosteel subsidiary Ningbo Iron &

Contact: www.siemens.com/metals

Steel (photo by courtesy of Baosteel)

MPT International 6 / 2014

58

››› TECHNICAL INNOVATIONS

Electrical power unit cuts energy use in coking plant ENVIRONMENTAL PROTECTION ArcelorMittal Bottrop in Germany has invested in an electrical power unit at its coke plant. This unit, supplied by Enva Systems and traded under the name Energy Module, partially substitutes a steam pressure reducing station and uses the resulting energy to produce electricity for the coking plant’s wash water treatment.

It has been in use since September 2013. The energy is also fed into the coking plant’s power grid and consumed by various machines, plant units and pumps. With a production of 80 kW per hour, the annual output would be sufficient to supply around 100 four-person households with electricity. Using the new electrical power unit also reduces operating costs, as it eliminates the need for steam turbines which are significantly more expensive and require more intensive maintenance. Beyond economic benefits, the optimized use of steam through the new technology also results in CO2 and primary energy savings.

Electrical power unit installation

The Energy Module technology is of compact modular design. It can be precisely tuned, both electronically and thermodynamically, to meet the requirements of a wide variety of applications. Apart from its application as a substitute for a pressure reducing station, it can also be used as a waste steam unit in front of condensers or chimneys, contributing very cost-effective power production.

Contact: www.enva-systems.de

Coil drying SURFACE COATING Very good drying of chemcoatings, pretreatment and antifingerprint coatings and a robust, low maintenance construction are just two of the features of the new generation of adphosNIR® coil coating dryers. Adphos recently supplied a dryer of this type to a customer in Oman. Before the delivery of the complete system to the customer, Adphos performed a complete check-up and near operation tests. The only measures left to be performed at the customer’s site were to properly position the unit and make the electrical connection. The adphosNIR® coil coating dryer was ready for production within one day.

Contact: www.adphos.com

Coil coating dryer

Drive solution achieving high torque capacity with small-diameter rolls HOT ROLLING As part of its plant modernization in the heavy plate mill in Linz, Austria, Voestalpine Grobblech opted for the newly developed high-performance drive from Voith. The GearLink concept, consisting of two high-performance universal joint shafts and two curvedtooth coupling shafts, was put into operation at the end of 2013. The equipment enables higher torques with smalldiameter rolls. The revamped rolling mill can now roll significantly higher-strength steel grades in widths of up to 4.2 m. Based on a minimum roller diameter of 980 mm, each of the two main drive shafts transmits torques of 7,500 kNm. In contrast to conventional slipper spindles, modern uniMPT International 6 / 2014

Gear solution for high torque transmissions

NEW COURSE: versal joints minimize play in the drive. Power loss as a result of friction and the environmental impact of lubricants are also minimized.

The development of the new GearLink concept is the result of close collaboration between the rolling mill operator Voestalpine Grobblech, Voith and Buma Engineering. In the rolling mill of Voestalpine, universal joints with a rotational diameter of 1,300 mm are used. The fully forged universal joint shafts are all of different lengths, which results in the shafts being offset on the roll side.

This means that shafts of equal size can also be used on the roll side regardless of the roll diameter of 980 mm. The GearLink element (a curved-tooth coupling shaft) guarantees the connection between the offset shafts and the coupling sleeves. This reduces the load of bending moments on the roll journals to the greatest extent possible and allows axial CVC (continuous variable crown) displacement of the roll. The coupling shaft also provides an axial emergency outlet in case of a roll fracture.

Contact: www.voith.com · www.buma.at

High-capacity slag grinding plant MATERIALS PROCESSING In March 2014, Shanxi Taigang Stainless Steel in Taiyuan, China, commissioned a blast furnace slag granulation plant. The plant was supplied by Loesche. It is a vertical mill of the LM 63.3+3 type, driven by a motor with an output of 7,400 kW and designed for slag granulation rates of up to 255 t/h at a fineness of 4400 Blaine. Loesche’s 2 + 2 / 3 + 3 system provides high grinding bed stability and highly efficient crushing as a result of improved internal friction of the grinding stock on the table.

