Metallurgical Plant and Technology G 25074
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ISSN 0935-7254
USA’s most recent steelworks, Big River Steel, to be built in Osceola, Arkansas
February 2015
Joint venture of Mitsubishi Heavy Industries and Siemens starts operations
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
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EDITORIAL
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New initiatives in plant making Big investments in the construction of complete new steel mills have been rare for quite some time. Currently, most steel producers are rather cautious about investing in new production capacities. Contrary to this trend, Big River Steel – a new electric steel mill with a future production capacity of 1.5 million t per year (even to be doubled in later stages) – is being established in the Midwest of the United States. The project includes production lines for liquid steel and hot rolled coils. Also a cold rolling mill will be immediately set up. The plants will be designed for the production of most advanced steel grades. Initiator of this greenfield project is John Correnti, a prominent American entrepreneur, who has been instrumental in the success of Nucor and, only a few years ago, built the steelworks in Columbus, Mississippi, (formerly Severstal NA) which today belongs to Steel Dynamics, Inc. The Big River Steel project is not beyond dispute in the USA. From the outset, it has been subject of controversial discussion in the media. John Correnti has once again succeeded in attracting investors to establish a steel complex using the latest of technology and equipment at a very apt location. In this issue of MPT International, we are presenting first details about the technological concept of this steel mill. Further articles focusing on key areas of the works will follow in subsequent issues. We will keep you updated on the progress of this project.
Dipl.-Ing. Arnt Hannewald
A second highlight in this issue is the presentation of a new star in the plant making firmament. “Primetals Technologies” is a new name which from now on will be naturally mentioned in the context of plant engineering, technologies and services for the production of iron and steel and NF metals. As announced last year, Primetals Technologies is the joint venture company established by Mitsubshi Heavy Industries and Siemens. Siemens contributed its metals sector (Siemens VAI) to the JV. The new company with the fine-sounding name has around 9,000 employees in more than 40 locations worldwide. In this issue, we present the company and its managing board, and some of the technical articles will show that the JV between Siemens and MHI definitely ranks among the “big three” in metals technology.
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››› CONTENTS
International industry news 20 SMS group inaugurated new manufacturing and service workshop in Bhubaneswar, India The new manufacturing and service workshop is one of four locations operated by SMS India
Company profile 22 Joint venture of Mitsubishi Heavy Industries and Siemens starts operations Headquartered in London, Primetals Technologies commences operations
24 G roundbreaking for a new generation of steelworks to be initially built in Arkansas, USA
Coverphoto: USA’s most recent steelworks, Big River Steel, to be built in Osceola, Arkansas SMS group, Düsseldorf, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com
The Mississippi river provided the inspiration for the name of the USA’s most recent and one of the country’s cleanest steelworks, Big River Steel
Steelmaking
Environmental protection
30 Reconditioning of monolithically lined ladles in steel plants
32 Variable management technology of electrostatic precipitators in steel plants
The new vertical ladle milling unit MLC 2011 simplifies the reconditioning of monolithically lined steel ladles, while cutting costs for refractory and waste disposal. The automatic process reduces personnel requirements to a minimum. The automatic milling operation takes approximately one hour.
Operational costs of electrostatic precipitators in steel mills can be reduced using a sophisticated management system
34 Advanced design of water treatment plant with “zero liquid discharge” recovery system This article shows how to achieve an optimal management of the water cycle by reducing or even zeroing primary water needs through the reuse of treated waste water
Heat treatment
Hot rolling
40 W orld’s first application of new in-line rail hardening goes commercial at Baotou
42 New side guide system extends service life by up to ten times
The “Injector Dual-phase Rail Hardening” system enables long hardened rails up to over 100 m length to be in-line processed for improved resistance to contact fatigue and wear
The Eco Slide Disc system is significantly reducing maintenance costs in the down coiler area of hot strip mills. Replacement of wear plates can be avoided during mill operation. Thanks to improved strip guidance, surface defects caused by the down coiler entry guides are eliminated.
Strip processing 44 Strip cutting and welding using solid-state laser technology During the last few years, eight solid-state laser welders manufactured by Primetals Technologies have been implemented in strip processing lines. Now, after more than one year of industrial feedback, the results show that the welders perform very well MPT International 1 / 2015
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42 34 44 20
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Columns 8
International industry news
54 Literature service
50 Technical innovations
56 In the next issue
53 Cartoon
56 Imprint
Advertisers’ index ABB AB 33 Association for Iron & Steel Technology 52 Danieli S. P. A. 6, 7 Fabris InC. 43 FC Technik AG 18 Fontaine Engineering und Maschinen GmbH 41 hpl-Neugnadenfelder Maschinenfabrik GmbH 16
IMI Z & J Germany 37, 38 IMS Messsysteme GmbH 47, 48 JATO-Düsenbau AG 13 LAP GmbH 50 Messe Düsseldorf GmbH 19 Morgardshammar AB 15 MTS Sensor Technologie GmbH & Co. KG 29 Plakoma GmbH 58 Primetals Technologies Austria GmbH 9
Schenck Process GmbH 23 Schuh Anlagentechnik GmbH 51 Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG 27 SMS Siemag AG 2 STEIN INJECTION TECHNOLOGY GmbH 31 TML Technik GmbH 17 Verlag Stahleisen GmbH 57 PAUL WURTH S. A. 11, 12
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Pagine 2013 A3 esecutivi 2013_08_08_qxd8_A3 esecutivi 20/01/15 14.31 Pagina 18
Featuring PSP-Profile Sizing Process (a 3-stand UFR pre-finishing reversing mill plus a separate finishing/sizing stand) and patented RH2 in-line Rail Head-Hardening process, Danieli mills achieve top-quality and high-production.
Four latest references out of total 35 ARCELORMITTAL LUXEMBOURG 2007: “Grey-mill� major modernization, enhancing plant operation, efficiency and final product quality for jumbo beams up to 1,000 kg/m.
Long product rolling mills
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MECHEL CHELYABINSK RUSSIA 2011: 1.1 Mtpy medium-section mill for rails, beams and special profiles. Featuring patented Rail Head Hardening RH2, the plant will be the new world technological benchmark.
Danieli Headquarters 33042 Buttrio (Udine) Italy Tel (39) 0432.1958111
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DANIELI MORGÃ…RDSHAMMAR RAIL AND HEAVY SECTION MILLS TO ROLL DOWN TO 1/2 DIN TOLERANCES AND HIGH SURFACE QUALITY PRODUCTS
EMIRATES STEEL UAE 2012: 1.0 Mtpy heavy section mill for beams up to 1,000 mm wide and king-size sheet piles (part of DRI-based minimill #2).
1914 / 2014 DANIELI CENTURY
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VOESTALPINE SCHIENEN AUSTRIA 2006: After a very fast start-up the new universal mill produces all kinds of rails, such as Vignol rails, grooved rails, crane rails, and other special sections rolled in 125-m lengths.
DANIELI THE RELIABLE INNOVATIVE PARTNER TO BE FRONT RUNNERS
www.danieli.com
04.02.15 17:12
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››› INTERNATIONAL INDUSTRY NEWS
Africa Algeria Altumet orders pipe end finishing machine. Altumet SPA has ordered a pipe end finishing machine from PWS. The new machine will be integrated into the existing line at the company’s Algiers site. It will finish up to 20 pipe ends per hour in three-shift operation. The diameters of the finished pipes range from 8” to 42”, with wall thicknesses from 5 to 20 mm and pipe lengths between 5 and 13 m. The finished pipes of grades up to X80 will conform to API 5L certification. Commissioning of the machine is scheduled for the third quarter of 2015.
Botswana BCL to modernize nickel smelter. Outotec has been awarded a contract by BCL for modernizing the nickel flash smelting furnace in Selebi Phikwe. BCL’s nickel smelter was originally built in the 1970s using Outotec® flash smelting technology. Outotec’s modernization work now includes the redesign of the flash smelting furnace, delivery of new advanced cooling elements and their integrating into the furnace. A 36-month service agreement covers the supervision of installation and commissioning, preventive maintenance planning, equipment maintenance and spare parts.
The Americas Brazil CBMM orders submerged arc furnace. CBMM (Companhia Brasileira de Metalurgia e Mineração) has placed an order with SMS Siemag for the supply of a submerged arc furnace (SAF) to increase the production capacity at its Araxá plant. SMS Siemag’s scope of supply includes the engineering and the supply of a submerged arc furnace, a 15 MVA transformer, a gas cleaning system, a water quench facility as well
as a reactive-power compensation system. The new furnace will produce refined niobium concentrate, which will be further processed into ferroniobium (FeNb) and niobium oxides. Commissioning of the furnace is scheduled for the end of 2016/beginning of 2017.
Venezuela Siderúrgica Nacional starts second construction stage. SMS Siemag has been awarded an order for the supply of plants for the second construction stage of the new integrated steel making and processing complex of Siderúrgica Nacional (SN) in Venezuela. The scope of supply comprises a ladle degassing plant and a twin-stand Steckel mill for the production of hot strip. The first stage of the works complex, which is currently under construction, comprises an electric steelmaking plant, a continuous caster and a heavy-plate mill. In its final construction stage, the works, located in Ciudad Piar in the federal state of Bolivar, will have an annual capacity of 1.55 million t. It will produce heavy plate and hot strip for the local industry. The new 200 t X-eed® vacuum degassing plant to be supplied by SMS Mevac will complete the X-Melt® electric steelmaking plant. In the final construction stage, the ladle degassing plant will have two treatment stands. The twin-stand Steckel mill will be designed for the production of 844,000 t/ year of hot strip with a maximum strip width of 1,880 mm. The core equipment of the Steckel mill will consist of two identical four-high stands in tandem arrangement. It will roll out the transfer bars arriving from the heavyplate mill to final thicknesses between 1.5 and 18 mm. SMS Siemag is also supplying the complete electrical and automation package for the plants of the second construction stage.
Asia China Anhui Masteel orders continuous galvanizing line. CMI Industry Metals will supply a continuous galva-
nizing line to Anhui Masteel Engineering & Technology Group (Masteel). The new galvanizing line will process strip thicknesses ranging from 0.25 to 2.0 mm, and widths up to 1,430 mm. The material grades will range from deep-drawing steels, hot-formed and high-strength steels to dual-phase steels. Besides traditional GI coating, the new line will be designed to optionally also process aluminized (AlSi) coatings. The line comprises a multi-stage cleaning section, vertical annealing furnace, air-knife system, low-vibration cooling system, inline skin-pass mill and tension leveller, chemical post-treatment, side trimmer and exit shear. The project is scheduled to be completed by the end of 2016.
China Handan to modernize automation of hot rolling mill. Handan Iron & Steel has placed an order with Primetals Technologies to modernize the process automation system of the hot rolling mill at its Handan factory. The core items of the new process automation are a profile and flatness control system as well as a new cooling solution package. The hot rolling mill produces hot strip with a width of up to 1,680 mm. The annual capacity amounts to 2.5 million t/year of high-grade steel for use in the automotive industry, in shipbuilding and pipeline construction, as well as corrosion-resistant structural steels and deep-drawn steels. Primetals Technologies will modernize the process automation system, supply hardware and software and handle the project planning, programming and commissioning. To avoid unnecessary plant downtimes and the resulting production shortfalls, the new hardware and software will be installed in parallel with existing systems, initially run in the “shadow mode” and finally switched over to productive operation with the aid of a switch-over unit. The project is scheduled for completion at the beginning of 2016.
Taiwan Wei Chih to modernize bar mill. Primetals Technologies has received
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AS ONE We are stronger
Two powerful companies in the metals industry have forged together. Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies have united to become the new global force in metals technologies. Creating the future of metals as one.
primetals.com
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an order from Wei Chih Steel Industry to modernize the company’s bar mill in Tainan. This will enable Wei Chih to produce not only rounds with dia meters up to 100 mm but also flat and square bars. Modernization work is scheduled to be completed by the middle of 2015. Primetals Technologies will supply the process equipment for the modernization project and assist Wei Chih with the engineering of the items Wei Chih will provide. The entry into the cooling bed will be equipped with braking slides with special plating to substantially reduce the risk of scratching the surface of the newly rolled bars. The cooling bed itself will receive a new rake system to handle the different geometries of the end products newly added to the range. Primetals Technologies will also install an abrasive saw to cut the bars to length and provide the bar bundling and handling machines with equipment designed to handle the new bar dimensions.
Europe Bosnia and Herzegovina ArcelorMittal Zenica to build dedusting system for BOF. ArcelorMittal Zenica will install new dust filters in its basic oxygen steel plant. Using “best available techniques”, the BOF’s secondary dedusting system is the latest in a series of technical investments aimed at reducing the ecological impact of the plant, which was restarted in 2008 following almost two de cades of disuse after the conflict of the 1990s. Work on the new filters is expected to be completed by early 2016. More than 95% of fumes from production operations will be captured and cleaned in the bag filter, which will result in dust emissions below 10 mg/m3 (stp).
Finland Outokumpu invests in mercury cleaning equipment. Outokumpu will invest in mercury cleaning technology to be installed at its Tornio plant. Mercury is a foreign matter in
stainless steel production. Although Outokumpu does not use any mercury in its stainless steel production, small amounts may sometimes be present in recycled steel. Outokumpu decided to purchase the mercury cleaning equipment following intensive tests in the Tornio melt shop, during which the process proved to be effective and safe.
