MPT International 2/2015 (Apr)

Metallurgical Plant and Technology G 25074

2

ISSN 0935-7254

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April 2015

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FIRST CLASS LONG PRODUCTS

Continuous Casting Machines are the backbone of SMS Concast‘s fifty-yearplus reputation for first class casting equipment. The secret of a CONCASTcaster is found within our competence to combine cutting edge metallurgical know-

how with powerful automation and superior steel plant equipment. The result is a tailor made system which satisfies our customer‘s specific requirements for world class steel quality and maximum production rates.

PASSION for PROCESS

Submerged Casting

Beam Blank Casting

Final Stirrers

www.sms-concast.com

Discharge Area

EDITORIAL

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The showcase for metals technologies is opening again at METEC Düsseldorf in Germany will be staging the METEC 2015 international metallurgical trade fair in June this year. Every four years, plant makers, equipment suppliers and service providers for the steel industry use this key trade and information platform to present their products, service offers and latest developments. Together with the three other metallurgy trade fairs THERMPROCESS, GIFA and NEWCAST taking place in parallel, around 70,000 visitors are expected to the technological forum, which will be rounded off by various congresses. Düsseldorf will therefore be the industry’s most important technology forum in early summer this year. METEC is being staged for the ninth time. It ranks as Europe’s most important pilgrimage for metallurgical plant engineering. At least equally as important as the exhibitions are the European Steel Technology and Application Days – ESTAD – with an extensive and exclusive conference programme.

At METEC, it is tradition to present the latest in technology. To give you a general idea of the enormous range of technology on offer, this present issue of MPT International contains a first preview of exhibitors. In general, current developments are focussing on innovations that further optimize the production chain. New technologies on show are expected to achieve higher productivity, reduce consumption of resources, provide optimum energy efficiency and minimize the carbon footprint of plants. With the aid of state-ofthe-art automation systems and through the combination of big data analysis and diagnostics, it has become possible to develop strategies which make the various production processes increasingly better controllable.

Dipl.-Ing. Arnt Hannewald

This should be reason enough to travel to Düsseldorf, Germany in June. METEC – this technology shop window is a can’t-miss event for decision makers in the iron and steel industry. Information is the basis for decisions that safeguard the future. Meeting people face-to-face still remains a veritable goldmine of knowledge and experience.

MPT International 2 / 2015

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››› CONTENTS

Events 24

GIFA, METEC, THERMPROCESS, NEWCAST trade fairs taking place in Germany in June

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METEC & 2nd ESTAD – European Steel Technology and Application Days

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AISTech & ICSTI will be steel’s premier technology event in the USA this year

Steelmaking 58

Coverphoto: %NQ SGD Ă–QRS SHLD @ ADKK SXOD @MMD@KHMF OK@MS HR NODQ@SDC AX @ ETKKX @TSNL@SDC BQ@MD RXRSDL +.( 3GDQLOQNBDRR &LA' $RRDM &DQL@MX "NMS@BS VVV KNH CD $ L@HK @MCQD@ JDGQX SDMNU@ BNL

World champions 2015 of the 9th virtual steelmaking challenge The World Steel Association announced the new champions of the 2015 steeluniversity challenge

Environmental protection

Hot rolling

60 ' PGTI[ GHĆ‚EKGPV ICU ENGCPKPI VJTQWIJ intelligent control

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For the control of the gas extraction process in steelworks, SMS Siemag has developed a new system which models the existing gas cleaning network

The “Twin pipe rotor� is an alternative to the traditional single-pipe rotor. The results obtained with this technology were even better than expected

70

Material flow logistics 80

“Pocket Mill� – an investment-saving solution for small and medium-capacity long product rolling mills A rolling mill concept was developed to reduce the overall investment as much as possible, while providing highly cost-effective steel production

Improving the dispatch of stainless steel long products The increased volume of stock carried has meant that Bird Stainless Steel Service Centre has doubled its storage area by building a free standing structure with bespoke racking

Progress in loop laying head technology saves costs in high-speed wire rod mills

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NLMK Kaluga produces angle sections on its rebar mill The Russian steelmaker operates a flexible rolling mill for both rebar and sections

Automation

Quality assurance

82 0 GY QXGTURGGF UYKVEJ VQ HWNĆ‚N KPETGCUGF safety requirements

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ThyssenKrupp Steel Europe AG installs a particular overspeed switch EGS(H)ÂŽ 41 certified to highest safety integrity level and performance level as well

Optical 3D surface measuring technology: CEEWTCVG RTQĆ‚NG TGRTQFWEVKQP QH VJG Ć‚PGUV structures Highly precise principles can present the sample topography and roughness structures according to tactile measurement methods

Columns 8

International industry news

30

METEC 2015 - preview of exhibitors

90

Technical innovations

101 Cartoon 102 Literature service

104 In the next issue 104 Imprint

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Advertisers’ index ABB AB 99 Alpine Metal Tech Holding GmbH 97 Applicazioni Tecnologiche Siderurgiche spa 9 Associazione Italiana di Metallurgia 85 Aumund Fördertechnik GmbH 59 Automazioni Industriali Capitano srl 95 Badische Stahl-Engineering GmbH 43 Boldrocchi srl 31 Braun Maschinenfabrik Gesellschaft m.b.H. 63 Can-Eng Furnaces 73 Combilift Ltd Co 85 Danieli S.P.A. 6, 7 Delta Kamerasysteme GmbH 63 Deutsche Edelstahlwerke GmbH 85 Endress+Hauser Messtechnik GmbH & Co. KG 93 Eredin Scabini Srl 45 Evertz Hydrotechnik GmbH & Co. KG 63 Fontaine Engineering und Maschinen GmbH 87 framag Industrieanlagenbau GmbH 15 Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS 37 Guild International Inc. 77

Instituto Aco Brasil (IABr) 73 IMI Z&J Germany 39, 40 IMS Messsysteme GmbH 11, 12 INTECO special melting technologies GmbH 13 JATO-Düsenbau AG 19 Maschinenfabrik Köppern GmbH & Co.KG 59 Koll Anlagenbau GmbH + Co. KG 89 KSK Kuhlmann-SystemKühltechnik GmbH 18 Küttner GmbH & Co. KG 16 LAP GmbH 51 LDV Laser- und Lichtsysteme GmbH 89 Lubas Maschinen GmbH 20 Messe Düsseldorf GmbH 96 Metal-Expo,JSC 69 MICRO-EPSILON MESSTECHNIK GmbH & Co. KG 23 NextSense GmbH 98 Oerlikon Leybold Vacuum 15 Pert srl 47 Plakoma GmbH 55 Primetals Technologies Austria GmbH 105 Quaker Chemical Corporation 53

R+W Antriebselemente GmbH 41 RV Rheinbraun GmbH 91, 92 Sarclad Ltd 94 Scheuch GmbH 10 SGL CARBON GmbH 106 Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG 75 SMS Concast AG 2 STEIN INJECTION TECHNOLOGY GmbH 81 TES Transformer Electro Service srl 33 ThyssenKrupp Industrial Solutions AG 35 TML Technik GmbH 29 TMT Tapping Measuring Technology 27 Transformers & Rectifiers (India) Ltd. 79 ThyssenKrupp Uhde Engineering Services GmbH 49, 50 Stahlinstitut VDEh 90 VELCO GmbH Ges. f. Förder-, Spritz- und Silo-Anlagen mbH 48 Ventilatorenfabrik Oelde GmbH 17 Verlag Stahleisen GmbH 83, 100 Vesuvius Group SA 57 PAUL WURTH S.A. 21, 22 Zumbach Electronic AG 37 ,/3 (MSDQM@SHNM@K

Innovative and reliable slab casting technology featuring patented INMO mould with hydraulic oscillator, dynamic soft reduction, and Optimum segment with split-roll design, to guarantee top quality carbon and stainless steel slab production.

Four significant references out of total of over 126 strands ARCELORMITTAL GROUP Six slab caster projects, totalling 9 strands, delivered in the last years in Europe, North and South America.

Slab and bloom casters

THYSSENKRUPP GROUP A two-strand slab caster at Beeckerwerth plus a high-productivity slab caster for top quality stainless steels at Terni.

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

www.danieli.com

DANIELI DAVY DISTINGTON SLAB CASTING TECHNOLOGY IS CONSISTENTLY CHOSEN TO CAST THE HIGHEST STEEL GRADE QUALITIES

BAOSTEEL GROUP CHINA Five slab casters supplied since 2005, for a total capacity exceeding 10.5 Mtpy.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

SHOUGANG JINTANG CHINA Caofedian project: the largest slab casting complex in China for a total production capacity of 9.5 Mtpy.

MEET THE DANIELI TECHNOLOGY AT DANIELI LOUNGE HALLE 4 / G28

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››› INTERNATIONAL INDUSTRY NEWS

The Americas

to anticipate this adjustment and has produced sufficient inventory to meet customer demand during this period.

Mexico Gerdau starts up new steel mill.

With the start of steel production scheduled for the first quarter of 2015, the melt shop of Gerdau’s new steel mill in Mexico is in its final testing period. The forecast is for the rolling area to start up operations in the second quarter. The plant is managed by the Gerdau-Corsa joint venture and will have an annual installed capacity of 1 million t of steel and 700,000 t of rolled products.

USA Aleris to build new cold rolling mill. Aluminium coil manufacturer Aleris has placed an order with SMS Siemag for the supply of a singlestand six-high aluminium cold rolling mill as key equipment for a major expansion of the facilities at its Lewisport, Kentucky, site. The new mill will be designed to produce up to 2,350-mm-wide prime quality coil, enabling Aleris to cater to the expected growing demand by the North American automotive industry for car body sheet made of aluminium. In extensive integration tests prior to shipment, the electrical and automation system will be prepared for time-saving commissioning. The full-line supply will also include an air purification system, which will recover valuable rolling oil from the exhaust air and feed it back into the process cycle.

USA U. S. Steel to adjust production.

United States Steel will temporarily adjust operations at Lone Star Tubular Operations in Lone Star, Texas, and Fairfield Tubular Operations in Fairfield, Alabama. The adjustment in operations is a result of softening market conditions that reflect the cyclical nature of the energy market. It is a temporary reduction in operating levels and not a full idling of plant operations. The company has worked with its customers MPT International 2 / 2015

USA TMW to enhance in-house EPS capability. The Material Works (TMW) has reconsidered its plans to open a flat rolled toll processing centre adjacent to the Big River Steel mill being currently under construction. TMW will instead expand the capacity of its present Red Bud, Illinois facility to include a new EPS (Eco Pickled Surface) processing and technology centre to process the new generation of higher-strength steels.

While the attractiveness of a new toll processing facility next the Big River Steel mill has not diminished, the surge in demand for EPS technology has changed the situation. The new EPS centre at Red Bud will not be just a processing centre, but also a technology development centre, plus a training centre for customers who buy EPS lines. TMW will be installing an advanced 12.7 mm tension-levelled EPS coil line capable of pickling carbon, high-carbon, HSLA, alloy, AHSS, silicon steel, and stainless steels. TMW will also be installing a new 12.7 mm Red Bud Industries stretcher leveller cut-to-length line.

USA Steel Dynamics to build new pickling line. Steel Dynamics has awarded Nelson Steel and Butech Bliss contracts to provide equipment to upgrade the existing hot band finishing line at their Butler, Indiana facility. The upgrade will enable the line to convert hot bands to hot-rolled pickled and oiled (HRPO) coils. Nelson Steel will provide the process section equipment and Butech Bliss the exit end terminal equipment. The line will be capable of converting hot band coils in thicknesses up to 9.525 mm by widths up to 1,625 mm at speeds up to 183 m/min. The line will also maintain its current capability to level and side trim hot band coils when required by bypassing the pickling section.