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Contact:www.loesche.com Metallurgy )RXQGU\ 0DFKLQHU\ 0HWDOOXUJLFDO 3ODQWV DQG 5ROOLQJ 0LOOV 7KHUPR 3URFHVV 7HFKQRORJ\

European Metallurgical Equipment Association

IN CO-OPERATION WITH:

Plant for the granulation of blast furnace slag

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Phone +49 (0) 2 11/45 60-77 93/-77 07 Fax +49 (0) 2 11/45 60-77 40 RyfischD@messe-duesseldorf.de BurbullaK@messe-duesseldorf.de

www.messe-duesseldorf.de

60

››› TECHNICAL INNOVATIONS

Non-contact thermometers with highDEÖBHDMBX QNTSD L@M@FDQ MEASURING EQUIPMENT A high-efficiency route manager and new protections against accidental damage have been added to the Cyclops line of portable non-contact thermometers offered by Ametek Land. The new Cyclops L family includes four models measuring across a range from 200°C to 3,000°C. They are aimed at a wide range of applications including liquid metal, steel and glass production, and furnaces.

The route manager for efficient use in multiple locations requiring regular, reliable monitoring enables users to identify each location with a description, an emissivity value, a window correction factor (if applicable) and a unique identifier. This mode allows for complete repeatability of readings, making the thermometer an ideal tool for multiple locations requiring regular and reliable monitoring.

The thermometer stores up to 9,999 temperature measurements. All can be downloaded to an optional logger to capture, view and record live temperature readings for further analysis and comparison. The thermometers have precise, narrow field of view and continuously focusable optics with through-the-lens sighting for accurate sample point selection. Long-term, drift-free measurement with available UKAS calibration to the highest international standards assures confidence in the readings. A new industrial

rubber casing cover and lens hood provide additional damage protection. The thermometer software allows users to connect via Bluetooth to a mobile device or personal computer to view, analyze and record live temperature readings.

Contact: www.landinst.com

Thermometer models suitable for applications in the steel industry

GBS sensor with SSI interface MEASURING EQUIPMENT Users of the new magnetostrictive Temposonics® GBS sensor from MTS Sensors can now select between SSI and analogue output. The newly available SSI interface is distinguished by reliability and signal robustness in industrial environments. In addition, the Temposonics® sensor provides reliable and accurate signals even at operating temperatures of up to 100°C. With the SSI interface the GBS magnetostrictive position sensor obtains another customary output and allows a resolution of up to 5 μm. The programming software allows the user to set and adjust for example a synchronous or asynchronous measurement mode, the measuring direction, the coding and the data length. The rod-shaped sensor is not only programmable using the hand-programmer unit, or via USB port using the computer. It is also suitable for wireless configuration via Bluetooth. This feature facilitates start-up and maintenance. The sensor is pressure-resistant and has a flat and compact electronic housing.

MPT International 6 / 2014

Therefore it can be easily installed under restricted space conditions. The sensor is available with a measuring length between 25 and 3,250 mm. It offers an ingress protection mode IP67 with adapted connector or protection to IP68 for models with cable output.

Contact: www.mtssensors.com

Position sensor

TECHNICAL INNOVATIONS

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61

Synthetic oils for air compressors LUBRICANTS Designed to enhance performance and durability of rotary-screw and vane air compressors, the synthetic oils of the Mobil SHC™ Rarus Series introduced by ExxonMobil help increase the productivity and durability of rotary-screw and vane compressed air systems. During extensive laboratory and real-world testing, these oils demonstrated the ability to deliver very good protection against wear, rust and corrosion, even under extended drain interval periods. The benefits for the companies include reduced oil usage and disposal costs. In addition, testing results showed how Mobil SHC Rarus Series oils can maintain compressor cleanliness during the long haul by helping to minimize sludge, varnish and deposit formation, which can occur when compressors operate in extreme load and temperature conditions. Mobil SHC Rarus Series is available in three viscosity grades: 32, 46 and 68.