Finland Steelmakers invest in liquefied natural gas project. Manga LNG Oy, a joint venture of Outokumpu Group, SSAB, Skangass and EPV Energy, will build and operate a liquefied natural gas (LNG) terminal at Tornio harbour and procure LNG for its owners. Outokumpu and its stainless steel mill in Tornio will be the main user of the natural gas imported through the terminal. Replacing the use of propane with liquefied natural gas sourced directly from the global market will reduce production cost through lower and more stable energy prices. SSAB will make use of liquefied natural gas at its site in Raahe, replacing liquefied petroleum gas in the walking beam furnace in the strip mill and using LNG as a support fuel in the boiler of the new power plant. The use of liquefied natural gas will positively contribute to a decrease in particulate, NOx, SOx and carbon dioxide emissions.
France ArcelorMittal to invest in Bourgen-Bresse plant. ArcelorMittal will invest a major sum to expand the production capacity of its plant at Bourg-enBresse and support the development of its customer Technip, a company active in project management, engineering and construction for the energy industry. In September 2013, ArcelorMittal was chosen by Technip to supply high-performance, high-strength steels used in the manufacture of flexible pipes for the development of deepwater and ultra-deepwater oil and gas fields, particularly at depths in excess of 1,500 m. The five-year partnership agreement between ArcelorMittal and Technip has recently been extended by two years. Arce-
lorMittal Bourg-en-Bresse supplies steel for Technip’s flexible pipe manufacturing plants located in France, Brazil and Malaysia. In 2015, the Bourg-en-Bresse plant will be equipped with a new heat treatment furnace and a new rolling mill. The commercial contract comes with a research and innovation contract, which will strengthen technological progress at Bourg-en-Bresse. The plant is currently developing new wire solutions tailored to Technip’s requirements.
Germany DEW to install casting platform robot. Deutsche Edelstahlwerke, which is part of the Schmolz + Bickenbach group, has awarded Primetals Technologies an order to supply a LiquiRob casting platform robot for its Siegen plant. The robot will be installed on the continuous billet caster to handle the firing of the ladles. Until now this has been performed manually. The use of the robot will make casting operations significantly safer, since it will no longer be necessary to enter this hazardous area. Currently, six such robot systems are working in continuous casting plants around the world, plus one on an electric arc furnace and another on a converter.
Germany ESF uses ORC-based heat recovery system. Turboden is a manufacturer of organic rankine cycle (ORC) turbo-generators for distributed power generation employing renewable sources and waste heat. At ESF (Elbe-Stahlwerke Feralpi) in Riesa, the company, a group member of Mitsu bishi Heavy Industries (MHI), implemented for the first time in the world an ORC-based heat recovery plant on an electric arc furnace. The new 3 MW electrical output ORC unit exploits a portion of the saturated steam produced and recovers heat from the exhaust gases downstream an electric arc furnace. The recovered energy reduces net power consumption, allowing significant CO2 reduction. In addition to electricity production, the remaining portion of the steam is fed into the municipal steam supply system.
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BF Technology & Equipment cooling & lining concepts and systems, automation, top charging technology, special equipment.
Auxiliary Plants sintering plants, hot blast stoves, stockhouse, pulverized coal injection, slag granulation and dewatering.
Coke Making Plants complete plants and batteries, coke oven gas by-products recovery systems and auxiliary plants, centralised supervision and process control.
Direct Reduction Plants engineering & construction of Midrex® Direct Reduction Plants.
Recycling Technologies multiple hearth based technology: PRIMUS®, rotary hearth based technology: RedIron™, RedSmelt™.
Environmental Protection BF top gas cleaning, aspiration systems, hot blast stove heat recovery, coke oven gas treatment, sinterplant off-gas cleaning.
Paul Wurth S.A. 32, rue d’Alsace Tel. +352 4970-1 L-1122 Luxembourg paulwurth@paulwurth.com
Paul Wurth, the Paul Wurth Logo, PRIMUS, RedIron and RedSmelt are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction. Midrex is a registered trademark of Kobe Steel, Ltd and used under licence.
Blast Furnace Plants engineering & construction of complete blast furnace plants, modernisations, rebuilds and relines.
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verso
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INTERNATIONAL INDUSTRY NEWS
Germany
Russia
ThyssenKrupp Rasselstein to modernize continuous annealing line. Andritz has received an order from ThyssenKrupp Rasselstein to modernize continuous annealing line No. 4 at the Andernach plant, which makes carbon steel products for packaging applications. The scope of supply by Andritz Metals comprises an electrical package, including drive and automation technology, instrumentation, measured value logging, comprehensive safety features and equipment, as well as modifications and extensions to the mechanical and hydraulic equipment. The plant speed will be increased and terminal equipment optimized. The line is to resume operation at the end of 2015.
Trubodetal to build new seamless pipe complex. Trubodetal, a subsidiary company of OMK, has placed an order with Danieli for an integrated pipe complex. The new plant, with a designed annual capacity of 500,000 t/year, will be built and operated on the premises of the former Chusovoy steel works in Chusovoy, Perm region. It will produce high-quality seamless tubes according to international API and Gost standards. The production range will include tubes with diameters between 73 and 245 mm and a wall thickness range from 4 to 35 mm. Friedrich Kocks will be responsible for the process, design, supply and commissioning of the extracting block (EXB) and the stretch reducing block SRB®, as essential components of the continuous hot rolling mill. These rolling blocks will provide for operation with both non-adjustable and adjustable three-roll stands. The SRB® will be designed for a concurrent operation with two different roll stand sizes. The stands of the EXB are interchangeable with the corresponding SRB® stands.
Italy ABS installs EAF off-gas analysis system. Acciaierie Bertoli Safau (ABS) has installed a LindarcTM real-t ime laser off-gas analysis system on its 100 t AC electric arc furnace. Since 2007, the AC furnace has been equipped with a More chemical energy package, comprising burners, oxygen, carbon and lime injection systems. In order to improve the efficiency of post-combustion, optimize the melting process and have a reliable and accurate detection system for any water leakages inside the shell, ABS awarded More and Danieli the order to supply an off-gas analysis system. With lasers installed on the movable duct right behind the roof elbow, the LindarcTM system uses tunable diode laser absorption spectroscopy (TDLAS) to perform real-time measurements of the furnace off-gas atmosphere, tracking CO, CO2, H 2O and the off-gas temperature. Real-time water gas concentration tracking is processed by a smart and self-learning adaptive detection system which warns the operator in case of undesirable and harmful water leaks in the furnace. Danieli Automation has integrated a self-learning, intelligent process supervisor with adaptive optimizer into the system.
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Turkey Asil Çelik orders reducing & sizing block. Asil Çelik placed an order for a major revamp of its medium section mill with an international consortium made up by Danieli, Fematek and Friedrich Kocks. In this consortium, Kocks is responsible for the supply of a heavy-duty reducing & sizing block RSB®. The 3-roll block will be implemented in the 400,000 t/year medium section mill behind the roughing and intermediate mill consisting of 18 HV 2-high stands. It will finish roll the total straight bar production in the range from 19 to 100 mm dia meter round and from18 to 80 mm hexagon onto the cooling bed in SBQ quality. The RSB® allows rolling to be performed out of only one pass series in the roughing and intermediate mill, significantly reducing the number of required feeders. Any desired finished dimension of the whole dimensional range can be produced in any desired sequence with a small number of roll sets and just a few stand changes. MPT International 1 / 2015
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Companies SGL continues streamlining of organization. As part of its cost savings programme, SGL group has reduced its five business units to three. The restructuring is intended to create further synergies and to streamline the organization and business processes within the business units. The two separate business units Graphite & Carbon Electrodes (GCE) and Cathodes & Furnace Linings (CFL) have been combined to form the business unit Performance Products (PP). The business units Graphite Specialties (GS) and Process Technology (PT) have been merged to create the business unit Graphite Materials & Systems (GMS). The business unit Carbon Fibers & Composite Materials (CF/CM) has remained unchanged.
PSI takes over Broner Metals Solutions. PSI has acquired 100% of the shares of Broner Metals Solutions. Broner Metals is a leading provider of IT solutions in the field of production planning and control, supply chain management and MES for the steel and aluminium industries. Together, PSI and Broner Metals have more than 350 experts for the global support of the production processes for the metals industry. The Watford site near London will be expanded as project and product development site. In addition, it will be expanded as the sales and service base for the British market for a number of PSI business units. The existing product lines and service agreements will be continued. In the midterm PSImetals will be supplemented by additional unique selling propositions from the Broner software.
EID comment on action plans climate protection and energy efficiency. The Energy-Intensive Industries in Germany (EID), a joint platform of six energy-intensive sectors, among others represented by the German Steel Federation and the German Non-Ferrous Metals Association, see light and shadow in the German federal government’s decisions on achieving the en-
ergy efficiency and climate targets. A positive aspect is that the plans focus on those potentials which are not covered by emission trading. But the EID criticize that the decisions also impact sectors which already fall under European regulation on emission trading. According to the EID spokesman Utz Tillmann, the national measures in these sectors bring no additional benefit for the climate. With further rising electricity prices, the EID sectors fear for their international competitiveness. The EID are largely positive about the measures under the National Action Plan Energy Efficiency (NAPE). In particular, it is appreciated that the NAPE bets on financial incentives and voluntary steps.
Voss Edelstahl relocates from Essen to Düsseldorf. The newly founded RHB Voss GmbH Röhrenhandel Böntgen, a wholly owned subsidiary of Voss Edelstahlhandel, has taken over the premises of former Heinen & Böntgen Röhrenkontor in Düsseldorf-Heerdt. The location in Essen did not allow any further expansion. The premises of former Heinen & Böntgen in Düsseldorf do not only provide the necessary space. Also the warehouse with its high-bay racks forms an ideal complement to the warehouse facilities of the other locations of Voss group Europe. The new facility adds some 17,000 m² storage space, thereof 9,000 m² roofed.
Andritz acquires Herr-Voss Stamco. Andritz has acquired HerrVoss Stamco, headquartered in Callery, Pennsylvania, USA, enlarging its service and product offerings for North American customers in the metals sector. Andritz Herr-Voss Stamco generates a major portion of its sales with service business. In addition to a very comprehensive service portfolio, the company is one of the leading suppliers of coil and sheet metal processing solutions for both ferrous and non-ferrous applications worldwide.
Küttner signs basic cooperation agreement with JP Steel Plan tech. Küttner, Germany, has signed
a basic cooperation agreement with JP Steel Plantech, Japan. Through this agreement, the two companies intend to strengthen the mutual broad cooperation relating to iron and steel technology and their overseas activities.
Paul Wurth and SAB set up valve competence centre. Paul Wurth, technology provider for the primary stage of integrated steelmaking, and SAB, an engineering and manufacturing company particularly specialized in blast furnace mechanical components, have joined forces by creating a Luxembourg-based competence centre for all types of special valves related to the blast furnace, such as stoves valves, goggle valves, equalizing valves and bleeder valves. Additionally, the portfolio will include blast furnace tuyere stocks of advanced design. The activities of VCL Valve Competence Luxembourg cover engineering, manufacturing, assembly and commissioning with a strong focus on all related after-sales and repair services. The joint business is limited to the European territory.
NLMK-TV recognized as best electronic corporate media. The NLMK group’s media project – NLMKTV corporate television – was recognized as the winner of the best electronic corporate media in the Russian and CIS steelmaking industry. This was one of the categories of a competition held as part of the Metal-Expo 2014 international industry exhibition in Moscow.
NLMK almost halves occupational injuries. As a result of implementing occupational health and safety (OHS) programmes, the NLMK group has reduced the amount of injuries at its Russian sites by 40% from the beginning of 2014. At the Lipetsk site, the decrease was approximately 50% year-on-year. Systematic efforts have delivered a 41% year-on-year reduction in lost time injury frequency rate per 1 million man-hours in 2014. NLMK was able to achieve these results
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Quaker acquires Binol. Quaker Chemical Corporation has acquired Binol, a bio-lubricants producer primarily serving the Nordic region. Binol develops, produces and markets environmentally friendly products to customers, among others, in the metalworking industry. Products are primarily sold through company sales representatives in the Nordic region as well as an international network of distributors. In addition, Binol has distributed Quaker’s water-miscible products in the Nordic region since 2004. Quaker intends to operate Binol as a wholly owned subsidiary.
...150 years! We are strong in know-how, engineering and service of long product rolling mills and guide systems. bitors at i h x e e r 5 We a 0.06.201 2 . 6 0 . 6 METEC 1 d 5/A28 Stan
United States Steel to establish new management structure. United States Steel Corporation will realign its reporting segments North American Flat-Rolled, Tubular and U. S. Steel Europe. The North American Flat-Rolled realignment will include the creation of enterprise-wide commercial entities to specifically address the markets automotive, consumer, industrial, service centres and mining. Each entity will be led by a business expert with vast knowledge of customers’ current and future needs. U. S. Steel Tubular Prod-
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olling! r fe
... s
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ArcelorMittal Ostrava merges with ArcelorMittal FrýdekMístek. ArcelorMittal Ostrava has simplified its corporate structure and streamlined its internal processes, principally through a merger with its subsidiary ArcelorMittal Frýdek-Místek, a cold rolling mill that mainly produces electrical steels. ArcelorMittal Frýdek-Místek will now operate under the commercial name of ArcelorMittal Ostrava. ArcelorMittal Frýdek-Místek also operates a cold rolling mill in Ostrava-Vítkovice, which is located on the premises of Vítkovice Steel. As a result of the changes, major parts of the cold rolling production activities in Ostrava-Vítkovice have been transferred from Vítkovice to ArcelorMittal Frýdek-Místek.