USA Steel Dynamics to install optimization systems for EAFs. Steel Dynamics has placed an order with Tenova Goodfellow for the supply and purchase of two EFSOP holistic optimization® systems for both EAF batteries at their SDI, Butler, IN steelmaking facility. The systems will provide full spectrum evaluation via upstream and downstream offgas analysis and water detection technology for all four EAF shells. The scope of supply will also include newly developed optical sensors for measuring the off-gas velocity and temperature. Installation and commissioning of the systems is scheduled to take place by April 2015.

USA Constellium/UACJ orders aluminium processing lines. Andritz has received an order from the joint venture Constellium/UACJ to supply a continuous annealing and pickling line and a finishing line for the production site in Bowling Green, Kentucky. The continuous annealing and pickling line with floating furnace will have an annual capacity of more than 100,000 t. It will be used to process aluminium grades 5xxx and 6xxx for body-in-white aluminium used in the automotive industry. The scope of supply comprises the complete mechanical and electrical equipment as well as the chemical treatment and neutralization sectors. With the inline tension levellers, it is possible to process coldrolled aluminium in widths between 800 and 2,200 mm and thicknesses between 0.5 and 3.5 mm. Start-up of the equipment is scheduled for mid-2016.

Asia China Guangxi orders galvanizing and annealing equipment. In September 2014, Guangxi Iron & Steel, part of the Wisco group, awarded Fives orders for the supply of two continuous galvanizing lines, one continuous annealing line, and one vertical furnace for another continu-

BAR COUNTING AND BUNDLING

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EXACT, NO-TWIST, ALIGNED PRECISE BAR COUNTING AND SEPARATION Bar are counted by laser and TV camera system to form sub-bundles and main bundles with exact number of bars.

NO-TWISTED BARS INSIDE BUNDLES Bars are kept always in layers and bundle formation is made by controlled falling of the bars.

ALIGNED BUNDLE HEADS Multi step bar aligning process assures a perfect alignment of the bars in the final bundle.

SHORT TYING CYCLE FOR SUB AND MAIN BUNDLES The fastest machines on the market, high productivity with reduced number of machines for plant servicing.

SOLID AND SIMPLE STRUCTURE Sturdy construction and simple design result in a free maintenance machine.

IN-HOUSE TEST All machines are assembled and tested in our workshops before their shipping to the customer.

20 YEARS OF EXPERIENCE IN OUR MACHINES ATS - Applicazioni Tecnologiche Siderurgiche S.p.A. Via Chiavola, 10 - Zona Industriale - 33010 Trasaghis (Ud), Italy Tel. +39 0432 984185 - Fax +39 0432 984232 - ats@ats.ud.it

www.ats.ud.it

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››› INTERNATIONAL INDUSTRY NEWS ous galvanizing line. The ordered galvanizing lines, with a combined annual capacity of 870,000 t, will be installed at Guangxi’s new integrated plant in Fangchenggang. These orders follow a contract signed earlier in 2014 for the supply of a continuous annealing line with an annual capacity of 930,000 t, also to be installed in the Fangchenggang plant.

For the same plant, Fata Hunter will supply two vertical chemical coaters to be integrated into two of the continuous galvanizing lines to be installed there (CGL 1 supplied

by WISDRI and CGL 2 supplied by Fives). The chemcoaters will be equipped with automatic nip pressure control and operate at a maximum speed of 200 m/min and 210 m/min respectively and with a maximum strip width of 1,880 mm.

WWW.SCHEUCH.COM

China Baotou to build continuous galvanizing lines.

Fives has received the order to supply two continuous galvanizing lines to Baotou Steel Union. The lines, with a combined annual capacity of 840,000 t, will be used to produce a wide range of high value-added automotive steels, including advanced high-strength steels (AHSS).

China

THE BENCHMARK

Zenith Steel to revamp two wire rod mills. Zenith Steel has signed a contract with Primetals Technologies to revamp two wire rod outlets located in its Changzhou facilities. New equipment will allow thermomechanical rolling to produce fine grain rebar at significantly reduced costs.

Included in the scope of supply are mini-finishing blocks, a Morgan pinch roll and a new laying head. The revamped mills will be able to roll rebar ranging in diameter from 6.0 mm to 16 mm, and rod sizes from 5.5. mm to 20 mm on the same outlet. In addition, Primetals Technologies is providing an integrated solution with electric and automation upgrades for the mills. The mills will operate at a speed of 105 m/s. Commissioning is planned for early 2016.

FOR THE METALS INDUSTRY China In close collaboration with our customers, we keep technology on the move and offer complete solutions with high levels of operating reliability, safety and efficiency. In particular, our extensive expertise and innovative analytical and computational tools for dealing with secondary emissions provide the foundation for the lowest possible life cycle costs in extraction and dedusting plants.

Scheuch GmbH Weierfing 68 4971 Aurolzmünster Austria Phone +43 / 7752 / 905 – 0 Fax +43 / 7752 / 905 – 65000 E-Mail office@scheuch.com

MPT International 2 / 2015

Rizhao starts coil production from thin slabs.

Rizhao Steel has rolled the first coil on the Arvedi ESP (endless strip production) plant No. 1 supplied by Primetals Technologies. Earlier this year, the first casting as well as the rolling of the first plates were successfully carried out. The plant is designed for an annual production of 2.55 million t of high-quality, ultra-thin hot strip, in widths up to 1,600 mm and thickness down to 0.8 mm. Primetals Technologies was responsible for the engineering of the Arvedi ESP plant and supplied the mechanical equipment, media systems, technology packages and automation. The project also includes a comprehensive training and support package. The plant is one of five casting-rolling plants, which Rizhao ordered from Primetals Technologies in 2013 and 2014.

5 | 5eBld2orf1

Düss Germany 15 6.20 – .

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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

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Thickness

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Coating

5 | 5eBld2orf1

Düss Germany 15 6.20 16. – 20.0

Dimension

China Baosteel Zhanjiang orders processing line furnaces. Fives has received an order from Baosteel for the design and supply of two Stein Digiflex® vertical annealing furnaces for its new 1,550 mm cold rolling mill project in Zhanjiang in the Guangdong Province. One of the furnaces will be used in a 700,000 t/year continuous annealing line (CAL), the other in a 270,000 t/year continuous galvanizing line (CGL).

CARNIVAL of Technologies

***16.-20.June 2015*** METEC Hall 4 E09, Düsseldorf

Beisteel orders pipe forming press. Beisteel has placed an order with SMS Meer for the supply of a JCO® pipe forming press for its plant in Yingkou, Liaoning province. With this machine, the company will be able to expand its product spectrum to include longitudinally welded large-diameter pipes with lengths of up to 18 m and wall thicknesses up to 65 mm in steel grades up to X100. The annual capacity of the plant will be approximately 250,000 t. The press is scheduled to go into production in the fourth quarter of 2016.

Kuwait KWTSteel to modernize rebar rolling line.

United Steel Industrial Company (KWTSteel) has awarded Primetals Technologies an order to modernize its rebar rolling mill in the Shuaiba industrial area. The rolling line was supplied in 1999 by the then VAI and is designed as a compact-cassette rolling mill. Under the project, the rolling mill will be equipped with an inline quenching system (PQS, Pomini Quenching System) and a new hot dividing shear with a higher capacity.

The quenching system will be installed between the last stand of the finishing mill and the hot dividing shear ahead of the cooling bed. The PQS enables rebars to be produced with increased yield strength and good weldability properties. This means that expensive alloying elements, such as niobium and vanadium, can be largely eliminated from the steel production. The modernized rolling mill is scheduled to go on stream in late 2015.

Europe Bosnia and Herzegovina ArcelorMittal Zenica invests in new bar-in-coil facilities. ArcelorMittal Zenica will further enhance its production facilities in a major investment project. Once the project is complete, the new facilities will be capable of producing high-density coils of rebar, reducing the cost of finishing. Machinery will be installed by the SMS group.

Come and marvel at ... ... our Continuous Caster dŚ /Ed dŚĞ /E d K K 'ƌŽ ƌŽƵƉ ƵƉ ŽīĞ īĞƌƐ ƌƐ ĐŽŶ ŽŶƟŶ ƟŶƵŽ ƵŽƵƐ ƵƐ ĐĂƐ ĂƐƟŶ ƟŶŐŐ ŵĂ ŵĂĐŚ ĐŚŝŶ ŝŶĞƐ ĨŽƌ ůŽŶŐ ƉƌŽĚƵĐƚƐ ĂƐ ǁĞůů ĂƐ ƐƉĞĐŝĂů ƐŽůƵƟŽŶƐ ĨŽƌ ƚŚĞ ƉƌŽĚƵĐƟŽŶ ŽĨ ƐƉĞĐŝĂů ƐƚĞĞůƐ dŚĞ ƉŽƌƞŽůŝŽ ĐŽǀĞƌƐ ĐŽŵƉůĞƚĞ ŐƌĞĞŶ ĮĞůĚ ŽĨ ƐƉĞĐŝĂů ƐƚĞĞůƐ͘ dŚĞ ƉŽƌƞŽůŝŽ ĐŽǀĞƌƐ ĐŽŵƉůĞƚĞ ŐƌĞĞŶ ĮĞůĚ ƉƌŽũĞĐƚƐ ĂŶĚ ƌĞǀĂŵƉƐ ŽĨ ĞdžŝƐƟŶŐ ĐĂƐƚĞƌƐ͘ /Ed K͚Ɛ ĐŽŵƉĞƚĞŶĐĞ ĐĞŶƚĞƌ ĨŽƌ ĐĂƐƟŶŐ͕ /Ed K d Z͕ ŽīĞƌƐ ďĂƐĞĚ ŽŶ ŝƚƐ ůŽŶŐͲƚĞƌŵ ĞdžƉĞƌŝĞŶĐĞ ŝŶ ĞŶŐŝŶĞĞƌŝŶŐ ĂŶĚ ĚĞƐŝŐŶ ŽĨ ŝŶĚŝǀŝĚƵĂů ďůŽŽŵ ĐĂƐƚĞƌƐ͕ ƚĂŝůŽƌͲŵĂĚĞ ƐŽůƵƟŽŶƐ ĨŽƌ Ăůů ŬŝŶĚƐ ŽĨ ƐƚĞĞů ƉƌŽĚƵĐĞƌƐ͘ Bloom and Billet Casters dŚĞ ĐŽŶƟŶƵŽƵƐ ĐĂƐƟŶŐ ŽĨ ďůŽŽŵƐ ŚĂƐ ďĞĐŽŵĞ Ă ǁĞůůͲĞƐƚĂďůŝƐŚĞĚ ƚĞĐŚŶŽůŽŐLJ ĨŽƌ ƚŚĞ ƉƌŽĚƵĐƟŽŶ ŽĨ ƐĞŵŝƐ ĨŽƌ ŚŝŐŚͲƋƵĂůŝƚLJ ĂƉƉůŝĐĂƟŽŶƐ͘ ^ŝŵŝůĂƌůLJ͕ ĐŽŶƟŶƵŽƵƐ ĐĂƐƟŶŐ ŽĨ ďŝůůĞƚƐ ŝƐ ƚŚĞ ďĂƐŝƐ ĨŽƌ ŚŝŐŚ ƉƌŽĚƵĐƟǀĞ ƐƚĞĞůŵĂŬŝŶŐ͘ /Ed K d Z ƐƵƉƉůŝĞƐ ƌŽďƵƐƚ ĐŽŶƟŶƵŽƵƐ ĐĂƐƟŶŐ ŵĂĐŚŝŶĞƐ ǁŝƚŚ ŚŝŐŚĞƐƚ ƋƵĂůŝƚLJ ŽĨ ƚŚĞ ĮŶĂů ƉƌŽĚƵĐƚ͕ ůŽǁ ŵĂŝŶƚĞŶĂŶĐĞ ƌĞƋƵŝƌĞŵĞŶƚƐ ĂŶĚ ŚŝŐŚ ŽƉĞƌĂƚŽƌ ĨƌŝĞŶĚůŝŶĞƐƐ͘ ƌĞƋƵŝƌĞŵĞŶƚƐ ĂŶĚ ŚŝŐŚ ŽƉĞƌĂƚŽƌ ĨƌŝĞŶĚůŝŶĞƐƐ͘ ^ƉĞĐŝĂů ĂƐƟŶŐ ƉƉůŝĐĂƟŽŶƐ ŽŶƟŶƵŽƵƐ ĐĂƐƟŶŐ ŵĂĐŚŝŶĞƐ ĨŽƌ ƐƉĞĐŝĂů ƚĞĐŚŶŝƋƵĞƐ͕ ƐƵĐŚ ĂƐ ŚŽƌŝnjŽŶƚĂů Žƌ ǀĞƌƟĐĂů ĐĂƐƟŶŐ ƌŽƵŶĚ ƵƉ ƚŚĞ ƉƌŽĚƵĐƚ ƉŽƌƞŽůŝŽ ŝŶ ƚŚĞ ĮĞůĚ ŽĨ ƚŚĞ ƉƌŽĚƵĐƟŽŶ ŽĨ ƐƉĞĐŝĂů ƐƚĞĞůƐ͘ ŇĞdžŝďůĞ ĂŶĚ ŝŶƚĞůůŝŐĞŶƚ ĚĞƐŝŐŶ ĂŶĚ ƚŚĞ ŝŵƉůĞŵĞŶƚĂƟŽŶ ŽĨ ĐƵƐƚŽŵĞƌ ĚĞŵĂŶĚƐ ĞŵƉŚĂƐŝnjĞ ŽƵƌ ĐŽŵƉĞƚĞŶĐĞ ŝŶ ƚŚŝƐ ƉƌŽĚƵĐƚ ƐĞŐŵĞŶƚ͘