Contact: www.mobilindustrial.com

Lubrication of rotary screws

© Utz Peter Greis, Düsseldorf

Cartoon

Enterprises are often compared to ships sailing on the high sea. In that sense, plant engineering companies are currently in an economic lull.

MPT International 6 / 2014

62

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

Pan conveyor for transport of hot sinter material SINTER MAKING At Tata Steel IJmuiden in the Netherlands, a second vibrating feeder line for hot sinter transport will be replaced by metallic plate conveyors from Aumund.

The type KZB-S 1500/25 pan conveyor will transport up to 140 t/h of hot sinter material from the sintering furnace to the circularly arranged coolers. Wear on metallic plate conveyors is significantly lower than on vibrating feeders. Pan conveyors also have a positive effect on the quality of the sinter. As there is no vibration, the amount of fines and cracks in the sinter material is markedly reduced. The material has better cooling properties and the improved air flow in the burden improves the blast furnace process.

At the Dutch steel plant, the space available for the installation of the new conveyor poses a challenge, due to the fact that only a very small opening is available on the platform. The entire conveyor has been fitted into a torsion-resistant frame. This frame can be divided into five sections. Each of these sections can now be threaded through the opening provided. This installation approach had already proved successful during the

installation of the first conveyor. Delivery of the second conveyor is scheduled for December 2014. Start of operation is expected for the first quarter of 2015 after completion of the entire conversion activities.

Contact: www.aumund.com

The compact design allows the conveyor to be transported as C YJQNG QP C Ć&#x192;CV DGF VTWEM

Horizontal forging machine FORGING A new horizontal forging machine used for the preforming of parts has been developed by SMS Meer.

The forging machine (SMI 430/8 MN) is a special type of the companyâ&#x20AC;&#x2122;s SMX radial forging machine. With the aid of forming tools, a defined mass distribution is generated in the forgings which will subsequently be processed in closed-die forging machines. A special feature of the horizontal machine is the integrated die shifting device. As a

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

+49 211 69936-200, Fax +49 211 69936 -128 e-mail mpt@stahleisen.de Publisher: Steel Institute VDEh Executive Member of the Management Board: Dr.-Ing. Peter Dahlmann Editorial Staff: P.O. Box 10 51 64, 40042 DĂźsseldorf, Germany e-mail mpt@stahleisen.de Chief Editor: Dipl.-Ing. Arnt Hannewald

+49 211 69936 -120 Assistant Editor: Edith Mielke

+49 211 69936 -121

MPT International 6 / 2014

result, a second die can be quickly used within one forging process. This solution minimizes set-up times and increases the output.

The first machine of this type is in operation in Japan. It is equipped with two forging manipulators and an additional manipulator for fully automatic loading and unloading.

Contact: www.sms-meer.com

Publishing Staff: Managing Directors: JĂźrgen Beckers, Arnt Hannewald Advertising Manager: Sigrid Klinge

+49 211 69936-125, Fax +49 211 69936 -129 e-mail sigrid.klinge@stahleisen.de Distribution Dept.: Gabriele Wald

+49 211 69936-260, Fax +49 211 69936-262 e-mail gabriele.wald@stahleisen.de Production Manager: Burkhard Starkulla e-mail burkhard.starkulla@stahleisen.de Production/Layout: Mike Reschke e-mail mike.reschke@stahleisen.de Advertising rate card No. 37 of 01.01.2014 Publication: Every 2 months Annual subscription rate (incl. postage): Germany: â&#x201A;Ź 199.00 incl. 7% VAT Member states of the EU: subscribers with VAT ID number â&#x201A;Ź 185.98; subscribers without VAT ID number â&#x201A;Ź 199.00 Other countries: â&#x201A;Ź 199.00 Single copy: â&#x201A;Ź 38.00 Minimum subscription period 12 months.