Branch Office:
Morgårdshammar AB SE-777 82 SMEDJEBACKEN, Sweden Phone: +46 240 668500 Fax: + 46 240 668501 E-mail: mh@morgardshammar.se www.morgardshammar.se
Morgårdshammar AB Sales office Krefeld P.O. Box 101552 D-47715 KREFELD, Germany Phone: +49 2151 81290 Fax: +49 2151 611795 E-mail: office@mh-guides.de
www.gk-mas.de
by using a preventive approach to organizing OHS management.
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News in brief JSW Steel, India, has started up the new greenfield cold rolling mill at its Vijayanagar works. TMEIC supplied the complete electrical equipment, including motors, drives, automation hardware and process sensors, for the mills and processing lines.
Baotou Iron & Steel, China, has entered regular commercial production of hardened rails using the Idrha+ (Injector Dual-phase Rail Hardening) process developed by Primetals Technologies and Rina-CSM.
AK Steel, USA , has successfully completed the reline of the blast furnace at its Ashland, Kentucky works. The blast furnace has returned to full production following an approximately four-week outage.
Tata Steel, United Kingdom, has completed the upgrade of the hot strip mill at its Port Talbot steelworks. The upgrade was focused on the installation of a new reversing rougher.
ucts’ commercial and manufacturing operations, now Energy Solutions, will also be aligned to include customer solutions for the oil and gas industry, focusing on the go-to-market tubular goods business strategy, from mill to rig. U. S. Steel Europe will become U. S. Steel European Solutions and is already aligning to accelerate focus on their customers.
ThyssenKrupp Metallurgical Products concludes off-take agreement with NioCorp. ThyssenKrupp Metallurgical Products has expanded its product portfolio and concluded an offtake agreement for ferroniobium, a rare heavy metal, with NioCorp Developments. Under the ten-year agreement, ThyssenKrupp Metallurgical Products will purchase 3,750 t/year of ferroniobium, which equates to approx. 50% of NioCorp’s total production. This offtake agreement makes ThyssenKrupp Metallurgical Products the exclusive European distribution partner to NioCorp, which is developing the only primary niobium deposits in the USA at its Elk Creek project in Nebraska. The term of the agreement is scheduled to begin in 2017 when production starts.
ThyssenKrupp takes further important step in IT harmonization. ThyssenKrupp has signed a contract with Deutsche Telekom subsidiary T-Systems for the set-up and operation of central data centres. Before the end of the year, T-Systems will
start transferring IT systems and services previously accommodated in around 700 data rooms and eleven data centres to five global data centres. In addition, over 80,000 computer workstations and 10,000 server systems of ThyssenKrupp worldwide are to be moved to the cloud. The IT resources will then be made available from T-Systems data centres via secure data networks. Employees of the diversified industrial group will be able to use workplace devices around the world flexibly and easily and share data and documents securely. Harmonization of the IT infrastructure is part of the ThyssenKrupp group’s strategic way forward.
Xiwang Special Steel obtains licences from IMR. Xiwang Special Steel has entered into a technology licence and cooperation agreement with the Institute of Metal Research, Chinese Academy of Sciences (IMR). Under the terms of this agreement, Xiwang Special Steel obtained ten licensed special steel production technologies. IMR will provide technological services and support related to the licensed technologies to facilitate Xiwang Special Steel to improve product quality, refine production technology and enrich the product mix.
Impact of declining oil price on US shale industry. Oil price volatility is going to push the US shale industry into a next phase of con-
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INTERNATIONAL INDUSTRY NEWS solidation and productivity gains. According to new research by Frost & Sullivan, declining oil prices are impacting short term exploration and production capital expenditures (CAPEX) and profitability, and will provide impetus to shift toward smart CAPEX and innovative operational expenditure (OPEX). The research estimates global exploration and production spending in 2015 to decline to US$ 659.8 billion, down from an estimated US$ 723.3 billion in 2014, if the price of crude oil remains around US$ 60 per barrel. Under any price situation, the oil and gas industry will accelerate toward the totally integrated digital oilfield. The industry is entering a transformative phase where leaders will further consolidate.
presence of leaders of the global steel industry.
Worldsteel announces steel challenge regional champions. The World Steel Association (worldsteel) recently announced the regional champions for the 2014 steel challenge. The challenge had been to create steel at the lowest total cost and required quality for a construction application, using the basic oxygen steelmaking method, in a simulation on steeluniversity.org. The competition attracted 1,566 teams and 1,922 participants representing 34 countries. The new regional champions in the ‘Industry’ and ‘Student’ categories will be invited with expenses paid to compete for the title of world champion in Brussels in February 2015. They will compete in the
U. S. Steel to relocate headquarters. United States Steel will relocate its corporate headquarters to the former Civic Arena site in Pittsburgh’s lower Hill District. This announcement assures that the company will help anchor new development in the region while sustaining more than 800 jobs in Pittsburgh at the headquarters location. To be completed in 2017, the new headquarters will promote collaboration and best practices for U. S. Steel employees in the advanced work environment. Additionally, by housing employees from a number of locations under one roof, the new headquarters location will provide significant cost savings for the company.
Oschatz founds strategic subsidiary. Oschatz, a globally active company in the fields of plant construction, energy recovery and environmental technology with its headquarters in Essen, Germany, has founded a strategic subsidiary “Oschatz Filtertechnology”. Approx. 20 employees of Paul Wurth Umwelttechnik, which is also based in Essen, have moved to the Oschatz headquarters. Oschatz paid only a symbolic price for the transfer. The intention of the transfer is to generate new know-how in the field of flue gas cleaning, off-gas treatment and dedusting solutions.
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News in brief Schmolz + Bickenbach, Switzerland, has decided to stop the open-ended selling process for distribution activities in Germany, Belgium, the Netherlands and Austria on the ground that the offered purchase price for the distribution activities did not reflect their value.
Outokumpu, USA, expects to re-start the 1,370 mm stainless steel cold rolling line at the Calvert, Alabama stainless steel mill in early 2015 after an outage since June 2014.
Outotec, Finland, has completed the employee cooperation negotiations concerning its Finnish operations. Due to reduced workload and restructuring, a total of 90 jobs will have to be reduced.
TenarisTamsa, Mexico, has installed an Estrop manipulator from More for cleaning the EBT tap hole of the 170 t electric arc furnace.
ThyssenKrupp, Germany, has extended the contract of executive board chairman Heinrich Hiesinger until September 2020.
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HALL 5 / Stand D22 TML Technik GmbH | A Company of the Fon: +49 (0)2173 - 95 75 100 | Fax: +49 (0)2173 - 95 75 400 E-mail: info@tml-technik.com | www.tml-technik.com
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Personalities New members on NLMK management board. The NLMK management board has been expanded from eight to ten members as a result of the inclusion of Ilya Guschin, vice president for sales; and Sergei Likharev, vice president for logistics.
New appointments and contract extensions for Thyssen Krupp board members. The supervisory board of ThyssenKrupp Steel Europe has extended the appointments of several management board members and appointed new ones. In the Steel Europe business area, the appointments of Andreas Goss as CEO and Thomas Schlenz as chief human resources officer and labour director have been extended. Premal Desai has been appointed as a new member of the management board. Currently chief strategist for the ThyssenKrupp Group, Desai will take over as the business area’s chief financial officer with responsibility for controlling, accounting & risk, information technology, purchasing raw materials/energy & materials management and compliance.
Premal Desai
IMS names general manager of global sales & projects. IMS, manufacturer of x-ray, isotope and optical measuring systems for hot and cold mills and service centres, has appointed Jörg Busch as general manager of global sales & projects. In that capacity, Jörg Busch will be responsible for the performances of IMS subsidiaries and sales agents throughout Europe, North America, Asia and South America. He will also oversee the com-
pany’s project management activities worldwide. Prior to assuming his current position, Jörg Busch spent 13 years as general manager of cold mill applications.
New director general of Eurofer. Axel Eggert, since 2007 Eurofer’s director for public affairs and communication, has been nominated director general of Eurofer.
Axel Eggert
New sales director of Loesche Latinoamericana. Vicente Fernández has been appointed as the new sales director of Loesche Latinoamericana (Spain). Vicente Fernández has been working with Loesche Latinoamericana since 2006. Prior to his new appointment as sales director, he has been actively involved in various functions within the sales and procurement departments of Loesche Latinoamericana.
CFO to leave Schmolz + Bicken bach. Hans-Jürgen Wiecha, chief financial officer of Schmolz + Bicken bach is stepping down from his responsibilities for the company at the end of February 2015 in mutual agreement and on the best of terms with the board of directors. Hans-Jürgen Wiecha is considered the architect of the ongoing performance improvement programme.
New CEO of Georgsmarienhütte Holding. Effective 1 January 2015, Michael Süß assumed the position of chief executive officer of Georgsmarienhütte Holding, succeeding Peter van Hüllen, who will re-
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tire from the company in mid-2015. Also effective 1 January, Frank Koch has been appointed to the managing board of Georgsmarienhütte Holding, in addition to his position as a managing director of Georgsmarienhütte GmbH. He succeeds Hartwig Kockläuner, who is leaving the managing board for reasons of health. worldwide
Dillinger Hütte appoints executive officer. The supervisory board of Aktien-Gesellschaft der Dillinger werke (Dillinger Hütte) apHütten pointed Bernd Münnich to a five-year term as executive officer, technical division, effective 1 January 2015. Bernd Münnich began his career in 1991 in the Dillinger Hütte steelplant and managed various plants there from 1993 to 2007. Most recently he served as the head of human resources for Dillinger Hütte and Saarstahl as well as labour director and member of the management board of Saarschmiede GmbH Freiformschmiede.
Change in the management of Saarschmiede. The supervisory board of Saarschmiede GmbH Freiformschmiede appointed Önen Togar as a new management board member. Togar suceeds Jürgen Horsthofer, who is leaving the company at his own request with effect from March 31, 2015.
Events ›› 20 – 24 September 2015 Leoben, Austria Organizers: Asmet www.lmpc2015.org
LMPC 2015. The Liquid Metal Processing & Casting Conference will focus on the latest technological and scientific advances in industrial processes used to cast large ingots of high-alloyed metals. Topics covered will include VIM, VAR, ESR, plasma melting, physical property measurements of liquid metals, modelling of metallurgical processes, ceramic, slag and refractory reactions with liquid metals, refining, etc.
Strike while the iron is hot The 9 th international trade fair for metallurgy, steel casting and steel production with congresses converts visions into plants and products.
Growth engine metallurgy METEC with its supporting events is the top event when it comes to plants and products for raw iron, steel and non-ferrous metal production.
Welcome to Düsseldorf!
Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Tel. + 49 (0)2 11/45 60-01 _ Fax + 49 (0)2 11/45 60-6 68
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SMS group inaugurated new manufacturing and service workshop in Bhubaneswar, India The new manufacturing and service workshop, built with an investment of approximately EUR 31 million and covering an area of 21,000 square meters, is one of four locations operated by SMS India. The new manufacturing facility will focus on the supply of steelworks equipment and services tailored to the growth market India. On 27 November 2014, the SMS group inaugurated its new manufacturing and service workshop in Bhubaneswar, in the Indian state of Odisha, built for an investment of approximately 31 million euros. In the presence of more than 250 guests from politics and in-
bourg to India), Rainer Schmiedchen (German consul general in Kolkata) and Christian Klein (CEO & managing director SMS India). Currently, SMS has more than 1,000 employees in India. In future, at Bhubaneswar, some 200 SMS employees
expected to grow from its current level of 80 million tons to 300 million tons over the next 15 years.” The new manufacturing workshop, equipped with machinery of the latest state of the art, is strategically located centrally to the customers of SMS
The manufacturing and service workshop covers a total area of 21,000 square meters
dustry, Chief Minister Naveen Patnaik, who attended the event as a guest of honor, cut the red ribbon in a festive ceremony. Then, as a traditional Indian inauguration ceremony, a lamp was lit by Naveen P atnaik together with Dr. Heinrich Weiss (chairman of the supervisory board of the SMS group), Burkhard Dahmen (spokesman of the managing board of the SMS group), Sam Schreiner (ambassador of Luxem-
SMS group, Düsseldorf, Germany Contact: www.sms-group.com E-Mail: communications@sms-group.com
will form a further pillar of the SMS group’s worldwide network of quality-manufacturing sites. With this new asset, the SMS group is consistently pursuing its customer-focused strategy by expanding its local service presence in the important growth market India. “This investment strengthens our manufacturing network for steelworks equipment in India,” says Burk hard Dahmen, CEO of SMS Siemag and spokesman of the managing board of the SMS group. “It is an important step for the SMS group in tapping this growth market and participating in the upswing taking place in this country. Annual steel production in India is
group. Most of them are within a range of some 300 kilometers. This makes it possible to fulfil individual customer requests locally and in time. Moreover, it will also be possible to supply customers outside India with components made at the Bhubaneswar workshop via the marine port of Paradip, which is just 130 kilometers away. The steelworks components manufactured at Bhubaneswar will be specifically aligned to the requirements of the Indian steel market. The range of equipment made at the workshop will include electric arc furnaces, secondary-metallurgy plants like ladle furnaces and RH degassing plants, and BOF plants, including cooling stacks for
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Tour of the newly erected workshop on the inauguration day
gas cleaning systems. For continuous casting plants, ladle turrets, tundishs, tundish cars and roller tables will be supplied. All the plant equipment will be manufactured, assembled and tested in Bhubaneswar. This ensures high quality of the equipment. The service workshop of SMS India is equipped with various hightech machines. These machines are critical to meeting OEM standards in the rendered repair and maintenance services. The new location also has plenty of capacity for customer training courses provided by the TECademy. In his address, Naveen Patnaik, Chief Minister of Odisha, emphasized the out-standing importance of the new manufacturing and service workshop for consolidating the relationship between the SMS group and its Indian customers. It is planned to expand the workshop in the future and continue to invest in modern machinery and additional qualified personnel. As a sys-
tems supplier, SMS also offers a broad range of services, including spare parts services, the manufacture and repair of plant components in OEM quality, the manufacture of value-added components (segment rollers, spindles, mandrels), copper plating of casting moulds as well as technical assistance in on-site installation and maintenance activities.