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China

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››› INTERNATIONAL INDUSTRY NEWS

News in brief SSAB has divested Finnish Plannja Oy to Metehe Oy. Upon the combination of SSAB and Rautaruukki, SSAB’s subsidiary Plannja AB was combined with Ruukki’s construction businesses. As part of the approval for the combination between SSAB and Rautaruukki, the European Commission had required the divestment of Plannja’s Finnish subsidiary, Plannja Oy. The World Steel Association has announced the launch of the second annual Steel Safety Day. Worldsteel is requesting all its members and the wider steel industry to carry out an extensive safety audit on the five main causes of incidents – moving machinery, falling from heights, falling objects, gas and asphyxiation, and moving cranes – between now and the Steel Safety Day on April 28th.

ArcelorMittal Zenica will be the sole producer of rebar in coil in the Balkan region.

France Constellium to build aluminium processing lines. Constellium has placed an order with Andritz for the supply of a continuous annealing and pickling line and a finishing line for its production site in Neuf-Brisach. The continuous annealing and pickling line with floating furnace will have an annual capacity of more than 100,000 t and will be used to process aluminium grades 5xxx and 6xxx for body-in-white aluminium used in the automotive industry. The scope of supply comprises the complete mechanical and electrical equipment as well as the chemical treatment and neutralization sectors. With the inline tension levellers, it is possible to process coldrolled aluminium in widths between 800 and 2,200 mm and thicknesses between 3.5 and 0.5 mm. Start-up is scheduled for the second half of 2016.

Russia NLMK to increase blast furnace capacity. NLMK is performing a scheduled overhaul of blast furnace No. 5 at its main Novolipetsk production site in Lipetsk. As a result, the average capacity of the furnace will increase from 6,000 t/day to its design capacity of 8,000 t/day. Novolipetsk currently operates five blast furnaces.

As a result of an efficiency improvement programme, 2014 steel output grew by 1.3% compared to 2013 reaching 12.56 million t, with capacities running at 100%. Productivity of all blast furnaces was increased as a result of improved technology, mastering pulverized coal injection and increased operational efficiency.

Russia MMK introduces advanced IT solutions. In 2014, the MMK group launched a strategic programme for the adoption of advanced IT in opera-

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MPT International 2 / 2015

INTERNATIONAL INDUSTRY NEWS tional and management processes. Key areas of implementation include an integrated in-house corporate communications system, mobile access to core business applications, modelling and forecasting, continuous planning of customized production and operational management in order execution.

This involves the implementation of the mobility project by creating and introducing new mobile applications, such as an app allowing MMK customers to monitor delivery status 24/7 online, providing complete transparency at all stages of order execution including production. This ensures optimal delivery terms and timely adjustments to the process, as needed. The Mobile Maintenance and Repairs application makes it possible to ensure the timely execution of both scheduled and unscheduled repairs, and to determine equipment defects early on. During the last year, the company has also launched other mobile applications aimed at optimizing business processes and in-house corporate communications. MMK plans to continue implementing this IT development strategy throughout 2015.

Russia ArcelorMittal to sell coal mines.

ArcelorMittal will sell its interest in the Kuzbass coal mines in the Kemerovo region of Siberia to Russia’s National Fuel Company (NTK). The assets include the coal mines of Berezovskaya and Pervomaskaya, which together produce 700,000 t/year of coal. ArcelorMittal acquired the Kuzbass mines in 2008 as part of the company’s strategy to secure delivery of coal to ArcelorMittal steel operations in Ukraine.

The decision to dispose of the Kuzbass coal mines follows a strategic review of the assets. ArcelorMittal’s Ukraine steel operations now source coking coal from ArcelorMittal’s mines in Kazakhstan.

Russia NLMK outsources maintenance of steelmaking operations. Novolipetsk Iron & Steel Corp (NLMK) has signed a contract with the SMS

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15

News in brief Simec, Mexico, has started rebar and wire rod production at its Brazilian facility near the city of Pindamonhangaba in the state of SĂŁo Paulo (Brazil). The mill will have an annual capacity of more than 500,000 tons.

Oman Aluminium Rolling Company, a light-gauge sheet producer, has concluded the final performance tests. The facilities include hot rolling, cold rolling and finishing equipment supplied by Fata Hunter, and also a Hazelett belt caster.

Ovako has signed an agreement with SSAB to acquire steel and metals distributor Tibnor in Finland.

Tibnor purchases, warehouses, processes and distributes steel and other metals for the engineering, process and construction industries.

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THE ENTIRE WORLD OF IRON AND STEEL MAKING

Coking & sintering technologies

group for full-time service of key process equipment in the BOF shops of its Lipetsk production site. Never before have maintenance of steelmaking operations been outsourced in Russia at such a scale. As part of a five-year contract, SMS group experts will ensure the maintenance and repair, both on and offline, of all nine continuous casting machines and of the SMS Mevac-supplied RH plants and ladle furnaces. For the duration of the contract, 274 NLMK workers that were responsible for the maintenance of steelmaking equipment, will be taken on board by the SMS group’s Russian subsidiary. SMS group will additionally bring in 34 highly qualified experts to implement structural changes to operational practice. The team will have to cope with the challenge of having to deal with casters built during a period ranging from 1967 through 2012.

NLMK also entrusted the SMS group with the management of the spare parts inventory of the continuous casting plants and the secondary-metallurgy facilities.

The SMS group now stocks the daily requirements of parts in a warehouse on the works premises.

Material handling Iron making plants

Sweden

Steel making plants Rolling mill plants Recycling plants / Shaft furnaces Electric and process automation Heat and energy recovery Dedusting and gas cleaning

PROCESS DEVELOPMENT TECHNOLOGY TURNKEY RELOCATION UPGRADING REVAMPING OPERATOR MODELS NON FERROUS Küttner GmbH & Co. KG Essen/Germany info@kuettner.com www.kuettner.com METEC 2015 Stand 4C28

SSAB to close galvanizing and colour-coating lines. Through the closure of the galvanizing line and color-coating line in Borlänge, the SSAB Europe division is optimizing and streamlining the production of certain products to different production sites. The strategic aim of this restructuring is that the Borlänge mill will in future specialize in hot-rolled and cold-rolled strip products. SSAB has given notice of redundancy regarding 210 employees out of a total of 2,100 employees at SSAB´s mill in Borlänge. This measure represents part of the previously announced efficiency and synergy programme resulting from last year´s combination of SSAB and Rautaruukki. Hot-dip galvanized steels will continue to be produced in Hämeenlinna, Finland, and colour-coated products in Hämeenlinna and Kankanpää in Finland, and in Finspång in Sweden.

Companies Eurofer comments on Chinese removal of steel export rebates. China has lifted the VAT export rebates promoting higher value-added products.

However, the removal of the export rebates applies to a selection of the steel products concerned and only when boron is added. Reportedly, Chinese operators are looking for ways to circumvent the rebate removal by replacing boron by other alloys such as chrome. According to Eurofer director general Axel Eggert, the boron-specific VAT removal is a welcome sign of China’s awareness of concerns voiced by the global steel industry on China’s steel policy and practices. However, this measure excludes the basic hot-rolled wide strip prod-

I am aggressive!

uct while at the same time creating new incentives for Chinese exporters to continue enjoying the export rebate through the back door. Eurofer anticipates a continuation of the peak exports recorded in 2014 for these alloyed products and emphasizes that such trade-distorting industrial policies by third countries are detrimental to the recovery of the European steel industry.

Voestalpine sponsors Steel Research Award 2015. Research, development, and innovation have always enjoyed the highest priority at Voestalpine. For this reason, the group is supporting young scientists, sponsoring the first Voestalpine Steel Research Award in 2015, in cooperation with Montanuniversität Leoben and the Austrian Society for Metallurgy and Materials (ASMET). The award will be presented every two years to young academics from all over the world for outstanding work in steel-related research.

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Outotec acquires Middle East and Africa businesses from Kempe. Outotec has acquired Kempe Engineering’s aluminium smelter technologies as well as its service and spare parts businesses in the Middle East and Africa. Kempe is an Australian privately owned company providing technology for aluminium smelters, operation and maintenance services, modernization services and spare parts.

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Voestalpine acquires Trafilerie Industriali.

Voestalpine Wire Technology, a company in the Metal Engineering division of the Voestalpine group, has acquired 100% of Italian company Trafilerie Industriali, specialists in the production of drawn wire. Through this acquisition, Voestalpine Wire Technology is extending its own portfolio of drawn and blank wires.

World crude steel output in 2014. According to figures published by the World Steel Association, world crude steel production reached 1,662 million t in 2014, up by 1.2% compared to 2013. In 2014, the Middle East, the smallest region for crude steel production, had the most robust growth. Crude steel production in the EU (28), North America and Asia grew modestly in 2014 compared to 2013, while in the C.I.S. and South America it decreased. In December 2014, world crude steel production for the 65 countries reporting to the World Steel Association was 133.7 million t, an increase of 0.1% compared to December 2013. The crude steel capacity utilization ratio of the 65 countries in December 2014 was 72.7%, 2.4 percentage points lower than in December 2013. The average capacity utilization in 2014 was 76.7% compared to 78.4% in 2013.