Termination of subscriptions can only be made from 31st December and notice of termination must be received by the Publishers by 15th November. Otherwise, the subscription is automatically renewed and payable for a further 12 months.

Š 2014 Verlag Stahleisen GmbH, Dßsseldorf This journal and all articles and illustrations contained in it are protected by copyright.

With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems.

Upon acceptance for publication, the author agrees to grant, transfer and assign to the pub-lisher all exclusive rights to publish the work during the lifetime of the copyright.

In particular, the publisher will have full authority and power to reproduce the work for commercial purposes in copies of any form (microfilm, photocopy, CD-ROM, or other means) and/or to store the work in electronic or other databases.

Certification of circulation by the German Audit Bureau of Circulation (IVW) Permit number: 011-224, ISSN 0935-7254

Printed by: Kraft Druck GmbH Industriestr. 5â&#x20AC;&#x201C;9, 76275 Ettlingen, Germany Printed on paper bleached totally chlorine-free (TCF) using heavy metal-free printing ink.

LITERATURE SERVICE

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63

Industrial sludge treatment and dewatering 6 pages, English

We filter for you!

In this brochure, Filtratec describes its products, services and expertise in the field of sludge dewatering and oil sludge separation for industrial companies. Products include mobile and stationary plants for a wide range of treatments, including separation with three-phase decanters. > FILTRATEC Specialist for industrial sludge treatment and dewatering

Contact: E-mail:

www.filtratec.com info.filtratec@filtratec.com

filtratec.com

4GHTCEVQTKGU CPF ECUVKPI ƃWZGU 12 pages, English A brochure describing the company history and the product and service range of Intocast, suppliers of refractories, casting powders and slag formers. Services include the assessment of wear profiles, tailor-made solutions and general consultations, installation, provision of machinery and logistics, etc.

Contact: E-mail:

Broad Base. Best Solutions.

www.intocast.de sales@intocast.de

Graphite electrodes 20 pages, English, Chinese

graphite electrodes

Ultra-HighPerformance Graphite Electrodes

A comprehensive brochure outlining the expertise of SGL Carbon as a producer of graphite electrodes. It provides detailed information on graphite electrodes in steel and non-steel applications and gives performance data of electrodes and connecting pins. A major part of the brochure is dedicated to the services rendered by the company.

Contact: E-mail:

www.sglgroup.com/graphiteelectrodes info-ge@sglgroup.de

Refractory systems 20 pages, English, German This brochure outlines the range of refractory solutions provided by Steuler-KCH. It includes examples of refractory systems for blast furnaces, direct reduction furnaces, non-ferrous metallurgy, waste gas and waste water incinerators, etc. Also roof and wall constructions with ceramic anchoring systems are described.

Contact: E-mail:

www.steuler-kch.de info@steuler-kch.de

Equalizing and relief valve 4 pages, English A product brochure highlighting the features of the enhanced design of Paul Wurth’s equalizing and relief valve for blast furnaces. In addition to a description of the benefits of the new design, a cutaway illustration shows the key components of the equipment.

Contact: E-mail:

www.paulwurth.com paulwurth@paulwurth.com

MPT International 6 / 2014

QUALITY PRODUCT

ENDLESS INNOVATION

TECHNICAL ADVANTAGES

LOW MAINTENANCE

ECONOMIC BENEFITS

Danieli Automation MV and LV drives are designed and realized for demanding rolling mill applications, with focus on high ï¬&#x201A;exibility and operability. QDRIVE is the perfect choice as AC/DC converters and multi-drive DC link inverters arrangement.

The design of power modules, realized with wheeled frames, allows a fast and easy maintenance.

We know how.

info@dca.it - www.dca.it

QDrive