Long-time business of SMS group in India Thanks to its predecessor companies, SMS India is well established in the country. In 1989, lndomag Steel Technology Ltd. was founded in Delhi as a subsidiary of Mannesmann. In 1994, SMS Schloemann-Siemag established SMS lndia in Mumbai. Both companies merged in 1999 along with the merger between Mannesmann Demag Metallurgy and SMS Schloemann-Siemag. Since then, SMS India has constantly grown. Today, the company has offices
in Gurgaon, Kolkata, Pune, and in Bhubaneswar in the state of Odisha, where the new workshop was built. SMS India has its headquarters in Gurgaon. The staff of SMS India has expertise in the design and sale of components, in project management tasks, in the fields of electrics & automation and in service. They competently handle the complete product range of the SMS group from coal and ore preparation via the blast furnaces from Paul Wurth down the process chain to strip processing lines, for the construction of new plants and for revamps. Also in India, the successful integration of Paul Wurth into the SMS group and the resulting technological and sales-related synergies have contributed to the further expansion and completion of the SMS group’s portfolio as a provider of plant and mechanical engineering solutions for all process chains in the metallurgical industry. SMS India has already demonstrated its competence in almost 200 large-scale projects. MPT International 1 / 2015
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Joint venture of Mitsubishi Heavy Industries and Siemens starts operations Headquartered in London, Primetals Technologies commences operations. The new company with around 9,000 employees in more than 40 locations worldwide offers products, solutions and services for the entire metals value chain.
Primetals Technologies, Limited; London, United Kingdom Contact: www.primetals.com E-mail: rainer.schulze@primetals.com
uct portfolios, production know-how Primetals Technologies will operate and geographical distribution. While with 9,000 employees at more than 40 the technology strengths of the for- locations based in Asia, Europe, Russia, mer Siemens VAI Metals Technologies the Americas and Africa to serve cuslie in particular in iron and steel pro- tomers in the global metals market. The duction, continuous casting, automa- company’s structures will be lean and tion, environmental technologies and tailored to market requirements and lifecycle services, MHI’s technology the international competitive envicompetence is primarily focused on hot and cold rolling, processing as well as production expertise. With the combined portfolio, Primetals Technologies offers its customers solutions for the entire value chain in iron, steel, and nonferrous production that extends from technologies for the treatment of raw materials to processing and finishing at the end of the production process, including the related lifecycle services. The shareholders have nominated five directors to manage the new company: three Yasukuni Yamasaki was appointed CEO of Primetals directors from MHI – Technologies and chairman of the board including the CEO – and two directors from Siemens. The ronment. The company headquarters names and functions are as follows: will be located in London to underline ▪▪ Yasukuni Yamasaki, chief executive the intention of the two companies to officer (CEO) and chairman of the strike out on a new path together. The board, headquarters of the business segments ▪▪ Peter Schraut, chief financial of- and operational responsibility for the ficer, respective global business activities ▪▪ Heiner Roehrl, chief operating of- will remain in the principal locations ficer – upstream, of Linz (Austria), Erlangen (Germany), ▪▪ Ryoichi Nishi, chief operating of- Tokyo and Hiroshima (Japan). China, ficer – downstream, India, Japan, the U.S.A., Germany and ▪▪ Etsuro Hirai, chief technology of- Austria have been defined as key reficer. gions for sales and services.
Schenck Process GmbH Pallaswiesenstr. 100
As announced in May 2014, itsubishi Heavy Industries (MHI) M and Siemens have established a new joint-venture company named Primetals Technologies, Limited for the metals industry. With this joint venture both partners are forming a globally-operating complete provider of plants, products and services for the iron, steel and nonferrous industries. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and IHI Corporation – holds a 51% stake and Siemens a 49% stake in the joint venture. “Our joint venture comes at a time of challenging business environments and high market price pressure and when the steel industry has experienced a strong regional shift to Asia. With the combination of the competencies and regional presence of both partners, we have formed a high-performance company for the metals industry. Primetals Technologies is a leading, innovative and globally active technology provider and a reliable partner for its customers, backed by two strong mother companies,” said Yasukuni Yamasaki, chief executive officer and chairman of the board of Primetals Technologies. The joint venture will focus fully on the iron, steel and nonferrous business sectors. The two partners are uniting their respective technological legacies and industrial strengths in the joint venture. Both companies complement each other with regard to their prod-
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Groundbreaking for a new generation of steelworks to be initially built in Arkansas, USA The Mississippi river provided the inspiration for the name of the USA’s most recent and one of the country’s cleanest steelworks, Big River Steel (BRS) in Osceola, Arkansas. When the foundation stone was laid on September 22, it was also a milestone for a new generation of steelmaking plants. Big River Steel and SMS group intend to set new standards for tomorrow’s steel production. What the name additionally references apart from the location on the banks of Ol’ Man River is the massive flow of goods that is going to travel on the waterway to and from the flat-steel plant. It is also an allegory for the course of the liquid steel through the impressive, 1.6-million-dollar project that represents a step up in the USA steel industry. Applying innovative, clean, and energy-efficient processes, the company will produce high-quality steels for the energy, automotive, oil and gas industry from recycled steel scrap. These materials will contribute significantly to achieving President Barack Obama’s ambitious climate protection goals. Envisaged is an annual production rate of 1.5 million tons of hightech hot and cold steel strip. There are also plans to double this capacity later in three expansion stages. The main initiator, the chairman and chief executive officer of Big River Steel, is John D. Correnti, known in the USA as a pioneer in the future-oriented steel industry. Due to its credentials as a systems supplier, the SMS group, headquartered in Düsseldorf, Germany, received the order for the supply of all production lines including electri-
Thilo Sagermann, SMS group, Düsseldorf, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com Big River Steel, LLC, Osceola, Mississippi County, Arkansas, USA Contact: www.bigriversteel.com
cal and automation systems, coil logistics, technical assurance of installation, and commissioning. Big River Steel is planning to start steel production on the Mississippi in the first half of 2016.
Targeting sustainable steel production
New in the USA is a burgeoning e-mobility trend that is driving demand for small, safe, and weight-optimized vehicles. However, according to Mark Bula, chief commercial officer of Big River Steel, the company also targets new branches of industry that can offer crucial market advantages through the material properties of these high-performance steels. Also ranking high
Experts at the International Energy Agency (IEA) expect the global consumption of electricity to double by 2030. This is the same period covered by President Obama’s climate protection initiative, which aims for a 30% cut in US emissions of CO2, fine dust, nitrogen oxides, and sulfur dioxides by 2030. President Obama’s regulations apply to electricity utilities as well as coal-powered steelworks, new efficiency standards for cars and trucks, and improved energy efficiency of household appliances. So now is the ideal time to launch construction of an innovative steelmaking plant to be completed by SMS Siemag AG, one of the world’s leading manufacturers of metallurgical and steel mill technology facilities. Big River Steel fully responds to the spirit of the President’s climate requirements with a particularly clean, energy-efficient steel production from regionally-sourced steel scrap. Additionally important, the range of quality grades produced here will be geared towards the higher performance demands of challenging, fast-growing niche markets. Specifically, alongside standard steel grades for construction and white goods, there will be a focus on high-strength, multiphase steels for structural automotive parts. This industry requires ever more lightweight, consumption-optimized, yet high-strength materials.
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COMPANY PROFILE on the product list will be high-quality pipe grades up to X70 required for pipelines in oil and gas transportation. With an aim to advance the mill to also make X80 products. The third key product group is electrical steels – enjoying a fast growing demand. Increasing energy consumption in America requires ever better networks with correspondingly more powerful generators and transformers. These must adequately cope with grid fluctuations caused by irregular feedins of renewables as well as cyclical consumption. It’s a tendency not restricted to the American market. That’s why John D. Correnti sees excellent global market opportunities for grain-oriented and non-grain-oriented steels – not just on US markets, but internationally as well. Therefore, unlike other steelworks in the region, Big River Steel is specifically designed with technology capable of the complicated production of these types of silicon strip. However,
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John Correnti (Big River Steel), Heinrich Weiss (SMS group) and Mike Beebe (Gouverneur of Arcansas) during the groundbraking ceremony on September 22, 2014
Plant layout of the whole mini-mill complex
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The CSP ® plant can be extended later by a second casting strand
as John D. Correnti emphasizes, Big River Steel is also planning “to produce steels in gauges and widths previously not yet available from flat steelworks.” Due to its longer CSP® tunnel furnace and so-called RH-Top degassing plant (Ruhrstahl-Heraeus process), Big River Steel is also equipped for the cost-effective manufacture of a broad range of high-quality, high-strength advanced high-strength steels, API pipe grades, and silicon steels. As of today, only fully integrated steel works are able to produce these steels.
Trust that has grown over decades Seeking the best contractor for the innovative design and implementation of this flat-strip steelworks, John D. Correnti chose the SMS group because – regularly over the last 30 years and more – the two partners have jointly set new standards in steel production. That was demonstrated, for example, when Correnti, then a senior manager at Nucor, was instrumental in the very first implementation of the compact strip production (CSP®) thin slab technology developed by SMS. Then a revolution in the industry, now globally established, this process involves casting the liquid steel into near-net-shape thin slabs and combining the caster with the rolling mill via a tunnel furnace. Now, in the first project undertaken by Correnti on his own account, the Düsseldorf systems supplier was the natural choice to provide process management and plant engineering. All this explains why SMS was John D. Correnti’s first choice as a partner to develop Big River Steel. Not
only responsible for the metallurgical plants and rolling mills as well as all the process lines including batch annealing furnaces, the plant constructor is also supplying the entire electrical and automation systems as well as the coil logistics. All components will be tested and commissioned on the basis of the proven SMS plug & work method. Actively involved in the specification and layout of the new steelworks was the Düsseldorf consulting company MET/Con who supported the SMS group. Big R iver Steel is the third-largest order in SMS group’s corporate history.
Plant flexibility a hallmark Core elements of the future-oriented steelworks are a DC electric arc furnace, a ladle furnace, an RH-Top plant for secondary metallurgy, a single-strand CSP® plant, a coupled pickling line/tandem cold mill and a hot-dip galvanizing line. Once charged into the electric arc furnace, the scrap metal is melted to form a thermally and metallurgically homogeneous steel bath. Next in line is secondary steel production – controlling the chemical composition and temperature of the liquid steel and slag – which takes place in a double-ladle furnace. The key secondary metallurgy aggregate for high-quality steel production at Big River Steel is the RHTop degassing plant to be supplied by
SMS Mevac. This is where the carbon contained in the steel is reduced rapidly and to the maximum extent under vacuum. Simultaneously, it removes unwanted, dissolved gases such as hydrogen or nitrogen. A sophisticated process with a rapid-change system including pre-heating and vessel repair stand as well as a dedicated crane guarantees the required high productivity. Downstream of this, the steel goes through an integrated process to emerge as high-quality hot strip. Here again, John D. Correnti relies on the CSP® technology that has proved its worth over decades and that SMS is continually improving. A single-strand CSP® plant has a designed capacity to produce 1.5 million tons of hot rolled coils per year. Later to be supplemented by a second casting strand the capacity can be extended to 3.0 million tons per year. Worth mentioning, the plant casts and subsequently rolls the widest thin slabs to date, measuring 1,930 millimeters wide. Producing this new material dimension means the company meets the special requirements of ERW tubes. New at Big River Steel is an SMS-developed roller-hearth furnace, in which the slabs produced in two casters of the CSP® plant are transported via a parallel carriage to the mill stand. It enables Big River Steel to fully utilize the high rolling capacity of the six-stand CVC® plus mill.
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E Siemp
www.vip-kommunikation.de
Reliable, Robust and PRecise
Plants foR Ring-Rolling foRming / Rolling Siempelkamp supplies presses and rolling mills for the entire process chain in the production of rings made of high-strength materials. www.siempelkamp.com MPT_Int_01_2015_MB382_SMS_Big_River.indd 27 E Siemp.Anz.Ringwalzen131111.indd 1
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Layout scheme of the universal annealing and galvanizing line
RH-Top vacuum degassing plant
Variable product range for demanding markets Some one third of the products manufactured on the CSP® plant in the new flat steelworks progresses after rolling through a continuous pickling line with a turbulence pickling section. There, the material is descaled and oiled ahead of sale as hot strip in various qualities. The remaining twothirds proceed directly from the pickling section to a tandem cold rolling mill. Roughly 900,000 tons of the pickled hot strip are rolled on the fivestand tandem mill. Then half of this rolled cold strip travels into a continuous hot-dip galvanizing line, designed to also operate as an anneal-only line, while the other half goes into the batch annealing furnaces. Big River Steel is the only minimill in the USA that boasts technology for such a wide range of cold rolled and finished products, giving it the capability to produce both semifinished non-grain-oriented grades as well as the entire spectrum of laminated motor steels. In the CAL®/CGL® universal annealing and galvanizing line, cold strip is annealed, galvanized, rap-
Rolling stands of the CSP® hot strip mill
idly cooled, and skin pass rolled. The line produces commercial grade hotdip galvanized cold strip as well as highstrength, multiphase steels used above all for structural components in the automotive industry. The other half of the rolled cold strip proceeds through a discontinuous route with a batch annealing furnace and offline skin pass mill, emerging as carbon steel or high-quality electric steel. Essential for this first step is recrystallization in the batch annealing furnace to restore the strip’s ductility. Compared to most cold rolling mills, the offline skin pass mill applies much higher rolling forces to reroll the slightly siliconized material. These NGO grades are used for rotating motor parts in the electronics industry. This complex plant layout makes it possible to manufacture a very broad range of materials for highly demanding and sophisticated applications.