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Process and hot gas fans Process gas dust collection Process gas cleaning plants Secondary fuel technology Belt drying plants Vapour exhaust plants

18

››› INTERNATIONAL INDUSTRY NEWS

News in brief Acciaierie Bertoli Safau, Italy, has completed revamp of its “Mars” production line. The blooming stand 900 was replaced by a new blooming stand 1000. A new cooling bed was installed, and new pits for slow cooling were built. The revamp was carried out by Danieli. It followed on the modernization of the continuous casting plant No. 3, adding the 850-mm-diameter size.

Nampak Products, South Africa, has entered into a long-term tinplate supply contract with Nippon Steel & Sumitomo Metal ( NSSMC). Nampak has various steel can manufacturing facilities across Africa.

MSC Software, USA, has acquired Simufact Engineering, a provider of metal forming and joining software.

Borusan Mannesmann Pipe, USA, has issued the final acceptance certificate to Primetals Technologies for a heat treatment plant installed in its new ERW pipe mill in Baytown, Texas.

NLMK and OMK extend slab supply contract. Steelmaker NLMK and pipe manufacturer OMK have extended their contract for the supply of Novolipetsk slabs up to and including 2019. Under the contract, NLMK will continue to supply cast steel slabs that are rolled into plates for the production of large diameter pipes at the Vyksa Steel Works. The initial contract between NLMK and OMK had been signed in August 2012, and in November 2013 the companies signed an agreement of long-term cooperation for 2014 – 2017.

Partnership between Totem Steel and Tata International Metals Americas. Totem Steel International and Tata International Metals Americas, a division of Tata International Limited, have concluded a partnership agreement according to which Totem Steel will be continuing its operations as Tata International Metals Americas. Totem Steel International is a steel and forest products trading company located in Portland, Oregon.

CFSBI introduces new industry data programme. The Cold Finished Steel Bar Institute (CFSBI) has inaugurated a new, improved programme to collect and aggregate industry data for

Water-cooled components for the steel industry

carbon and alloy steel bars. Members of the CFSBI have been concerned that the industry data which was being collected presented an inaccurate and misleading picture of the cold finished steel bar industry. The new programme is expected to be substantially more accurate and valuable. The new programme will be administered by GES, a subsidiary of the law firm Kelley Drye & Warren, legal counsel to the CFSBI. GES will collect confidential monthly shipment data from member and non-member companies alike.

ThyssenKrupp reports firstquarter results. ThyssenKrupp achieved its operating targets in the first quarter of the 2014/2015 fiscal year and confirmed its forecast for the full year.

TK Steel Europe reported a decrease in orders and sales in the reporting quarter due to lower prices and volumes resulting from the sustained decline in steel prices and by production bottlenecks due to the delayed completion of a continuous caster modernization which in turn delayed the start-up of a relined blast furnace. However, adjusted EBIT climbed significantly by EUR 61 million to EUR 79 million. Measures under its efficiency programme had a positive impact on earnings, while lower raw material costs also contributed.

Order intake and sales at TK Steel Americas were respectively 22% and 7% low-

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MPT International 2 / 2015

Kuhlmann-System-Kühltechnik GmbH D - 45721 Haltern am See . An der Ziegelei 11 Phone: +49(0)2364/10 53 9-0 . Fax: +49(0)2364/10 53 9-16 E-mail: info@k-s-k.de . Web: www.k-s-k.de

INTERNATIONAL INDUSTRY NEWS er year-on-year due to the disposal of ThyssenKrupp Steel USA.

Tata Steel acquires Nordic strip products service centres. Tata Steel in Europe has reached an agreement with steel producer SSAB to buy its strip products service centres at Halmstad in Sweden and Naantali in Finland. Tata Steel will also acquire from SSAB the remaining 50% stake it does not already own in Norsk Stål Tynnplater, another strip products service centre based in Fredrikstad, Norway.

NLMK outsources internal logistics. Russian steelmaker NLMK and Freight One (PGK), rail freight operator in Russia, intend to launch a pilot project for outsourcing the internal logistics at the two Urals sites of NLMK Long Products division. Freight One will manage railway transportation operations and the railway department shared by the two plants, and provide maintenance of track facilities and locomotives.

Gega changes name. Gega Lotz GmbH has changed its name to Alpine Metal Tech Gega GmbH. The established product brand will remain the same in the future. All contracts with customers and suppliers remain unchanged and valid.

SSAB to divest shares in Norsk Stål. SSAB has received approval from the European Commission to sell 50% of the shares in Norsk Stål AS, Norway, to Leif Hübert AS. This transaction is part of the divestment remedies that the European Commission deemed necessary for the combination of Rautaruukki with SSAB. The transaction is still subject to the approval by national competition authorities.

Ferragon acquires Steel Rolling Holdings. Ferragon Corporation has acquired the Steel Rolling Holdings

‹‹‹

19

(SRH) facility in Gibraltar, Michigan and will rename the facility Ferrolux Metals Gibraltar Plant. The acquisition doubles the Ferrolux presence in Detroit, with the Gibraltar facility providing batch annealing, temper rolling and tandem mill cold rolling for automotive grade steels and the Ferrolux Metals Wayne Plant offering world class slitting and inspection of coldrolled sheets for exposed automotive applications.

Personalities New CFO at Schmolz + Bickenbach. Schmolz + Bickenbach has won Matthias Wellhausen as new chief financial officer. Matthias Wellhausen can look back on a long career in finance, treasury and controlling positions as well as in the steel industry.

Since 1996, he has been holding several CFO positions within the ArcelorMittal group, both operative in the mills and in the headquarters.

Chairman of SSAB board leaves assignment. SSAB’s chairman of the board, Sverker Martin-Löf, will not be available for re-election at this year’s annual general meeting. Sverker Martin-Löf has been chairman of the board since 2003. The company’s principal owner, Industrivärden, will propose to nominate Bengt Kjell as the new chairman of the board.

Simufact strengthens sales team. As senior sales manager, Michel Pereme will be responsible for the further development of Simufact Engineering’s sales activities in the EMEA region. He will be closely cooperating with Stefan Zimmer, who holds the overall responsibility for Europe and Asia.

Two additional independent directors on Timken Steel board. The board of directors of Timken Steel elected two new independent directors: Randall MPT International 2 / 2015

20

››› INTERNATIONAL INDUSTRY NEWS

News in brief

egy and finance for the Asia-Pacific region, has been nominated interim head of the business area.

NLMK, Russia, has successfully reduced dust emissions down to 22.09 kg/t steel at its Lipetsk production site by markedly improving the level of off-gas treatment.

The decrease in emissions in 2014 was achieved in parallel with a steel output record.

Changes to Ovako’s board. Björn Nilsson has been elected as a new member to Ovako’s board of directors. He takes over the position from Magnus Lindquist.

Zhejiang Kingland, China, has successfully commissioned a spiral pipe plant supplied by PWS. NLMK, Russia, has made a saving of 425 million roubles in 2014 through the use of pulverized coal injection at two blast furnaces at its Novolipetsk production site in Lipetsk.

NSSMC has opened a representative office in Ho Chi Minh City, Vietnam.

Edwards, president and chief operating officer of Premier Pipe, and Ronald Rice, president and chief operating officer of RPM International Inc. Nine directors now serve on the Timken Steel board.

Head of business area leaves Outokumpu. Austin Lu, Outokumpu’s head of business area Asia-Pacific and Outokumpu leadership team member, has taken a new challenge outside the company. Jan Hofmann, head of strat-

New general director of Stoilensky. Sergei Napolskikh has been appointed general director of iron ore producer Stoilensky, which is part of the NLMK group. In his new role, Sergei Napolskikh, previously deputy general director, production and technology, will continue to implement the operational efficiency improvement programme and investment projects. The position of general director was previously held by Yuri Larin, who will focus on developing the operational efficiency programmes at group levels.

New head of Outokumpu Nirosta. Oliver Picht has been nominated chairman of the board of the business unit Outokumpu Nirosta. Oliver Picht joins Outokumpu from Novelis, where he was project director Novelis Europe.

Dr. Oliver Picht

New managing director at Aumund Fördertechnik. Aumund Fördertechnik has a new managing director. Robert Gruss joined Aumund from SMS Siemag and is responsible for sales, service, technology as well as for research and development. He forms the management board of Aumund Fördertechnik together with Volker Brandenburg, responsible for finance, controlling, general administration, purchasing and production. Step by step, Robert Gruss will take over additional responsibilities from the managing partner Franz-W. Aumund.

Aperam appoints executive officer. Aperam has appointed Bert Lyssens as head of sustainability, human resources and communications.

Bert Lyssens will be a member of Aperam’s leadership team and will report to Aperam CEO Timoteo Di Maulo.

U. S. Steel names vice president and controller. Colleen M. Darragh has been promoted to the position of vice president and controller. Colleen M. Darragh has served as acting controller since July 2014. As the chief accounting officer for the company, she will be responsible for U. S. Steel’s global financial accounting, reporting and analysis functions.

Isra Vision expands management. Isra Vision actively continues its growth strategy with the addition of

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MPT International 2 / 2015

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Andreas Gerecke to the existing management. As a new member of the executive board, he takes over the worldwide responsibility for the operations segment.

Events ›

7 – 8 May 2015 Kolkata, India Organizers: Steel & Metallurgy www.steelmetallurgy.com

Technology, Market & Applications for Long & Flat Products.

This conference will focus on value creation in the Indian steel industry.

The topics covered by the papers include steel market developments, steel price trends, problem of overcapacity, new product developments, process and quality improvement, cost and energy savings, etc.

›

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

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

›

25 – 28 May 2015 Manila, Philippines Organizers: SEAISI www.seaisi.org

2015 SEAISI. This year’s SEAISI conference and exhibition will cover topics such as competitiveness and opportunities for the steel industry in the ASEAN Economic Community, steel trade analysis, value creation in the ASEAN steel industry, new technologies, etc.

›

28 May 2015 Brussels, Belgium Organizers: Eurofer www.eurofer.eu

European Steel Day 2015. The European Steel Day is an annual event hosted by the European Steel Association. It provides a common voice for the industry and underlines the benefits of steel as a material. This annual event is a unique occasion for representatives from the steel sector, EU policy makers, business representatives and journalists to discuss the competitiveness and main challenges of the steel industry in Europe.

›

17 – 21 August 2015 Rio de Janeiro, Brazil Organizers: ABM www.abmbrasil.com.br

ABM Week. This year, ABM will combine its annual events, bringing together nine traditional events in one week and in the same venue, namely the 70th Annual Congress, the Rolling Seminar, the Steelmaking Seminar, the Ironmaking & Mineral Technology Seminar, the Logistic Seminar, the Energy & Utilities Seminar, the Automation and IT Seminar, Enemet and the Drawing Seminar.

›

14 – 17 September 2015 Dresden, Germany Organizers: Steel Institute VDEh, Deutsche Gesellschaft für Materialkunde www.werkstoffwoche.de

Materialsweek 2015. Under the motto “Materials for the Future”, this event will provide an ideal forum for the exchange of information among developers, producers and users of modern materials. The congress will feature innovative material developments and applications.