Holistic planning for sustainable success To meet the high environmental requirements that apply here, Big R iver
Steel relies on state-of-the-art filter and water treatment systems in all its plants. This means, for instance, that the dusts in the gas purifier are collected and filtered. Byproducts such as zinc dusts are recycled in special reduction processes that recover valuable raw materials. Then there is a NOx treatment in the universal annealing and hot-dip galvanizing line that also helps reduce emissions to such an extent that the steelworks will be one of the cleanest in the USA. Furthermore, the electrical and automation systems for all plants and lines at Big River Steel are controlled in a process-spanning way by the X-Pact® solution from SMS. Included here is everything from drive control and sensors (Level 0) to integrated production planning (Level 3), plus all technological controls and process models (Level 1 and Level 2). Whether secure power supply for the steelworks, fully automated logistics systems, process monitoring and control from casting to cold rolling – every aspect of the plant provides optimum productivity and product quality. All components – the plants themselves as well as control
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COMPANY PROFILE circuits, process models, and controls – will be set up and tested in advance and in real time with the SMS-developed plug & work process. That ensures fault-free workflows and perfect operability. Invaluable here is the perfect opportunity to train the staff of Big River Steel under real-life conditions. Out of this comes significantly shorter commissioning times for all units, plus fast achievement of full production levels. Despite the vast dimensions, it’s business as usual for SMS: correspondingly, Big River Steel and SMS are optimistic about the rapid progress of the new steelworks construction project.
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1.5 million t of coil shall be produced annually starting in 2016
Temposonics® Magnetostrictive Linear Position Sensors
Maximum Safety The robust Temposonics® T-Series line is designed for use in hazardous areas or safety applications. The linear position sensor meets Safety Integrity Level (SIL) 2 standards and offers an ATEX and IECEx Zone 0/1 flameproof and increased safety certification for hazardous areas.
MTS Sensor Technologie GmbH & Co. KG • Tel. +49 (0) 23 51 / 95 87-0 • www.mtssensors.com
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The measurable Difference
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››› STEELMAKING – SPECIAL EQUIPMENT
Reconditioning of monolithically lined ladles in steel plants An automatic ladle milling unit saves time and money. The new vertical ladle milling unit MLC 2011, developed by Simpex Hydraulik, simplifies the reconditioning of monolithically lined steel ladles, while cutting costs for refractory and waste disposal. The automatic process reduces personnel requirements to a minimum. The automatic milling operation takes approximately one hour. The newly developed vertical ladle milling unit MLC 2011 simplifies the servicing of monolithically lined steel ladles. The mobile unit contains a precisely controllable milling head for the removal of fused refractory material and baked-on slag from the existing monolithic lining on the inside wall of the steel ladle. This is an optimal
The milling unit is placed into the casting ladle by crane
Andreas Berendt, Simpex Hydraulik GmbH, Gera, Germany Contact: www.simpex-hydraulik.de E-mail: andreas.berendt@simpexhydraulik.de
preparation for the application of the new layer of refractory material. Before the ladle can be relined, the inside wall must be “white” in order for the new refractory material to properly bond with the remaining refractory layer. This means that there must not be any fused areas or areas with baked-on slag left. At the same time, it is to be avoided that any material still in good condition will be removed. The new ladle milling unit operates with a precisely controllable milling head. The thickness of the layer to be removed is set according to the degree of fusion. While ladle wrecking by means of manually operated wrecking machines or caterpillars with hydraulic hammers is extremely difficult to control, the new machine removes the worn refractory layer in a perfectly controlled and uniform way. The entire operation takes place automatically. This dramatically reduces the time requirement compared to the previously common manual practice. The operation takes approximately one hour. When the milling has been completed, the inside walls are visually inspected. If necessary, more material is removed or certain areas are specifically reworked with the milling head operated manually. The system is also suitable for spot repairs in cases where it is not necessary to mill the complete inside wall of the ladle.
Precisely controlled machining instead of bulky wrecking The amount of removed material is dramatically reduced because the system does not take off more material than necessary. This cuts not only the transportation and disposal costs for the waste material, but also the consumption of refractory material. As the material consists of aluminium oxide (Al2O3), it may for example be used as slag forming agents, resulting in a closed and thus eco-friendly system. Additionally, the ladle milling unit extends the life of the permanent lining. As the ladle is in the upright position during milling, it sits solidly in the ladle cone. Therefore, it is only subjected to the pressure load. More over, there are no impact effects acting on the monolithic or the permanent lining, as would occur during manual wrecking with the ladle in a tilted position. Thus, the ladle milling unit avoids the occurrence of cracks and brittleness. Simpex Hydraulik has developed the ladle milling unit in cooperation with Hackenberg Ingenieurgesellschaft. Simpex Hydraulik can build on more than 35 years of expertise and quality in the fields of hydraulics, pneumatics and central lubrication technology. Today, the company is engaged in the development, manufacturing and commissioning of hydraulic plants and plant units, test stands and components for sensor and servo-technology. The design phase of the new vertical ladle milling unit MLC 2011 has been completed. The first prototype will be built shortly. According to A ndreas Berendt, managing director of Simpex Hydraulik, the system will provide numerous benefits: “The milling
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STEELMAKING – SPECIAL EQUIPMENT unit saves not only material and disposal costs. It also reduces the strenuous work and risk of accidents in the ladle service area of the steel plant.” The first ladle milling unit has been designed for ladles with a capacity between 80 and 160 t. It consists of the milling equipment proper, a holding frame and a container, which accommodates the hydraulic unit including the tank and the controls. The equipment is easy to use: A bay crane, which is typically available in any steel plant, lifts the milling unit into the ladle. Three hydraulic cylinders ensure that the unit is perfectly centred and fixed inside the ladle. Here a key advantage of this milling unit becomes obvious: The milling head is always accurately positioned relative to the ladle and it can be moved to any position of the lining – either automatically or manually by remote control. When the automatic milling process has been completed – in approximately one hour – the milling unit will be lifted into the provided holding frame or into the next ladle to be serviced.
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Three arms with hydraulically actuated clamps (red) hold the milling unit, while the lower part with the milling head rotates through 360°
INJECTION TECHNOLOGY GmbH
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i.e. flexible ceramic lined hose
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››› ENVIRONMENTAL PROTECTION
Variable management technology of electrostatic precipitators in steel plants Operational costs of electrostatic precipitators in steel mills can be reduced using a sophisticated management system. With a constant dust collection performance, Precon technology is reducing the electrical energy consumption there by more than 60 percent. Precon technology can easily be retrofitted in existing steel plants and may pay back within one year. With Precon, Primetals Technologies is offering steel works operators an en ergy management system for electro static precipitators in dedusting plants. The system includes components for
The first Precon systems are in opera tion at a European steel plant. With the same dedusting performance, the pre cipitators there are saving more than 60 percent of their electrical energy consumption. The system typically pays back within one year, and can be Primetals Technologies, Limited; retrofitted in existing plants without London, United Kingdom any additional shutdowns. Contact: www.primetals.com The electrostatic precipitator forms E-mail: rainer.schulze@primetals.com the heart of primary dedusting plants in steel works. It can re move around 99 percent of the dust from converter off gases. There is a direct volt age of up to 65 kilovolts be tween the discharge and collection electrodes. De pending on the size of the plant, the energy consump tion varies between 1.4 and 2.1 kilowatt hours per metric ton of tapped (liquid) steel. Therefore electrostatic pre cipitators are a major cost factor. The precipitators are usually operated so that dust concentration limits can be reliably maintained. How ever, as the dust emissions at the converter fluctuate wide ly in time, this operation practice is not in line with demand, and simply leads to higher operating costs. Precon takes into account the various operating states of the converter throughout the complete cycle, and reg ulates the energy use of the precipitator to match cur rent process conditions. This is achieved by precisely mon Overview of the important operating data of electrostatic precipitators in a European steel plant itoring the power consump data recording and processing, oper ator control and monitoring devices, and special software for controlling the precipitators. This enables the op eration of the electrostatic precipitators to be matched optimally to the actu al operating state of the converter. De pending on the environment and the type of electrostatic precipitator used, the energy consumption can be re duced by between 30 and 50 percent.
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ENVIRONMENTAL PROTECTION tion of each individual precipitation field, and by a special software to evalu ate all the relevant process data. On this basis, the high-voltage supplies to the precipitation fields can be controlled and optimized. The system includes pre-tested hardware, a Siemens Nano box industrial PC, and an integrated programmable logic controller for com munication with the high-voltage com ponents of the precipitators. A touch panel facilitates user-friendly operation of Precon. If necessary, the system can be quickly switched from normal to op
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About Primetals Technologies Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Sie mens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group com pany with equity participation by Hitachi, Ltd. and IHI Corporation – holds a 51% stake and Siemens a 49% stake in the company. The company employs around 9,000 employ ees worldwide. Primetals Technologies is a worldwide leading engineering, plant-build ing and lifecycle partner for the metals industry. The company offers a complete technol ogy, product and service portfolio that includes the integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain – in addition to the latest rolling solutions for the nonferrous metals sector.
timized operation. There is no difficulty in retrofitting it in existing plants, and this can be done without any addition
al plant shutdown. A test system for de termining the potential savings of a pre cipitation plant is also available.
Millmate Thickness Gauge. Lab accuracy in the mill.
With more than 150 installations worldwide the MTG has shown its reliability and exceeded our customers’ expectations. The green PEC measurement technology is environmentally-friendly, providing personal safety and totally eliminating the hazardous drawbacks of systems based on isotope or X-ray sources. MTG works impeccably in the toughest of environments and there is no need for calibration and alloy compensation inherent in older technologies. MTG is more than a thickness gauge and has several extra features including reliable clad measurement and a unique on-line measurement of electrical resistivity. www.abb.com/pressductor
ABB AB Force Measurement Phone: +46 21 32 50 00
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Advanced design of water treatment plant with “zero liquid discharge” recovery system At a superficial analysis, it seems to be impossible to achieve the goals of lower water consumption, less pollution and a lower cost of management all at the same time. However, Danieli has already proved many times that the rational and smart application of available innovative technologies may allow the simultaneous achievement of these goals. This article shows how to achieve an optimal management of the water cycle by reducing or even zeroing primary water needs through the reuse of treated waste water.
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ENVIRONMENTAL PROTECTION dustrial production. This involved the necessity to dispose of huge amounts of chemical products both in the dissolved phase and as sludge. Due to the above mentioned general approach to water cycle management, especially in tropical areas, water deficiency has become a chronic disease and, due to the poor state of surface and ground water, it is crucial to use water resources sparingly, avoiding wastage and preventing deterioration. The availability of water resources is linked to the control of two key factors: ▪▪ consumption must not exceed resource reconstitution; ▪▪ deterioration may not exceed the self-healing capacity of the resource. As a consequence, not only for ethical or environmental considerations, but also under purely economic aspects, it is necessary to critically review current uses of water and adopt, wherever possible, technologies enabling “zero liquid discharge” or minimizing the discharge of waste water.
General aspects of water cycles in industrial plants
Filters battery and reverse osmosis package
Industrial development stems from an old culture that has always considered water as a renewable and non-perishable gift of nature of unlimited availability. This thinking led to the indiscriminate use of the water resources because water was assumed to be inexhaustible and available at low cost. In recent decades, water cycle considerations have been focused on obtaining a quality suitable for use in in-
Antonio Nardella, Danieli Engineering Systems, Buttrio/Udine, Italy Contact: www.danieli.com E-mail: info@danieli.com
The water cycle of an industrial complex is determined by the operating flow of the production cycle, the chemical treatment of water and the waste products from the manufacturing process. Consequently, the water cycle of a typical industrial complex usually involves the following areas: ▪▪ Production of process water: the incoming raw water is treated to obtain industrial water and softened/ demineralized water; generally applied processes are clariflocculation, disinfection, filtration, desalination (for seawater) and softening/demineralization by ion exchange systems. ▪▪ Use of process water: industrial water and softened/demineralized water are used for the operation of the production units in industrial complexes. ▪▪ Waste water treatment: waters used in and discharged from industrial processes are usually treated to comply with the legal limits stipulated for the receiving water systems; the processes generally used are oil removal, neutralization, clariflocculation, filtration and biological oxidation.
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During the last few decades, water cycle considerations used to be focused on obtaining a quality suitable for use in industrial processes, while assuming unlimited availability of primary waters at low cost. As a result of this approach, every year several hundred tons of chemical residues dissolved in the treated waste waters are discharged to rivers and seas.
Applicable measures In order to correctly assess the actions needed to minimize the waste water in an industrial complex, it is first of all indispensible to become familiar with the existing situation. To be able to properly define when and how to intervene, it is important to know the production capacity, types of raw materials used, the type of primary water input, the type and condition of existing water treatment systems, the quantity and characteristics of waste water discharged, etc. Apart from building new water treatment plants with latest control and recovery technology, it is also possible to tackle the problem with existing plants. Old water softening and de mineralization systems based on ion exchange can be replaced by new units working without the addition of salts. Examples are water softening by the addition of lime and soda, reverse osmosis, electro-deionization, etc. The water-steam cycle can be upgraded by metering specific reagents that reduce the deposition of chemicals. This allows the number of acid washings of the boilers and heaters to be reduced, the condensate treatment systems to be used less intensively, with a consequent reduction in the number of chemical regenerations, etc. Waste waters can be treated for recovery by technologies such as the membrane bioreactor, reverse osmosis, etc. The membranes must be applied with great care. It is important to apply the appropriate pre-treatment for membrane protection, in order to achieve the maximum recovery possible and in any case a concentrate that complies with the legally required limits of the receiving water system. The “zero liquid discharge” technology can be applied by adding an evaporation-crystallization section for the brine resulting from reverse osmosis. MPT International 1 / 2015
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››› ENVIRONMENTAL PROTECTION
This solution allows for the further recovery of water, eliminating the discharge of waste water and obtaining crystallized salts. In the event that sulphate, sodium and potassium contents exceed those of calcium and magnesium, it may be economically interesting to recover pure salts as sodium sulphate, sodium chloride and potassium chloride.
Case study: Interpipe Steel at Dneprosteel, Ukraine In order to recover certain quantities of process water, a waste water treatment system was implemented at the 1.32 million t/year steelworks of Interpipe Steel, Dneprosteel Group, Ukraine. The waste water treatment plant was designed to carry out blowdown treatment for the steelmaking plant. In order to achieve “zero liquid discharge” (ZLD), a new water recovery system has been conceived, integrating cooling circuits in order to allow the following goals to be achieved: The blowdown waste water from the cooling system is treated by means of a dedicated desalination technology. This improves the surface water as the discharge of saline waters can be dispensed with. Water with low salt content (TDS < 200 ppm) is obtained and redistributed to the cooling circuits. This minimizes the industrial use of groundwater and saves drinking water resources. The secretion concentrated with high salt content is used as a cooling and hydrating additive to the spray circulation system provided for the slag granulation process. The reconditioned water is fed to both non-contact and contact cooling circuits of the manufacturing facilities at the steelworks, e.g. electric arc furnace, ladle furnace, fume dedusting plant, vacuum degassing plant and continuous casting machine. Fresh water is taken from the nearby Dnepr river. Danieli has designed and supplied various cooling circuits. Closed-loop circuits for moulds and machines are installed at the continuous casting machines. Open non-contact circuits are implemented at the secondary side of plate heat exchangers, the hydraulic units, EAF and transformers, the fume dedusting plant, the twin-LF
Reverse osmosis package
Clariflocculation (pre-treatment phase)
and the transformers, static VAR compensator and other auxiliaries, such as compressed air station and all relevant heating, ventilation and air conditioning systems. The total capacity is cooled in a cooling tower consisting of three concrete cells. A contact loop cooling circuit (including a side stream sand filter), has been implemented for the VD steam condenser. For this vacuum degasser, a dedicated steam generation boiler has been installed. Two dedicated contact circuits have been installed for spray cooling the two continuous casting machines. Two scale pits are provided, and after that the two returning streams of dirty water are mixed, 100% filtered and cooled
together. The treatment is continued in a sludge thickener and completed by dewatering in a belt press filter. All accidental water leakage, process water discharges from maintenance activities and all the dirty water from sludges are treated in the same systems.
Design and operation of the “zero liquid discharge” technology Each of the above described cooling tower systems have the function to discharge water as blowdown in order to maintain the proper concentration factor and relevant water quality. The total water flow rate (designed rate: 60 m³/h) is treated in the supplied ZLD plant.
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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.
In terms of technology this is the extension of the blast furnace operating capacity as well as a decrease of the reduction agent consumption due to a systematic distribution of material. The structural arrangement and the kinematics of the chute minimise the loads on the gearbox. The material is distributed on the complete surface by the independent movement of the upper- and lower chute. This concept ensures a failure- and maintenance free operation of the charger.
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Contact IMI Z&J Germany GmbH Z&J Technologies Z&J Technologies GmbH Bahnstr. 52, Bahnstraße 52 Germany D-52355 Düren, D-52355 Düren, Tel: +49 (0) 2421Germany 691 0
IMI Z&J Houston Zimmermann & Jansen Inc. Zimmermann Jansen Inc.Dr. 4525 Kennedy&Commerce 4525 Kennedy Commerce Houston, TX 77038, USA Drive Houston, 77038, USA Tel: +1 (0)TX 281 446 8000
Tel: +49 2421 691 0 Email: imizandj.germany@imi-critical.com Email: imizandj.germany@imi-critical.com
Tel: +1 imizandj.usa@imi-critical.com 281 446 8000 Email: Email: imizandj.usa@imi-critical.com
Website: www.imi-critical.com Website: www.imi-critical.com
IMI Z&J South&Africa Zimmermann Jansen, South Africa Zimmerman Jansen S.A.(Pty.) Ltd. 11, Michelin & Street, 11 Michelin Street Vanderbijlpark 1900, P.O. Box 1335 South Africa Vanderbijlpark Tel: +27 (0) 16 1900 986 0159 South Email: Africa imizandj.sa@imi-critical.com
IMI Shanghai Z&JZ&J China Z&J Temperature Equipment Co Ltd. No.2High Workshop, 819 Yinchun Road, No. 2 Workshop Minhang District, Shanghai 201109, No. Yinchuan Road P.R. 819 China Minhang Dist., Tel: +86 (0) 21 Shanghai 6490 7780201109 202 China Email: imizandj.china@imi-critical.com
Tel: +27 16 986 0159 Email: imizandj.sa@imi-critical.com
Tel: +86 21 6490 7780 Email: imizandj.china@imi-critical.com
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ENVIRONMENTAL PROTECTION
Blow down water from cooling system Flow rate = up to 60 m3/h
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Collecting & equalizing tank 1300 m3 First pass two stages - 70% reverse osmosis BD pre-treatment chemical clariflocculation
BD pre-treatment neutralization and oxydation
Permeate recovered 42 m3/h make-up water for cooling system
Reject water 18 m3/h
Second pass two stages - 50% reverse osmosis
Permeate recovered 9 m3/h make-up water for cooling system
Reject water 9 m3/h
Block diagram of the ZLD system
BD pre-treatment final filtration
installed at Interpipe Steel
After a collecting and equalizing phase, the water is sent to a pre-treatment, consisting of clariflocculation with suitable chemicals, followed by neutralization and oxidation, and a final filtration. After the pre-treatment, the water proceeds to the osmosis phase, consisting in a first reverse osmosis pass with two stages, equipped with low fouling membranes, for a total permeate recovery of 70%, and a second reverse osmosis pass with two stages, equipped with the same type of membranes, for a further recovery of 50%. The remaining 15% – a concentrated secretion – is sent as a cooling and hydrating additive to the spray circulation system provided for the slag area. Therefore, the quantity of water supplied to the plant is totally used in internal systems (and no outside discharging of liquid is required). Zero liquid discharge (ZLD) is achieved. The entire process is very much in line with recent worldwide BAT specifications (BAT: best available technology). After stabilization in terms of quantity and quality of the blowdown released by the cooling circuits and the relevant pre-treatment, commissioning and tuning of the ZLD plant was carried on in less than three months. Danieli performed a soft start using only the first pass of the reverse osmosis system. Then, as soon as the
Meltshop slag area cooling and hydration
first pass had achieved the state of reliable operation, also the second pass was activated, increasing the overall amount recovered water and reducing the quantity of concentrated secretion going to the slag area. The operating parameters of the ZLD plant were monitored from the start-up until completion of the first three months of normal operation. The plant has reached stable and reliable operation and the total quantity of newly added water has always been less than the quantity required by the slag cooling/hydrating process. The most evident advantage of this plant is that it is environmentally friendly. It makes use of the most recent BAT in steel manufacturing. Consequently, it provides the company with other subsidiary advantages, such as Opex savings. The recovered water is fed back to the cooling circuits, thus improving the quality of the cooling water and achieving consistent cost savings. The specific water consumption of the steelmaking facility is less than 0.6 m³/t of steel production, also taking into account the higher consumption due to the steam requirement of the VD facility. Another consequence is the possibility of obtaining highly profitable financing rates. Finally, the use of this technology reduces the plant’s environmental footprint.
Conclusion Optimum management of the water cycle can be realized by reducing/zeroing the primary water needs through the reuse of treated waste water. Depending on the economic return and/ or lack of availability of primary water, 60 to 90% of waste water can be treated for reuse. If the “zero liquid discharge” technology is applied, the total waste water can be reused. In the first case, the applied technologies will allow the discharge of small quantities of treated effluents with characteristics in accordance with the “emission limits of discharges into surface water or public sewer systems”. In the second case (“zero liquid discharge”), the resulting waste only contains solids and the available technologies allow further recovery through the production of inorganic pure salts for industrial use. In fact, if sulphates, sodium and potassium contents exceed those of calcium and magnesium, it may be economically attractive to recover Na2SO4, NaCl and KCl. At a superficial analysis, it seems to be impossible to achieve the goals of lower water consumption, less pollution and a lower cost of management all at the same time. However, Danieli has proved that the rational and smart application of available innovative technologies may allow the simultaneous achievement of these goals. MPT International 1 / 2015
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››› HEAT TREATMENT
World’s first application of new in-line rail hardening goes commercial at Baotou The “Injector Dual-phase Rail Hardening” system enables long hardened rails up to over 100 m length to be in-line processed for improved resistance to contact fatigue and wear. The first system of this kind went into regular commercial production at Baotou Iron & Steel (Group) Co. Ltd. in Baotou, Inner Mongolia, China. Baotou Iron & Steel (Group) Co. Ltd. confirmed that the in-line “Injector Dual-phase Rail Hardening” (Idrha+) achieved the expected performances for the rail R60 U75V gr.340 according to TB/T2344-2012 norm and has therefore entered the regular commercial production. The system, contracted to Siemens in December 2012, is capable to improve the rail resistance to both wear and rolling contact fatigue, and was designed by Siemens Metals Technologies (now part of Primetals Technologies) and Centro Sviluppo Materiali S.p.A. (RINA-CSM), Italy. The grade U75V is one of the most widely produced rails for high-speed application. After head-hardening treatment with Idrha+ process, all the obtained mechanical and metallurgical characteristics of the rails exceed the values required by the applicable standards. In particular, the minimum values of UTS tensile strength and A% elongation are 1,180 MPa and 10%, respectively. The measured values of hardness range from 340 to 400 Brinell HBW10/3000 at the surface of the rail head, and from 34 to 42 Rockwell HRC across the rail section, according to the applicable measuring protocol. R60 U75V gr.340 is the first rail in the world to be commercially processed through Idrha+ technology, and is now in industrial production already at a rate of 15 pieces per hour with a 100 m standard length. With a rail production capacity up to 1.36 million tons annually (record
Hot tests of Idrha+ system at Baotou Iron & Steel, Inner Mongolia, China
reached in 2009), Baotou is the largest rail manufacturer in the world. The first in-line Idrha+ system is installed in the rail rolling mill No. 2, which has a yearly capacity of 400,000 metric tons and produces various sizes and grades of rails for domestic and export markets, according to the main international standards. The design of the Idrha+ system is based on thermo-mechanical and metallurgical process models, and validated by experimental trials in a pilot plant. This allows the simulation of various cooling strategies for dif-
ferent grades of rail steel prior to the start of production, thus enabling runup times to be shortened and nominal capacity to be attained faster while relevant performance parameters are fulfilled consistently and reliably. The Idrha+ system allows for a unique flexibility of use and consistency of performance, thanks to the integration of a selective induction heating station, including powerful sequential spraying cooling modules with adaptive settings. The in-line installation grants a very high productivity with significant energy savings.
About Primetals Technologies Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Siemens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and IHI Corporation – holds a 51% stake and Siemens a 49% stake in the company. The company employs around 9,000 employ-
Primetals Technologies, Limited; London, United Kingdom Contact: www.primetals.com E-mail: rainer.schulze@primetals.com
ees worldwide. Primetals Technologies is a worldwide leading engineering, plant-building and lifecycle partner for the metals industry. The company offers a complete technology, product and service portfolio that includes the integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain – in addition to the latest rolling solutions for the nonferrous metals sector.
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››› HOT ROLLING – SPECIAL EQUIPMENT
Eco Slide Disks in the hot rolling mill of Voestalpine Stahl, Linz, Austria
New side guide system extends service life by up to ten times The Eco Slide Disc system is significantly reducing maintenance costs in the down coiler area of hot strip mills. Replacement of wear plates can be avoided during mill operation. Thanks to improved strip guidance, surface defects caused by the down coiler entry guides are eliminated. With the newly developed Eco Slide Disc solution, Primetals Technologies offers operators of hot strip mills a side guide system which can be adapted to nearly all existing entry guides and elongates the lifetime of wear parts up to ten times compared to conventional wear plates. The core of the solution consists of wearing discs which are integrated into the entry side guides. After the wear limit has been reached, the discs can be simultaneously round up to eight times, every time offering a new sliding surface. Furthermore, the discs can be turned over to their back face to be used on both sides. This optimizes strip guidance, eliminates personnel-intensive replacement processes in the safety zone and reduces the costs of operational wear parts by up to 75 percent. The system can pay for itself within one to two years. The Eco Slide Discs are successfully in continuous use at Austrian steelmaker Voestalpine Stahl, Linz works, Austria, since August 2014. At the time
the photograph (see figure) was taken, the disks had been in continuous operation for 14 days. During that time, 3,638 coils with a total length of more than 2,800 kilometres were wound.