The exhibition will offer ideal conditions for producers, processors and users of materials as well as manufacturers of machinery, plants and testing equipment to present their products.

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24

›››

EVENTS

Approx. 500 exhibitors from 35 different countries have registered for METEC 2015

The four Düsseldorf metallurgy trade fairs taking place in June are on the winning track Known as “The Bright World of Metals”, the four international trade fairs for metallurgy and foundry technology – GIFA, METEC, THERMPROCESS and NEWCAST – will be held in Düsseldorf from 16 to 20 June 2015. Together they will cover more than 84,700 square metres.

These leading international technology trade fairs GIFA, METEC, THERMPROCESS and NEWCAST will be held

The Bright World of Metals Messe Düsseldorf, Germany 16 – 20 June 2015 Find more information on the Internet: www.tbwom.com · www.gmtn.com www.metec.de · www.thermprocess.de www.gifa.de · www.newcast.de

MPT International 2 / 2015

in Düsseldorf from 16 to 20 June 2015.

During this five-day event, visitors from all over the world will flock to the German city on the river Rhine to get latest information on topics related to the production of castings, foundry technology, metallurgy and thermal process technology. A programme of high-end events will again be taking place alongside the trade fairs, including seminars, international congresses and lecture series. All four trade fairs and the associated programmes

will emphasize issues related to energy and resource efficiency.

Last time, in 2011, a total of 79,000 experts from 83 countries visited the four trade fairs, in which 1,958 exhibiting companies participated. This year, “The Bright World of Metals” is setting a new record: by the end of February, already 84,706 square metres of exhibition space had been sold – an all-time high. Halls 3 to 17 are already fully booked. Also in terms of the number of exhibitors, these leading internation-

al metallurgy and foundry technology trade fairs are continuing their impressive development: about 2,000 companies will be presenting their products and services to the trade community.

Friedrich-Georg Kehrer, director at Messe Düsseldorf: “A development like this cannot be taken for granted nowadays because company take-overs and mergers would in fact justify stagnation or even a reduction in the number of exhibitors and space booked. The fact that “The Bright World of Metals” has such positive news to report shows that its uniqueness – combining different technology fields, namely foundry, metallurgy, thermal process technology and castings in one event – guarantees its success.”

METEC on the winning track METEC – the International Metallurgical Trade Fair – also continues its track record. With 486 exhibitors from 35 different countries and 21,456 square metres of exhibition space in halls 3 to 7, it is about to achieve its best-ever result.

Also as far as international exhibitors are concerned, METEC is performing outstandingly: 64% of the companies are from European countries outside Germany or from overseas. China takes the lead with 75 participants, followed

by Italy with 50, and the USA and India, both with 18 exhibitors. Project manager Markus Liedtke is proud to report: “The list of METEC exhibitors reads like the who’s who of the industry. With the SMS group, Primetals and Danieli, the major industry players are on board.

Danieli is exhibiting again at METEC after a long time.” During METEC, there will be an impressive programme of concurrent events. With the 2nd ESTAD (European Steel Technology and Application Days) and other accompanying events, METEC represents an excellent opportunity for the exchange experience at an international level. Liedtke: “Nowhere else in the world can experts inform themselves so extensively about the latest developments in the metallurgy field in such a short time and at a venue so conveniently located.”

Major industry players at THERMPROCESS The International Trade Fair and Symposium for Thermal Process Technology – THERMPROCESS – is

26

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EVENTS

also proving to become a success in 2015: the industry leaders like Inductotherm, Tenova LOI, ABP Induction, SMS group and Otto Junker have booked considerably more square metres this year. In total, the roughly 300 exhibitors in halls 9 and 10 have reserved more than 10,300 square metres of exhibition space. Project manager Gerrit Nawracala confirms the

als, heating technology and heat and surface treatment of metals, ceramics and glass.

ecoMetals campaign sets standards Energy efficiency and the minimization of resource input are currently definitely the central issues in the met-

“The Bright World of Metals” has positive news to report

encouraging progress made by the trade fair: “With almost 50% of exhibitors coming from outside Germany, also THERMPROCESS has become a world leading trade fair and a must-do for companies from 30 different countries.” Traditionally, Italian exhibitors represent the largest contingent at THERMPROCESS. They lead the list of foreign countries with 23 companies, followed by China (19) and the USA (15). It goes without saying that the accompanying programme will centre around heat-related topics: the THERMPROCESS Symposium will provide information about technical innovations relating to heat treatment and modern energy engineering concepts for plants, while the FOGI Special Show will be focussing on the heating, melting and casting of metMPT International 2 / 2015

allurgical and foundry technology industries. In order to be able to produce successfully in these energy-intensive industries – particularly in countries with high energy costs – it is essential to save energy in the production process, make efficient use of materials and resources, opt for renewable energy sources and carry out optimized energy controlling. The ecoMetals campaign, which Messe Düsseldorf launched four years ago, focuses on these areas. In cooperation with the VDMA, foundry machinery and thermal process technology trade associations and the Blue Competence initiative, companies with special energy- and resource-saving achievements may participate.

Messe Düsseldorf is offering visitors guided tours to the ecoMetals participants, in German and English lan-

guage. It is possible to register for these tours on “The Bright World of Metals” trade fair website (www.tbwom.com).

GIFA: “oldie but goldie“ The figure of 46,367 square metres of sold exhibition space reached this year by GIFA – the International Foundry Trade Fair and Technical Forum – means that the “oldie” of the four trade fairs at almost sixty years of age has exceeded its record number of 1999 (46,255). GIFA 2015 will be one of the most successful in its history also in terms of the number of exhibitors (801 participants). Friedrich-Georg Kehrer explains: “The English phrase “oldie but goldie” definitely applies to GIFA, which has performed at an excellent level for many years and will be presenting the global players of the industry again this year.” They include Bühler, Frech, Italpress as well as Hüttenes-Albertus, Foseco, ABB Automation, Künkel-Wagner, Heinrich-Wagner/ Sinto, ASK Chemicals, the Austrian company Fill, the Spanish company Loramendi and the Danish company DISA. Project manager Raphaela Müller adds: “61% of our GIFA exhibitors come from outside Germany. This is a clear indication of the global significance of the trade fair.” Like in the past, Italian companies again represent the largest contingent with 113 exhibitors, followed by China with 79 participants and the UK with 42 companies. For the first time, Egypt, Bulgaria and Singapore will be represented. With exhibitors from 46 different countries, GIFA will be a reflection of the world market for foundry technology in halls 10 to 13 and 15 to 17. A programme of high-end accompanying events including the Technical Forum and the GIFA Conference will be staged directly on-site in the exhibition halls. These events will be providing trade visitors important information about innovations and the technological trends of the future, especially in the fields energy saving and minimization of resource input.

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EVENTS

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NEWCAST with excellent DQQMKPI ƂIWTGU “NEWCAST has grown into a highly international trade fair,” emphasizes NEWCAST project manager Janike Rotthoff. The youngest of the four metal trade fairs was launched in 2003 and is becoming increasingly popular.

Rotthoff: “The production of castings has developed into a highly international business over the last decade and this is reflected by NEWCAST.” In 2015, about 370 exhibitors from 31 different countries will be presenting their products and services on just under 6,600 square metres of space in halls 13 and 14. The break-down of bookings by countries corresponds very much to the world market: 148 Chinese suppliers of castings will be exhibiting at NEWCAST, demonstrating that they have evolved into one of the biggest players on the world market. The second-largest international contingent comes from Turkey (42 companies), followed by Japan (30 companies) on the list of foreign exMPT International 2 / 2015

hibitors. NEWCAST will see international market leaders such as Georg Fischer Automotive, Class Guss, KSM Castings, Gießerei Heinisch or Finoba Automotive. There will also be an attractive side programme. The NEWCAST Forum will provide an opportunity for direct exchanges of expertise with well-known industry experts.

The popular NEWCAST Award – the “Casting Oscar” – will honour the most innovative and creative castings of the year.

Visit four trade fairs with one admission ticket GIFA, METEC, THERMPROCESS and NEWCAST offer trade visitors and exhibitors from all over the world outstanding synergy benefits. There will be one single admission ticket providing entry to all four trade fairs. Day tickets cost € 45.00 and the five-day ticket costs € 98.00.

Tickets can be bought at the online ticket shop.

Under the joint motto “The Bright World of Metals”, Messe Düsseldorf organizes not only GIFA, METEC, THERMPROCESS and NEWCAST, but also other premium metallurgical and foundry trade fairs all over the world.

These include FOND-EX (International Foundry Fair) and Stainless in the Czech Republic, Metallurgy India, Metallurgy-Litmash (International Trade Fair for Metallurgy Machinery, Plant Technology & Products) and Aluminium Non-Ferrous in Russia, indometal in Indonesia, metals middle east in Dubai, ITPS (International Thermprocess Summit) Americas and Asia and the aluminium trade fairs in China, India, the United Arab Emirates and Brazil. The range of events held for the metals industries at the Düsseldorf location is rounded off by the Valve World Expo (International Trade Fair and Congress for Industrial Valves and Fittings) and ITPS Düsseldorf as well as the international trade fair ALUMINIUM organized by Reed Exhibitions and Composites Europe.

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››› PREVIEW OF EXHIBITORS

Ironmaking and steelmaking Harmonized equipment for continuous casting Optimization of the casting process is achieved by using comprehensive technical solutions from one source, like the Alpine Metal Tech (AMT) package. All components developed from the leading brands Numtec, Gega, Magnemag, Koch H&K and Knorr will be presented. The range on display includes equipment for vessel preheating, shroud manipulation, powder feeding, torch cutting, deburring, marking, reading, scarfing and conditioning. This will be complemented by installations for inspection and measuring of rail and long products, and cooling beds and transfer/handling equipment for rolling mills.

Alpine Metal Tech Holding GmbH Hall 4, stand E18 (METEC) www.alpinemetaltech.com

steel and other metals casting. Berthold mould level systems support casting with highly reliable, precise measuring results, which are readily available for an optimum automatic control of the stopper rod or similar equipment. Due to the diversity of systems, Berthold is capable of providing customized mould level solutions, including systems for determining casting powder thickness.

Berthold Technologies GmbH & Co KG Hall 4, stand B30 (METEC) www.berthold.com

Refractories Calderys offers individual and fullpackage solutions for all refractory requirements, including bricks for full relines, partial relines and patching, gunning materials and castables, and

Hot converter gunning immediately Family of equipment for continuous

after tapping

casting plants

Mould level measurement in continuous casting Berthold Technologies present their range of mould level solutions for continuous casting applications, based on

Measurement of mould level during casting

electromagnetic or radiometric measuring systems. The product range covers all mould formats and sizes used in MPT International 2 / 2015

a full range of remotely operated application equipment. In addition to the product offerings, Calderys provides services such as design, product selection, thermal calculations, CFD analysis, installation, labour & machinery, supervision, repair service support, full refractory project management. High-performance BOF converter maintenance takes account of the balance between converter availability requirements and refractory life requirements. The aim is to increase overall furnace availability, extend vessel life and reduce the total refractory cost per ton of steel produced. The BOF maintenance products optimize the use of MgO and CaO bearing aggregates and use specialized and sophisticated phosphate bonding systems which interact with the converter slag to increase sticking, durability and re-

duce material consumption and maintenance time.