Up to 75 percent cost savings for operational wear parts Guiding hot strip during the coiling process into marketable coils results in high wear of the down coiler entry side guides. This requires a frequent replacement of the wear plates, sometimes daily, leading to high operational, maintenance and stockpiling costs. In most cases, the changeover is done during the short work roll changing break which takes about ten minutes.
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The turnable modules of the Eco Slide Disc system are featuring a robust and maintenance-free design, enabling simultaneous rotation of the wear disks during production. The consequent improvement in strip guidance reduces the risk of damage to the strip edges and additionally substantially increases the life cycle of the wear parts. The risk of strip surface defects due to burning burrs falling off the wear plates can be reduced by continuous rotation of the sliding discs. The exchange of worn out discs can be executed during a maintenance shift, which usually takes place every one to two weeks. There is no need for the repair welding and grinding work performed by many operators on the expensive wearing plates.
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About Primetals Technologies Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Siemens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and IHI Corporation – holds a 51% stake and Siemens a 49% stake in the company. The company employs around 9,000 employees world-
Primetals Technologies, Limited; London, United Kingdom Contact: www.primetals.com E-mail: rainer.schulze@primetals.com
wide. Primetals Technologies is a worldwide leading engineering, plant-building and lifecycle partner for the metals industry. The company offers a complete technology, product and service portfolio that includes the integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain – in addition to the latest rolling solutions for the nonferrous metals sector.
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Bar Mill Setup
Portable Alignment Camera Eliminate the guess-work from your guide, restbar and mill stand alignment.
Advantages: Portable camera based system for quick, accurate guide and mill alignment Variable focus allows operator to check alignment on various guide and mill components from a single mounting point
On Screen guide/mill profile ensures perfect alignment
Rod Mill Setup
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››› STRIP PROCESSING
Strip cutting and welding using solid-state laser technology During the last few years, eight solid-state laser welders manufactured by Primetals Technologies have been implemented in strip processing lines. Now, after more than one year of industrial feedback, the results show that the welders perform very well on highly demanding processing lines for a large range of products from silicon steels to high-strength dual-phase and TRIP grades. This laser welder concept using laser cutting and welding by a solid-state laser source is also recommended by Primetals Technologies for pickling lines and tandem mills with significant advantages compared to a standard solution. Primetals Technologies has manufactured welding equipment for the iron and steel industry for more than 40 years. During the last few years, the requirements on processing lines and the associated welding equipment have changed tremendously as a result of: ▪▪ the emergence of new steel grades and their constant further development, ▪▪ changes in strip format ranges, ▪▪ the high performance requirements including exacting welding quality criteria (weld robustness, over-thickness, …) and automatic welding quality control. Primetals Technologies welders must therefore incorporate all of the above aspects to be able to meet the current and future requirements of the steel industry. Therefore, Primetals Technologies has developed a laser welder range comprising two welder types: one for light gauge products (LW21L) as in galvanizing lines and inspection lines, and one for heavy gauge (LW21H) as in pickling lines and tandem mills. Through continued research efforts and the determination to always be at the leading edge of technology, Primetals Technologies has now taken a new step ahead with the integration of a solid-state laser source into its laser welder. This laser source replaces the CO2 re sonator and offers important benefits for steel producers. Meanwhile, results
Hervé Thomasson, Primetals Techno logies France SAS, Savigneux, France Contact: www.primetals.com E-mail: herve.thomasson@primetals.com Welding and cutting heads of the solid-state laser technology MPT International 1 / 2015
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Cutting quality (from left: 0.5 mm cutting edge, 2 mm cutting edge, 2 mm cutting face, 6 mm cutting face)
Tested specimens of laser-welded joints (ball test)
have become available from different industrial applications of this new machine concept. These results show that Primetals Technologies is offering a high-performance machine with simple and easy maintenance compared to the standard concept.
Requirements for welders Over the last few years, steel grades have changed dramatically. The main evolution trend concerns yield strength and elongation. New steel grades are characterized by high yield strength and high elongation values. Steel grades also increasingly contain additional alloying elements like silicon, manganese, aluminium, boron and others. With TRIP and dual phase (DP) steels, the lines are already processing high-strength steel grades of up to 1,000 to 1,400 MPa, and it is anticipated that they will eventually process steel grades with tensile strengths of up to 2,000 MPa in the future. In addition, the new steel grades will account for an ever increasing portion of the total production. The main evolution in welder capacity is that the thickness range is to include ever thinner gauges. The thickness range required for welders is now less than 1.0 mm for pickling lines and
tandem mills, and less than 0.3 mm for galvanizing, continuous annealing and finishing lines. Taking into consideration all the above points, also the performance required from the welder has been significantly improved. Availability, welding quality, weld over-thickness and cycle time have reached new levels. Also systems for automatic welding quality control have become a mandatory requirement for the customer. These systems avoid any human intervention and provide a clear statement as to whether the welding quality is in line with the customer’s request.
Welder development programme For more than ten years, Primetals Technologies has conducted an extensive R&D programme in the field
of welder technolgy. In the 1990s, the early stage of the programme was dedi cated to developing a new “flash butt” welder concept (pickling entry section, fully continuous rolling mill, …) and a new “mash lap” welder concept (galvanizing line entry, continuous annealing, inspection lines, …). The programme was continued in 2000 with the development of the laser welding process. The first stage of development focused on light gauge (LW21L) for galvanizing lines, inspection lines, etc. The development of the laser welder for heavy gauges (LW21H) was started in 2004 for thickness ranges from 1.0 to 7.0 mm. Through continued research efforts Primetals Technologies has now taken another step ahead with the integration of a solid-state laser source into its laser welder, replacing the CO2 resonator. The solid-state technology,
About Primetals Technologies Primetals Technologies is a joint venture of Mitsubishi Heavy Industries (MHI) and Siemens. Mitsubishi-Hitachi Metals Machinery (MHMM) – an MHI consolidated group company with equity participation by Hitachi, Ltd. and IHI Corporation – holds a 51% stake and Siemens a 49% stake in the company. The company employs around 9,000 employees worldwide. Primetals Technologies is a worldwide leading engineering, plant-building and lifecycle partner for the metals industry. The company offers a complete technology, product and service portfolio that includes the integrated electrics, automation and environmental solutions. This covers every step of the iron and steel production chain – in addition to the latest rolling solutions for the nonferrous metals sector. MPT International 1 / 2015
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››› STRIP PROCESSING
Tested specimens of laser-welded joints (micrographs)
which had already been used in other sectors like automotive, tailored blank welding, etc, leads to different and significant advantages compared to the CO2 solution. The solid-state technology makes it possible to transmit the beam from the laser source to the process heads (cutting and welding) through optic fibre instead of using mirrors. Primetals Technologies’ laser welding machine suggests itself for laser cutting operations, making it possible to have perfect cutting operations for the whole range of steel grades and thicknesses, while obtaining a perfect preparation for welding by laser.
Advantages of the solid-state laser technology This new technological achievement provides the steel producers with numerous benefits, including higher efficiency, lower energy consumption, higher process speed for cutting and welding, and easier maintenance because no mirror is installed on the machine. The benefits result from: ▪▪ simple laser beam guidance, ▪▪ high efficiency, ▪▪ low maintenance, ▪▪ high cutting and welding performance. The laser beam is transmitted from the laser source to the process heads (for cutting and for welding) by means of optical fibres. There are no mirrors or beam switches on the machine. With this beam guidance system, the adjustment of the welder is very easy and the maintenance operations for the beam path are reduced to virtually zero. Thanks to this optical fibre technology, it is possible to have a “plug and play” system which avoids difficult adjustment e .g. of mirrors in the laser guidance system. As has been confirmed in feedback from the industry
Tested specimens of laser-welded joints (tensile test)
on the performance of recent Primetals Technologies projects, this is a key aspect for commissioning and maintenance of the equipment. Two optical fibres are used, one is connected to the cutting head and the other to the welding head. At the other end, both are mounted to the laser source. Thanks to the length available for the fibres, it is possible to install the laser source separately from the welder. Therefore, the laser source can be installed in a dedicated area or room, which would not be possible with CO2 technology. Thus the laser source environment can be perfectly controlled, dramatically improving the life time of the laser source. Additionally, without a laser source on the machine, the space required by the machine, above all on the motor side of the line, is reduced. This point may be a key aspect in revamps where limited space is often an important issue. Higher energy efficiency may also result in a decrease in power consumption and downsizing of other systems
like the cooling unit. With the same laser power level, the installed electrical power for the chiller and the laser source can be reduced by 50%. For the maintenance of the system it is of great relevance that the optical fibre system has no overpressure system and no mirror, and does not require any checking of internal parts. Therefore, maintenance is limited to a visual check without having to dismount any parts. For the laser source itself, the maintenance is drastically reduced compared to CO2 technology. Only a simple yearly inspection is required. With the same laser power level, the hourly operation cost (including maintenance gas, electrical consumption) for the solid-state technology is 80% less than for CO2 technology. One main issue for the laser welding process is the initial preparation of the strip edges. Therefore, the cutting operation is an important prerequisite. With laser technology, the quality of the cutting area is perfect, without
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5 | 5eBld2orf1
Düss Germany 15 6.20 16. – 20.0
Measuring systems from IMS for highest product quality Improve your product quality! High precision x-ray, isotope and optical measuring systems from IMS contribute greatly to increased production efficiency in the steel, aluminum and metals industries.
IMS measuring systems are designed for online, non-contact operation in the measurements of: • Thickness and thickness profile • Wedge and crown • Edge drop
Your measurement task is our specialisation!
• Flatness and levelness • Width and position of material • Dimension and geometry • Edge defects and holes • Internal strip defects • Tube wall thickness and eccentricity • Tube diameter and ovality • Coat thickness and coat profile • Temperature and cross-sectional temperature profile • Speed and length • Strip and web tension
IMS Messsysteme GmbH | Dieselstraße 55 | 42579 Heiligenhaus | Germany phone: +49 2056 975-0, fax: -140 | info@ims-gmbh.de | www.ims-gmbh.de
Our contribution to your success! Thickness
IMS – Specialist in professional and collaborative partnerships We guarantee economic production with outstanding results when using IMS measuring systems.
Flatness (TopPlan)
We offer: • Individual advice and consultation • Engineering • Installation and commissioning • Training Width
• All-round service • Long-term customer support Worldwide coverage in Europe, America and Asia all ensure we are able to work with you throughout the world, offering the benefit of excellent communications and local support for international projects.
Tube
IMS, your partner in the application of innovative measurement technology. Coating
5 | 5eBld2orf1
Düss Germany 15 6.20 . – 16 20.0
Dimension
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deformation of the strip, as may occur with mechanical shearing. There is no limitation for the cutting capacity in terms of steel strength. As it is a none-contact operation, there is no wear of the cutting tools. Therefore, maintenance is almost zero compared to the maintenance effort required by mechanical shears, involving blade changes and grinding. Quality and reliability of cutting has been verified for the whole thickness range of the two applications LW21L (CGL/ CAL/RCL) and LW21H (PL/PLTCM). Because of the perfect laser beam in a solid-state system, cutting and welding speeds will be higher compared to CO2 systems with the same laser power installed. The cutting speed increases by 20 to 100%, the welding speed from 20 to 50%, depending on the thickness.
Results Welding quality has been verified on a wide range of products, namely: ▪▪ carbon to high-strength steel grades (CQ, DQ to TRIP, DP), ▪▪ silicon steel (grain oriented and non-grain oriented), with silicon contents of up to 3.5%, ▪▪ various stainless steel grades. Various tests were performed to qualify the welding parameters. Besides the stamping tests (ball test), tensile tests were performed for HSS, as well as macrograph and micrograph detection. Pre- and post-annealing can be performed on the laser welding machines. Annealing has to be verified depending of the steel grade and its use is based on the strength level and the carbon equivalent level. The annealing treatment is performed by an inductive heating unit. Annealing treatment is required for a high carbon equivalent level and is essential to achieving good weld joint results. In order to efficiently support the operation and maintenance team, a weld qualification system should be installed. It is based on welding quality control using a CCD camera. The intention is to assist the operator in qualifying the weld to avoid human errors.
Conclusion Primetals Technologies offers a variety of products, ranging from more conventional machines to advanced
Laser cutting head in operation
Strip edges are joined by laser welding
technology like laser cutting and laser welding systems. An important part of this approach is the permanent and intensive research and development effort targeted at optimizing a wide range of aspects – from installation, return on investment (ROI), consumption, maintenance through to service support. This latest innovation in laser welding technology is in perfect line with this approach, as it provides
higher efficiency and performance, easier installation and reduced maintenance. These new laser welders mean major gains for the customer, last but not least due to the lower investment level. References [1] 51st ABM Rolling Seminar “Processes, Rolled and Coated Products”, October 2014, Foz do Iguaçu, PR, Brazil MPT International 1 / 2015
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››› TECHNICAL INNOVATIONS
Survey of chemical management service programme
Overall performance
SUPPLY CHAIN MANAGEMENT Chemical management services (CMS) is an approach where an organization engages in a long-term relationship with a service provider to manage its chemical supply chain and range of other support activities. The goal is to improve the total cost of the manufacturing process and increase productivity for the organization. Quaker Chemical Corporation, a supplier of process fluids and chemical specialties, surveyed customers in its North America Steel and Automotive CMS sites. The survey asked customers ranging from a machine operator to the plant manager how well Quaker is doing and how it could improve. In order to stand apart from the competition, the survey was modified to include how Quaker associates perform their everyday activities in alignment with Quaker’s core values. Respect, integrity and teamwork were the top rated values reported by Quaker’s customers. The 2013 survey results demonstrated improvement over the last three years.
2013
2012
2011
Neutral
Highly satisfied
Core value 2013
2012
2011
Neutral
Contact: www.quakerchem.com
Satisfied
Satisfied
Highly satisfied
Survey results
LASER MEASUREMENT SYSTEMS ■ Profile
Straightness ■ Diameter ■
Ovality ■ Tube End Inspection ■
www.LAP- LASER.com
Extremely wearresistant coating MATERIAL DEVELOPMENT With its smooth and regular surface, the extremely wear-resistant coating HD8, developed by Castolin, is the ideal solution for applications where standard chromium-carbide wear plates are too heavy or not resistant enough. The coating is made by an innovative, high-de position welding technique. It has been specifically developed to achieve a very high density of tungsten carbides homogeneously distributed within a nickel-based matrix at high deposition rates. The critical parameters of the process, in particular the temperature, are automatically controlled in order to avoid severe carbide dissolution as may happen by standard welding techniques. Wear resistance is far superior to that of steel-hardened plates or common chromium-carbide wear plates. In order to provide the optimum wear resistance, the Castolin automated changeover system allows producing continuous beads of different alloys on the same surface. Consequently, the area exposed to the highest wear can be coated with HD8, while an iron-based powder may be deposited where wear is not as severe. This optimizes the part’s service life and offers the most cost-efficient solution. Plates and customized HD8 parts are provided exclusively by CastoLab® service workshops. HD8 can be applied directly onto the customers’ parts or provided as full plates. Contact: www.castolin.com MPT International 1 / 2015
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Permanent magnet generator with explosion protection SPECIAL EQUIPMENT The DSG P 112.14-6 Ex threephase synchronous generator offered by Huebner Giessen meets international standards for technical work on explosion-proof products and can be used in explosive atmospheres. Huebner has developed the IECEx-certified generator especially for applications as pilot exciters. The generator has now been used for the first time as a pilot exciter at a gas liquefaction plant. In this setting it is used in black starts, i.e. emergency starts to restore power following complete outages of the main electricity supply. If a plant is idle for a longer period of time, the main exciter will lose its remanent magnetization. As a result, the power generator will not have an exciter field during a complete outage of the main electricity supply and will not work properly. When this happens, a permanent magnet pilot exciter generator is needed. With every rotation of the turbine, the pilot exciter generates voltage and supplies the main exciter with a new magnetization curve. By doing so, the pilot exciter guarantees the availability of the main exciter and ensures the power supply at all times. The generator is coated with
a seawater-resistant coating which makes it perfect for use in coastal locations. It has an ingress protection rating of IP 55 and Ex nA IIB T3 Gc explosion protection. Contact: www.huebner-giessen.com
Permanent magnet three-phase synchronous generator
Control of servoproportional valves SPECIAL EQUIPMENT The new axis controllers of sizes 06 and 10 of the TEZ series offered by Atos include closed-loop drivers for servoproportionals, plus integral digital axis motion controllers. They can be easily configured and PC programmed to best manage position, speed and force of any electrohydraulic axis. They improve motion performance, simplify the automation architecture and may be easily interfaced by fieldbus to the machine. The new integral drivers of the TES series are designed for fine closed-loop control of servoproportional valves. Atos servoproportionals of the sizes 06 and 10 feature a spoolsleeve design for precise zero overlapping, digital electronics for software-based setting of the functional parameters and a high response rate with excellent reliability. The new
units are water-proof according to IP67 and their rugged design withstands vibrations and shocks. Contact: www.atos.com
Unit for the control of electrohydraulic axes
More than just pure air Dust removal systems Mist extraction systems Vacuum systems Trim removal systems
Shavings suction plants Heat recovery systems Regenerative condensation Cooling systems for kilns
Worldwide over 590 plants for industrial processing since 2002. Schuh Anlagentechnik GmbH Erinstraße 9 | 44575 Castrop-Rauxel | Germany | Telefon +49(0)2305.97 79-0 | www.schuh-anlagentechnik.de
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Big Data analysis tool SUPPLY CHAIN MANAGEMENT For several years, the concept pert consulting to a new level. Longstanding industry experiof Big Data has evolved into an integral part of most industries as ence and the know-how of how to tap potentials in certain areit indicates tremendous potentials for businesses. Experience has as can be related to a state-of-the-art methodology of analysis. meanwhile shown that huge quantities of data are an opportu- In interaction with the customer, the right approaches can be nity and a challenge at the same time. Often, the insights expect- identified, the impact of measures analyzed immediately and ed to be gained have failed to materialize as the means of analy- the success of initiated optimizations can be directly proved. SCM Control™ is currently used in projects at VDM Metsis did not keep up with the data quantities of business practice. Bronk & Company as a consultancy specializing in metal in- als, ThyssenKrupp Steel Europe, Böhler Edelstahl and furdustry supply chain management has developed SCM Con- ther companies. trol™, a dedicated tool for the analysis of Development of stock levels Order idle times in front of lines huge data volumes in order to make Big Days Data “smart”. Based on production feedbacks of the complete supply chain and any freely selectable period of time, analyUpper limit ses about issues such as lead times, idle Mean times, stock levels, material flows, proLower limit duction costs or adherence to delivery dates can be shown interactively in real- time. Complete transparency across the Every bubble symbolizing an order in front Display of incoming (red line) and outgoing of a process step (blue line) material whole data cube and data analyses tai Position of bubbles indicates idle time in Development of overall stock level in front lored to the specific industry allow to days, size indicates order quantity of line (yellow line) speed up the interpretation of causes and effects as well as the derivation of Examples of analysis results (data from a fictive show case) measures based on data rather than on experience and gut feeling. The use of SCM Control™ takes ex- Contact: www.bronk-company.com
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Damping system reduces vibrations of AOD converters STEELMAKING Installed on the tilting drive of AOD converters, the Drive Damper from Primetals Technologies reduces vibrations caused by the blowing processes, and thus the mechanical loads acting on the entire system from the converter down to the foundations. The patented system reduces wear and maintenance costs while also extending the lifetime of service parts. It can be installed in new plants or as an upgrade on existing converters. The damping system consists of two hydraulic dampers, developed in cooperation with the Austrian company Hainzl, as well as measuring devices, evaluation software and an automation system. The dampers are installed in parallel to the torque support of the converter tilting drive and driven independently of it. The design ensures highest availability and makes it easy to upgrade existing plants. Each damper has a closed hydraulic circuit, making an additional, external hydraulic system superfluous. The damping effect is achieved by means of an electrohydraulic proportional throttle valve, and is therefore continuously adjustable. The thermal energy generated by the damping is dissipated by an integrated water cooling system. The dampers are equipped with a position measuring system as well as pressure and temperature sen-
Damping system for AOD converters
sors. The first Drive Damper was installed at Taiyuan Iron & Steel, China. Contact: www.primetals.com
© Utz Peter Greis, Düsseldorf
Cartoon
In 2015, the steel economy will be moving uphill again. However, some risks will persist. MPT International 1 / 2015
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››› LITERATURE SERVICE Premium alumina for refractory applications 48 pages, English A detailed brochure describing the alumina product portfolio offered by Almatis for refractory applications. Comprehensive information is provided on refractory aggregates, calcium aluminate cements and binders, calcined aluminas, reactive aluminas and dispersing aluminas. Contact: www.almatis.com E-mail: info@almatis.com
Strip processing and surface treatment 28 pages, English, German A comprehensive brochure presenting the range of products and services offered by Andritz Metals in the fields of strip processing and surface treatment. This includes annealing and pickling lines, acid regeneration plants, annealing and coating lines, finishing lines and shears, laser and resistance welding, industrial furnace systems, etc. Contact: www.andritz.com E-mail: metals.at@andritz.com
Cast products 8 pages, English, German This brochure outlines the services and products provided by CASTService. The offered cast products for automotive and oven construction include charging racks for furnaces, annealing racks, furnace rollers, edge angles, etc. For the mechanical engineering and steel industries, products such as grate bars, bearing boxes, break drums, roll stands, roller heads, furnace rollers, etc. are manufactured. Contact: www.castservice.de E-mail: castservice@castservice.de
Water hydraulics 12 pages, English, German A brochure outlining the activities and the range of products provided by Evertz Hydrotechnik. Specifically featured are descaling equipment and complete descaling systems, e.g. for hot wide strip mills, plate mills, bar mills and thin-slab/strip casting lines; selective roll cooling systems for flatness control as well as special valves and customized solutions. Contact: www.evertz-group.com/hydrotechnik E-mail: hydrotechnik@evertz-group.com
Casting auxiliaries 8 pages, English This brochure provides an overview of casting auxiliaries in the form of powders, granules, pellets and briquettes supplied by Intocast. The products in the brochure are subdivided into continuous casting powders and granules, ingot teeming products, and covering agents and metallurgical slags. Contact: www.intocast.de E-mail: sales@intocast.de
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LITERATURE SERVICE
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Mechanical vacuum systems 8 pages, English A brochure describing the range of mechanical vacuum systems for efficient steel degassing supplied by Oerlikon Leybold Vacuum. The brochure features systems for VD/VOD processes, the RH/RH-OB process as well as typical system designs with the associated roots blowers and dry vacuum pumps. Contact: www.oerlikon.com/leyboldvacuum E-mail: info.vacuum@oerlikon.com
Shotblasting machines 48 pages, English, German A detailed catalogue of shotblasting machines offered by Rump Strahlanlagen. It covers overhead monorail, wire belt and rolling conveyor shotblasting machines as well as drum tumblers, free blast cabinets, etc. The descriptions of the products include technical details, illustrations and drawings. Contact: www.rump-oft.de E-mail: service@rump-oft.de
Safety technology for melting and holding equipment 28 pages, English This brochure comprises the full line of systems offered by Saveway for insulation monitoring and measuring tasks in melting and holding units: e. g. continuous monitoring of lining thickness, hot spot measurements, insulation monitoring and preventive maintenance, reporting of residual moisture and cooling water leakages, etc. Contact: www.saveway-germany.de E-mail: saveway@saveway-germany.de
Secondary metallurgy 22 pages, English, German This brochure outlines the range of secondary metallurgy technologies and services provided by Tenova. It includes ladle furnaces, ladle treatment stations, chemical heating stations, VD and VOD units, RH units, top lance systems, vacuum stream degassers, AOD units, etc. Contact: www.tenova.com E-mail: technometal@tenova.com
Industrial driveshafts 6 pages, English, German, Russian A brochure summarizing the activities and service offer of Welte Cardan-Service. These include the production of driveshafts for industrial applications, inspection and repair of driveshafts, technical advice, optimization service, stocking of a broad range of parts, etc. Contact: www.welte-group.com E-mail: info.essen@welte-group.com
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››› IN THE NEXT ISSUE…
Steelmaking Extension of the Fujian Fuxin stainless steel refining complex by a twin-tank VOD unit Fujian Fuxin Special Steel, a flat steel producer located in mainland China, runs a production line for stainless steel. In 2014 the secondary metallurgy complex was extended by a new VOD unit from SMS Mevac. The main reason for this extension was to increase the production flexibility for its variety of steel grades especially for grades which require low contents of both, carbon and nitrogen. The heat size for the new VOD unit is up to 150 t depending on the required ladle freeboard for the respective metallurgical treatment targets.
Quality assurance Accurate detecting of the finest structures to improve performance of surface inspection technology For surface inspections, the trend is heading toward smaller and smaller structures that must be reproduced or resolved accurately at nanometre level. Optical measurement processes as contact-free and destruction-free analysis and test methods are chosen for many applications because they are also suitable for sensitive samples. Highly precise, confocal reproduction principles can present the sample topography and roughness structures not only qualitatively, but also corres pondingly quantitatively using matching tactile measurement methods that are described in many industry standards. Piezo-based positioning systems are making considerable contributions in this field.
Material flow logistics Improving the dispatch of stainless steel long products Established in 1987, Bird Stainless is a privately owned independent company based in Sheffield, UK, which services a wide range of industries such as nuclear power generation, oil and gas, marine, architectural and automotive. It is one of the leading suppliers of precipitation hardening steels in the UK and its customer base includes major multi-national concerns in the home, European and Middle Eastern markets. The increased volume of stock carried has meant that Bird Stainless has doubled its storage area by building a free standing structure, again with bespoke racking, which will accommodate up to a further 1,500 tonnes of stock.
Events Preview of Europe’s main metallurgy expo and conference METEC 2015 The four metallurgy trade fairs GIFA, METEC, THERMPROCESS and NEWCAST are coming closer and closer and it is apparent that the events from 16 – 20 June 2015 with the motto “The Bright World of Metals” will once again be providing a complete picture of the international market. Exhibitor numbers and space bookings amount to a very high level. e coMetals campaign will be presenting innovative technologies for an energy- and resource-efficient future. The 2nd European Steel Technology and Application Days (ESTAD) 2015 run in parallel with the METEC trade fair. This preview may be subject to change.
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