Calderys Deutschland GmbH Hall 10, stand A18 (THERMPROCESS) www.calderys.com

Vacuum furnace technology As part of the Inductotherm group of companies, Consarc Engineering designs and manufactures vacuum and controlled atmosphere furnaces for the following processes: vacuum precision investment casting (VPIC), vacuum induction melting (VIM), vacuum cap furnaces (VCAP), vacuum arc remelting (VAR), electroslag remelting (ESR), induction skull melting (ISM), induction vacuum ladle (IVL), high temperature heating, chemical vapour deposition, vacuum heat treatment (VHT), vacuum brazing (VAB), diffusion bonding, vacuum de-oiling, custom/proprietary processes.

The equipment displayed will incorporate a laboratory/pilot plant sized vacuum induction melting furnace (VIM) together with complete high vacuum pumping system. The design utilizes a water-cooled vacuum chamber, providing optimum access for cold charging and servicing in a batch mode of operation. The chamber also houses auxiliary equipment with standard and optional features provided by Consarc to ensure maximum flexibility and ease of operation.

Consarc Engineering Ltd Hall 10, stand D42 (THERMPROCESS) www.consarc.com

Vacuum furnace

Refractory solutions Eredi Scabini works in close contact with international universities and external research laboratories to identify new products for specific refractory requirements. During the last few years,

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Eredi Scabini’s research work has focused on the development of nanotechnology and the application of its basic principles in the refractory sector, yielding highly convincing results.

Seven Refractories d.o.o.

Eredi Scabini will present its nanoplast products: NanoplastAlfaplast®, Sigmaplast® and Zetaplast®. In addition to these, the company owns a great number of exclusive proprietary products.

Stein will present its new process for re-carburizing steel by top injection.

The process uses a simple ordinary non-coated steel pipe to inject the carbon into the steel bath from above, instead of deep immersion made by a refractory lined lance. The advantage is that the lance pipe can be used for a long time with nearly no consumption of the pipe itself. For injection, standard dry compressed air can be used as carrier gas instead of nitro-

Eredi Scabini S.r.l.

Hall 10, stand F56 (GIFA) www.erediscabini.com

Vibrating equipment

Hall 10, stand C66 (GIFA) www.sevenrefractories.com

Top injection process for steel re-carburization

Jöst designs and supplies vibrating machines and systems for the steel industry. The company will present an interesting overview of products for primary and secondary metallurgy, ranging from solutions for the conveying of raw materials, screening, storage and dosing of various products up to the different furnace melting processes like EAF, RH, VD or LF. Innovative solutions for individual requirements will be presented.

dustries, including innovative, integrated solutions for complete process areas. In the field of steel and light-metals technology, Tenova will present its Energiron DR technology for the production of high-carbon DRI, will inform about fully integrated electric arc furnaces, energy recovery solutions from EAF processes and new secondary metallurgy plants. Thermal processing

The holistic approach for EAF steelmaking

technology presented will range from reheating to heat-treating of high-quality flat and long products. Also on display will be technology for processing metal strips from the hot strip mill down to all final products, as well as cold rolling mills and auxiliary equipment for ferrous and non-ferrous flat strip products. Information will also be provided on fully automated roll shops for hot strip and cold mills.

Jöst GmbH + Co. KG Hall 3, stand F33 (METEC) www.joest.com

Tenova S.p.A. Principle of the top injection process

Hall 5, stand A21 (METEC) www.tenovagroup.com

Refractory products and developments Seven Refractories has developed a full product portfolio for the iron, steel and thermal industries. Seven will present both standard products and new developments such as Seven Cast LCS, a no-cement chemical bonded castable for vibrating casting with highly beneficial drying characteristics. In addition, an innovative concept based on self-flowing and vibration for ladle repair and maintenance will be presented.

In terms of performance and environmentally friendly products, Seven offers an innovative range of high-performing resin-bonded tap hole clays, which also boast a very low concentration of benzo[a]pyrene. Due to intensive research, Seven has been able to dramatically reduce the concentration value and even exceed the limits set forth in German regulations without compromising on product performance.

MPT International 2 / 2015

gen or argon, avoiding nitrogen pickup. For injection into the ladle furnace, the turbulent zone of the melt is used. Compared to deep immersion, the new process saves costs due to a carbon yield of up to 99%, involves nearly no lance consumption, avoids lance breakage or plugging of injection holes and does not require any refractory for the lance. The equipment is directly connected to the ladle furnace PLC, ensuring an exact match with the carbon analysis calculated in advance.

Intelligent transformer system for EAFs TES Transformer Electro Service designs and manufactures high-power transformers. The transformer of an electric arc furnace is crucial to the melting process, its main task being the transformation of the voltage and current values used for the melting of ferrous metals, ferroalloys and scrap. At METEC, TES will introduce its new EAF SMARTrafo

Stein Injection Technology GmbH Hall 4, stand F09 (METEC) www.sit-gmbh.net

Advanced technologies for the metals and mining industry Tenova will present its advanced technologies, products, and services for the metals and the mining & minerals in-

Transformer for an EAF

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34

››› PREVIEW OF EXHIBITORS

project. This is an innovative project aimed to demonstrate and offer modern technological solutions, which enable significant savings in industrial processes, thanks to the installation of a new EAF transformer. The SMART transformer, sized to minimize electrical losses during its operation, ensures the increase and balance of energy input. This innovative solution improves the efficiency of the entire industrial system, reducing costs and providing economic benefits.

TES Transformer Electro Service S.r.l.

Hall 4, stand D36 (METEC) www.testransformer.com

Mini-format debricking machine TML will be showing its new Unidachs 220 debricking machine. The machine for debricking ladles, tundishes, furnaces, blast furnaces runners and rotary kilns is of an unusually small and compact design and features the unique kinematics of a telescopic boom. This means that the new machine can be deployed in very tight

spaces and where working space and height are restricted. It was built to be used in hot zones, and with its 360° endlessly rotating telescopic boom it can reach every point from which material needs to be removed. With a stroke of 2,000 mm, the Unidachs combines an optimum reach with a maximum of flexibility. It has been optimized for hydraulic hammers and for rotary drum cutters up to a weight of around 500 kg. The machine has been designed to cope with the hot zone conditions in steel works. The telescopic boom is fully enclosed, protecting the hydraulic cylinder and the hoses inside the boom from heat radiation and from falling debris. Thanks to the remote control operation, the driver is always at a safe distance.

refractory and systems components.

For ironmaking, the company will show the engineering and modelling of blast furnace runner systems, designed to optimize iron flow and maximize refractory performance.

Also techniques and products that target enhanced yield and efficient clean steel production will be shown.

Vesuvius will highlight its expanded product and technology portfolio, which now includes the tundish and mould powder technologies of Met-

TML Technik GmbH Hall 5, stand D22 (METEC) www.tml-technik.com

Specialized refractory components and system solutions As a partner of the steel industry, Vesuvius develops and produces highly specialized refractory components and system solutions for the controlled casting of steel. Vesuvius will be presenting its “Solutions through Technology” approach to the containment, process monitoring and flow control of iron and steel. The technology package comprises a wide spectrum of refractory lining technologies, flow control

Refractory components in an electric furnace

allurgica, the flow control systems of Sert and the data acquisition products of Avemis, ECIL and Process Metrix, illustrating the new solutions derived from the integration of these technologies into the Vesuvius portfolio.

Vesuvius Group SA Hall 5, stand D19 (METEC) www.vesuvius.com

Debricking machine with rotating telescopic boom

Rolling and processing technology Warehouse and transport management 3tn will for the first time present its technical warehouse management system TWMS/metals. It controls and visualizes transport and storage activities in the metals industry from continuous casting through to the shipment of the finished products and optimizes the use of storage capacities across various warehouses or even plant-wide.

TWMS/metals enables target-oriented storage of slabs, billets, coils and plate, MPT International 2 / 2015

ensuring that the means of transport, such as cranes or cross transfer systems, are efficiently used. The system optimizes crane movements, avoids unnecessary shifting operations and optimizes the transport activities in general. The results are optimal storage of all products, short transfer times, efficient use of personnel and means of transport, no damage due to improper storage, and safe working conditions. Moreover, the system reduces the tracing effort to virtually zero.

3tn developed TWMS/metals specifi-

TWMS/metals controls and visualizes transfer and storage operations

cally for the metals industry. The system is preconfigured for all products,

Injection technologies for metallurgical processes For the economic production of high-grade steel, ThyssenKrupp Industrial Solutions provides injection technologies for precise DQG FRVW Hƨ HFWLYH GHVXOSKXUL]DWLRQ RI KRW PHWDO DQG OLTXLG VWHHO +LJK SURFHVV ƪ H[LELOLW\ DOORZV WKH EHVW DGDSWDWLRQ RI SODQW RSHUDWLRQ WR FKDQJLQJ SURGXFWLRQ UHTXLUHPHQWV )OH[LELOLW\ TXDOLW\ DQG Hƫ FLHQF\ PDNH RXU PHWDOOXUJLFDO LQMHFWLRQ SODQWV PRVW economic and future-proof.

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››› PREVIEW OF EXHIBITORS

means of transport and warehouse arrangements common in this industry.

In one direction, it communicates with ERP and MES systems and, in the other direction, with the basic automation systems and the sensor equipment.

3tn Industriesoftware GmbH Hall 3, stand E35 (METEC) www.3tn.de

Equipment for long-product rolling mills ATS specializes in the design, manufacture and supply of plants for the steel and metals industries. At METEC, ATS will introduce its latest gen-

Finishing line equipment

eration of the TMB400 bar tying and bundling system. This machine has a simple solid structure resulting in a maintenance-free machine. The number and types of turns are set via a control panel. A standard tying cycle takes less than 7 s. Precise bar counting is ensured by a TV camera system.

ATS products also include conditioning lines for slabs and billets with grinding machines for hot grinding and optimized angle processing. ATS as well supplies bar rolling mills with high-speed delivery onto the cooling bed and finishing lines for bars and tubes including drawing, straightening, chamfering, cut-to-length and stacking systems. The company developed a proprietary high-speed bar delivery system, which includes a water quenching and tempering box, shear for cutting to multiple lengths, tail breakers and a drum system for bar breaking and discharging. The system is complete with automation equipment for controlling low temperature thermomechanical rolling. ATS’ after-sales support comprises the supply

of spare parts, production assistance, equipment upgrading and buy-back agreements. Therefore ATS is able to also supply second-hand equipment which is refurbished and guaranteed as new.

ATS S.p.A. Hall 3, stand A16 (METEC) www.ats.ud.it

HAGC cylinders Castellini has focused its core business on reliably supplying critical spares parts like mandrels, spindles, screwdown systems, bending blocks and HAGC (hydraulic automatic gauge

HAGC cylinders in the workshop

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PREVIEW OF EXHIBITORS control) cylinders to their customers. HAGC cylinders are a key device in rolling mills for flat products. Introduced almost 30 years ago, these cylinders are still the most effective solution for achieving good thickness control. Despite the widespread use of this equipment, the manufacturing requires a great deal of experience and a high degree of specialization.

Both in case of new or reconditioned equipment, Castellini performs force and pressure tests, hysteresis and bandwidth measurements on dedicated test stands before delivery for installation. %CUVGNNKPK 1HƂEKPG /GEEJCPKEJG 5 R C Hall 3, stand A04 (METEC) www.castellini.it

Pickling of carbon steel strip At METEC, CMI UVK will introduce its newly developed spray modules for pickling carbon steel strip. In these modules, the acidic pickling liquor removes the scale much more efficiently from the strip surface than in con-

‹‹‹

37

with high impact. Alone by the impinging acid jet is a large part of the scale adhering to the strip removed.

CMI UVK offers the full line of engineering and project management services for cleaning, degreasing and pickling solutions for strip, wire rod, tubes and pipes, as well as single parts.

CMI UVK GmbH Spray pickling modules (left) arranged

Hall 5, stand D04 (METEC)

upstream of the pickling tanks (right)

www.cmigroupe.com

ventional turbulence pickling lines.

Thus, carbon steel strip can now be pickled in markedly less time than before, and newly built pickling lines can be designed with a shorter length.

Moreover, it will be possible to flexibly adapt the pickling parameters from coil to coil. As a further advantage, the process saves energy because the pickling liquor temperature can be lower.

The new, patent-pending technology consists of several nozzles arranged across the width of the strip.

These nozzles spray the acid onto the strip surface from above and below

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Since only a vacuum or magnetic forces are applied to the split rings, their transport from the turnstile to the

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38

››› PREVIEW OF EXHIBITORS

Swivelling table on slides transporting split rings

storage area bears practically no risk of damage to the material. The system largely automates the separation of coils, their take-over from the turnstile as well as their tilting, strapping and further transport to the storage area. The core of this new system is a swivelling table on slides, superseding the use of a commonly used crane. The Coil-Hover avoids any damages to the strip edges or surface, because the coils do not get in contact with a crane hook and do not run on rollers. The coils are “floating” from the turnstile to the storage area. The system is designed to handle coils with an outer diameter of up to 2,000 mm and a width of up to 300 mm. It can be used for almost any kind of ferrous and non-ferrous metals. Ferromagnetic strips are held on the swivelling table by electro permanent magnets. For handling non-ferromagnetic strips, the swivelling table is equipped with an aluminium suction plate with several suction rings holding the split ring securely in place.

go through hot or cold levelling, may be turned or even bump into another plate or roller tables without damaging the tags. The high-quality barcode on the tag guarantees reliable and real-time plate tracking. The mill personnel can use commercially available hand-held bar code readers to identify each plate right on the stacks or install heavy-duty floor-mounted optical readers to identify the plate at any point during processing. Specially designed printers and

has been engineered in new special alloy, saving approximately 40% of the usual guide weight.

The new patented WEG exit guide can be adapted, with different rollers, to achieve several functions: as marker for marking the bar; as edger for making the edging pass and saving one stand at the beginning of the slitting process, or for sizing, i.e. decreasing the ovality of finished round products of up to 16 mm.

The WICON rolling simulation software provides continuous analysis in hot rolling mills for rod and wire, optimizes the setup of the rolling mill, calculates process parameters, automatically generates pass design and creates roll and groove drawings. Its wide range of applications makes it a useful tool at all levels in the company.

Morgårdshammar AB

Plates marked by metal tags

Hall 5, stand A28 (METEC)

attaching tools provide the possibility to mark hot and cold plates with thicknesses starting from 4 mm.

www.morgardshammar.se

IntelMet Technologies Ltd. Hall 4, stand C14 (METEC) www.intelmet.ru

Guides for long product rolling mills Morgårdshammar will have on display latest equipment and solutions for long rolling mills. A live demo will be giv-

hpl-Neugnadenfelder Maschinenfabrik GmbH

Sensors for rolling mill applications NSD will present its Absocoder true heavy-duty position sensor, which has been engineered to withstand the harshest environments prevailing in the steel industry, even in moisture, heat, dust, vibration and high shock.

Steel companies strive to improve their maintenance systems to reduce costly downtime and maintenance. Manufacturers of traditional optic encoders or general purpose position sensors try to improve the durability of these

Hall 3, stand F54 (METEC) www.hpl-group.de

Barcode marking system for plates IntelMet Technologies will present a new solution for identifying steel plates in each stage of the production process using MCL metal tags with the robot-based IntelMark AS-W PE marking system. MCL metal tags (produced by Pannier Corporation) are ceramic-coated to resist temperatures up to 1,000°C and marked online by a CO2 laser printer. The robot picks the tag up from the printer and attaches it onto the plate edge by spot welding. This method provides high reliability and quality of attachment. Plates bearing such tags may MPT International 2 / 2015

Exit guide with marking roller

en of the Smart Eye digital setting system developed for simple and precise calibration. Its user friendly interface makes it fast and easy to achieve precise settings for the roller guide and stand. It has a compact design and the screen projects a clear image of how to adjust the correct position.

A new patented roller guide for intermediate and finishing mill stands

Heavy-duty position sensors

instruments by making their housings bigger and stronger. However, the basic construction of the sensors remains the same. Their delicate com-

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 modiďŹ cation of the steel construction of the blast furnace necessary for such changes is no longer required, meaning no further modiďŹ cations 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.

Engineering ns GREAT Solutio

Valves for the Iron and Steel Industry Our current modern products for the Iron and Steel Industry are known world-wide for their extensive and trouble-free operation.

Basic product range: Plants • Energy Recovery Turbines (TRT plants) • Flare Stack Systems • Control Systems (elec./hyd./pneu.)

Measuring System for use inside Blast Furnaces • t-matriX: 2D - Gas Temperature Measurement System based on sound pyrometry.

• p-matriX: 3D - Radar Based Measurement System to scan the entire dumping profile Equipment • No-Bell Top Charging System • Lock Hopper Systems • Burners • Ignition Equipment • Tuyere Stocks - Energy saving design

p-matriX: 3D Radar Based Measurement

Valves for Stoves, Gas Systems, Blast Furnaces etc.

• Hot Blast Valves • Back Draught Valves • Goggle Valves (Line Blinds) • Lever Valves (2, 3 or Push-Lever) • Butterfly Valves (Control and Eccentric Type) • Snort Valves • Bleeder Valves • Pressure Equalizing Valves • Septum Valves • Gas Safety Valves

t-matriX: 2D Gas Temperature Measurement

We make the largest valves in our industry

Contact IMI Z&J Germany Z&J Technologies GmbH Bahnstraße 52 D-52355 Düren, Germany

IMI Z&J Houston Zimmermann & Jansen Inc. 4525 Kennedy Commerce Drive Houston, TX 77038, USA

Tel: +49 2421 691 0 Email: imizandj.germany@imi-critical.com

Tel: +1 281 446 8000 Email: imizandj.usa@imi-critical.com

Website: www.imi-critical.com

IMI Z&J South Africa Zimmerman & Jansen S.A.(Pty.) Ltd. 11 Michelin Street P.O. Box 1335 Vanderbijlpark 1900 South Africa

IMI Z&J Shanghai Z&J High Temperature Equipment Co Ltd. No. 2 Workshop No. 819 Yinchuan Road Minhang Dist., Shanghai 201109 China

Tel: +27 16 986 0159 Email: imizandj.sa@imi-critical.com

Tel: +86 21 6490 7780 Email: imizandj.china@imi-critical.com

PREVIEW OF EXHIBITORS ponents, such as a light source, glass disc, built-in transducer, and general lead cable, reduce the life of the overall sensor. In contrast to this, the Absocoder achieves an outstanding thanks to its innovative design which eliminates electronics and optics inside the sensor by using magnetic reluctance change. By changing over to Absocoder technology, time spent on calibration, troubleshooting, repair and replacement can be significantly reduced or even eliminated.

Precise position measurement in rolling mills, especially in finishing mills, is crucial to the achievement of a consistent surface finish and thickness of strip. For this, NSD will have on display the VLS-8SM series heavy-duty and high-accuracy linear position sensor for AGC, screw down and side guide. These sensors help to improve existing roll position control systems with a total sensor solution. The sensors can be conveniently installed in systems with existing AGC. The sensor housings will be designed to fit with the existing cylinders.

design. The company has its own electrical and automation division, structured as an independent company.

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41

guarantee a finished product of very high quality. The only spare parts the stands may require are the bearings, the rolling rings and the gaskets.

Nuova Carpentaria Odoloses SPA Hall 4, stand E26 (METEC)

Pert S.r.l

www.nco.it

Hall 4, stand B23 (METEC) www.pertengineering.com

Stands for long products rolling mills Pert will present its BS Stands® for rebar, wire rod, light section and special steel long product rolling. These stands have been specifically developed to reduce the initial investment and the production costs to a minimum. The high stiffness of the stands and the roll gap regulation with eccentric system

Stands for long product rolling

16.-20.06.2015 Halle 5 | 5 G 12

NSD Corporation Hall 3, stand C38 (METEC) www.nsdcorp.com

Rolling mill technology NCO Nuova Carpentaria Odolese has specialized in the design, manufacturing, start-up and revamping of rolling mills for long products and steel plants. It will present examples of its manufacturing range. The company’s manufacturing and assembling shops cover an area of approx.

15,000 m2 and are equipped with overhead cranes of up to 100 t capacity. All the machine tools feature CNC technology of the latest

THE POWERPACK ROBUST AND POWERFULL: OUR HIGH TORQUE COUPLINGS

Continuous train with CTS stands

RW-COUPLINGS.COM

THE COUPLING.

42

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS

Descaling test bench Operating reliability and effective performance are essential requirements for customers using descaling nozzles in the steel rolling process. PNR provides its customers the possibility to determine the performance of its descaling nozzles using a modern test bench, which allows a precise measurement of the flow rate at a given pressure. All descaling parameters are tested and vali-

dated with the most advanced measuring instruments and in full compliance with international standards. The PNR descaling nozzles, which have been successfully sold for nearly fifty years, are complemented with lab testing and validation field trials.

PNR Italia srl Hall 4 , stand A25 (METEC) www.pnr.eu

Test bench for descaling nozzles

Automation and quality assurance Tailored automation solutions AIC Capitanio Tailored Automation provides advanced and tailored automation solutions for the steel industry, with the aim to continuously improve both efficiency, competitiveness and safety of the production processes.

AIC boasts long-time experience and technical know-how for engineering, AC and DC drives, PLC and SCADA for complete level 0, 1 and 2 automation and process control. The RACS (rolling mill automation control system) integrated platform is a leading-edge technology developed by AIC for all mill applications and requirements.

Recent projects include the conveyor and mill drives at Gerdau Jackson, USA, a cooling bed upgrade at Gerdau SM Whitby, USA, the supply of com-

Control room

plete electrical and automation systems for a new bar mill built at Thai Steel Profiles, Thailand. A partnership with Canadian Quad Infotech allows AIC to provide advanced soft-

ware solutions for energy saving and level 2 platforms.

Automazioni Industriali Capitanio srl Hall 5, stand G03 (METEC) ¡ www.aicnet.it

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

Metallurgical Plant and Technology G 25074

2

ISSN 0935-7254

April 2015

METEC DĂźsseldorf, Germany, 16 â&#x20AC;&#x201C; 20 June 2015 Come and meet the MPT staff at METEC, hall 5, booth 5 / C30 'PGTI[ GHĆ&#x201A;EKGPV QHH ICU ENGCPKPI VJTQWIJ KPVGNNKIGPV EQPVTQN

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MPT International 2 / 2015

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www.harald-wehrle.de

Our engineering excellence will master any challenge!

In B Budget.

In S Schedule.

In E Expected results.

Secondary metallurgy Sec Seco ondary ond o aryy me metal tallur lurgy gy

When steelmakers start to realise that they could get more performance out of their facility, there are many good reasons why BSE is the first to be asked. An integrated engineering approach, backed by the operational experience of BSW – one of the world’s most efficient mini-mills – helps us to always see the complete picture and so to come up with solutions that will even exceed the customer’s expectations.

Get in contact with us and see how you can get more out of YOUR facility, too!

Electric arcc furnacee

Fume extraction system

Electrical engineering

Automation and control system

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

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş PREVIEW OF EXHIBITORS

Special equipment New concept for heavy-load robots Dango & Dienenthal will show a newly developed heavy-load robot (type SLR). Due to their enormous reach and the high load capacity, the DDS heavyload robots allow for an application range beyond those of standard industrial robots. DDS picked up on the forward-looking trend to replace hydraulic drive concepts with de-centralized electromechanical drives. By eliminating the numerous hydraulic components such as pumps, tanks, valves and piping, the service and maintenance efforts to this new generation of heavyload robots are significantly reduced.

Taking into consideration the cost aspect, the new electro-mechanical drive concept offers an advantage over the hydraulic variants in many ways. The new electro-mechanical generation of heavy-load robots will increasingly carry out demanding handling tasks in the field of metal forming. To complete the new concept, the lever system of the robot has been completely re-designed.

The result is a compact, lightweight lever system with added stability. The mechanically achieved linear horizontal

Process water treatment

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Besides its air knife technology, Fontaine Engineering und Maschinen GmbH/Foen now also offers a cost-effective and energy-saving process for the treatment of process water. The main field of use of the Foen EVAP equipment is the metals industry. However, virtually all kinds of waste water can be treated. The heart of the system is an evaporator based on the mechanical vapour recompression principle.

Unlike conventional evaporators with metallic heat exchangers, the Foen

Profinet is becoming the new standard interface for many applications because only one cable is necessary

#ORNKĆ&#x201A;GT HQT JKIJ URGGF VTCPUOKUUKQP

Evaporation container designed for 120 mÂł/ day with 24 plastic heat exchanger units

for most communication and switching functions. Also in the field of force and web tension measurement, Profinet technology is gaining increasing acceptance. With the new modular digital amplifier DCX, Haehne offers a Profinet interface for the conversion of up to eight measurement signals and additional input signals for high transmission rates. The advantages include very fast cycling time for time critical applications and convenient set-up in Profinet networks.

guidance of the tongs relieves the feed drive from the weight of the work piece.

Dango & Dienenthal will also present products in the field of forging and handling, heat treatment, slag skimming as well as water filtration.

EVAP system uses a patented polymeric heat exchanger. This technology has many benefits, including low operating costs through a large surface of thin polymeric film and low temperature difference. The low temperature difference (typically of less than 3°C) combined with low operating pressures makes it possible to use very thin plastic film as surface material for the heat exchangers. The non-metallic heat transfer surface is well suited for highly corrosive environments like rinsing water from pickling sections. Through the soft moves of the polymeric film, scaling elements can hardly settle on the surface of the heat exchangers. The heat of the condensate is used to preheat the feed solution. The equipment is designed to fit in standard containers for easy transportation and installation on site. The treatment capacity can be adapted anytime by adding further modules.

Dango & Dienenthal GmbH

Fontaine Engineering und Maschinen

Hall 5, stand D09 (METEC)

GmbH

%GTVKĆ&#x201A;GF QXGT URGGF UYKVEJ HQT

www.dango-dienenthal.de

Hall 5, stand E22 (METEC)

applications in heavy-industry

ZZZ GGV Ć&#x201A;OWHU FRP

www.foen-gmbh.de

environments

Heavy-load robot equipped with electromechanical drives and a parallellever system

MPT International 2 / 2015

Haehne Elektronische Messgeräte GmbH Hall 4, stand F16 (METEC) www.haehne.com

Electronic over-speed switch To comply with highest functional safety requirements, Johannes Huebner Fabrik elektrischer Maschinen offers the EGS(H) 41 electronic over-speed switch that operates independent of the closed-loop speed control system.

EGS(H) 41 is certified up to Safety In-

46

››› PREVIEW OF EXHIBITORS

tegrity Level (SIL) 2 in accordance with the international standard IEC 61508 as well as up to Performance Level (PL) d to DIN EN ISO 13849. Specially developed for use in heavy-industry applications, such as in steel and rolling mills, crane systems and the mining industry, it guarantees operators the highest level of plant safety and serves to ensure the safety of personnel. With an integrated sensor, logic circuitry and an actuator, EGS(H) 41 functions as an integrated system. The speed is sensed, evaluated and switched in sequence.

The safety device is equipped with two separate electrically isolated switches to monitor speed. A further switch automatically monitors safety functions relevant to the hardware and software modules. The switch also features integrated over-current detection and monitors the status of the wear-free, electronic switching contacts. Optionally, also standstill and slip monitoring functions are available.

fect is reduced by remodelling the weld transition and removing the welded seam faults. Secondly, the edge layer is stabilized in order to increase the resistance to crack formation and crack propagation. Thirdly, an internal compressive stress is applied to increase resistance to crack formation and crack propagation by overlapping the notch stress with internal compressive stress.

While it is hardly possible to make a bad weld seam a good one by a follow-up treatment, the service life of a good weld seam can, however, be extended by five to ten times by means of HiFIT. So it is possible to make steel structures lighter, and it makes sense to use higher-strength steels for fatigue-loaded components.

Medenus Gasdruckregeltechnik GmbH Hall 9, stand A34 (THERMPROCESS) www.medenus.de

Low maintenance gear couplings Flexible gear couplings from R+W can be used in various applications in a wide variety of industries. The model BZ1 is connected by standard keyway, with slip fit or interference fit. The high-precision gearing allows for a large contact surface, resulting in high tor-

Kranbau Köthen GmbH Hall 3, stand A64 (METEC) www.kranbau-koethen.de

%GNNWNCT ICU ƂNVGTU Johannes Huebner Fabrik elektrischer Maschinen GmbH Hall 4, stand A33 (METEC)

Medenus Gasdruckregeltechnik will present its new cellular gas filter series DF100. This completes the exist-

www.huebner-giessen.com

High-frequency impact treatment to optimize welded structures The service life of steel structures can be significantly increased by a follow-up treatment of the welds using the HiFIT technique, a certified high-frequency hammer method. This especially applies to new steel structures, but also weld transitions on existing steel structures can be optimized with this technique. The HiFIT method, in detail examined in a joint research project, has been determined as a particularly efficient technique. The HiFIT treatment works as follows: Firstly, the notch ef-

Impact treatment of weld seams in supporting steel structures MPT International 2 / 2015

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ing product range of gas pressure regulators, safety shut-off valves and safety relief valves. The new cellular filters are available in the size range DN25 to DN200, with DIN flanges PN16 or ANSI150RF. The filter cartridges’ standard dust rate efficiency is about 99.9% > 2 μm. The cartridges are suitable for all kinds of dry gases according to G260/262 (others upon request).

If necessary, it is possible to add a differential pressure gauge with or without remote indication and ball valves.

Gear coupling with special tooth shape

sional stiffness. This style of coupling can compensate for relatively large levels of shaft misalignment without imposing reaction loads on the adjacent shaft bearings. In the case of the BZ1, the special shape of the gear teeth ensures optimum lubrication, even with very low levels of shaft offset, some of which is required in gear couplings, in order to adequately spread the lubricant throughout the coupling. In addition to its gear tooth shape, the BZ1 is distinguished from other gear couplings by its high power density, occupying a smaller space envelope per torque rating than most. The model is available in twelve sizes, corresponding to torque ratings from 1,300 to 348,000 Nm, axial shaft misalignment from 3 to 10 mm, and general angular misalignment ratings up to 1.5°. All components are burnished for corrosion protection.

R+W Antriebselemente GmbH Hall 5, stand G12 (METEC) www.rw-couplings.com

Customized material handling solutions OM Siderurgica is active in the iron and steel industry, in the extraction

PERT BS ® SPINDLELESS STAND

High-quality technology to minimize the operational costs for long products rolling mill

Ò No spindles Ò No on-board piping Ò Compact dimensions Ò Minimized civil works and infrastructures Ò Achievable tolerances down to 1/6 DIN/EN (as sizing group) Ò Minimized spare parts

www.pertengineering.com / info@pertengineering.com

Visit us at METEC Hall 4 Booth, N° B23

48

››› PREVIEW OF EXHIBITORS

and processing of aggregates, the cement industry, and in the quarry and mining industries. The company supplies the full range of machinery from single machines to turnkey plants for storage, weighing, batching and feeding, crushing, screening, washing and transport. OM Siderurgica’s solutions are customized in order to satisfy all production and investment requirements. After-sales service is guaranteed all over the world. The engineering division offers services in the fields of mechanical engineering, electrical plant engineering, automation, and certifications. Services include all work required for plant pre-commissioning, commissioning and start-up.

Material handling systems OM Siderurgica srl Unipersonale Hall 4, stand A23 (METEC) www.omsiderurgica.it

Castings and components for heat treatment applications Thermocast manufactures steel and alloyed castings resistant to heat, wear and corrosion. The foundry products are among others used in steel plants, Radiant tubes

Cast rollers

continuous annealing and galvanizing lines, the cement industry and in heat treatment shops. The main products are furnace rollers, radiant tubes, immersed and stabilizing rollers and heat treatment tools.

Thermocast shares its trade fair stand with Nicro, which specializes in the fabrication of a wide range of components for different industrial applications in high-grade stainless steel alloys. Nicro offers an extensive pro-

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MPT International 2 / 2015

duction programme and tailor-made solutions to suit its customers’ specific requirements. Machinery for processing alloy steel plates include 3D laser machines, equipment for plasma cutting and welding, and for orbital welding. Nicro has been focussing its research on the development of a new line of products: radiant tubes for latest CAL and CGL plants.

The goal of this research is to combine the need to achieve higher temperatures and output volumes, while keeping energy consumption and emissions down.

Thermocast S.P.A. www.thermocast.it Nicro S.p.A. www.nicro.it Hall 9, stand F57 (THERMPROCESS)

German Engineering on top $W 7K\VVHQ.UXSS 8KGH (QJLQHHULQJ 6HUYLFHV ZH Rƨ HU D IXOO UDQJH RI HQJLQHHULQJ VHUYLFHV IURP IHDVLELOLW\ VWXGLHV WR (3& FRQWUDFWV LQ RXU FRUH EXVLQHVV DUHDV ZKLFK LQFOXGH VWHHOZRUNV SRZHU SODQWV SHWUROHXP UHƩ QHULHV DQG WKH FKHPLFDO DQG SHWURFKHPLFDO LQGXVWULHV ZZZ WNXHV FRP

ThyssenKrupp Uhde Engineering Services

German Engineering on top

REVAMPS, UPGRADES & MODERNISATIONS 3URFHVV LPSURYHPHQW ,PSURYHG TXDOLW\ ,QFUHDVHG DYDLODELOLW\ ,PSURYHG VDIHW\ DQG UHOLDELOLW\ &RVW HÆ« FLHQF\ Increased capacity

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ThyssenKrupp Uhde Engineering Services

STEELWORKERS KNOW...

Rolling and processing technology

SIZE MATTERS!

Logistics and maintenance for articulated shafts Wichmann’s logistics and maintenance concept for rolling mills significantly reduces the warehousing and storage costs for articulated shafts. The concept includes the surveying of the complete set of requirements for articulated shafts. The customer’s internal article numbers will be linked with Wichmann’s IT system. This allows the current requirements to be identified within seconds,

CONTOUR CHECK

RDMS

REAL-TIME INLINE PROFILE MEASUREMENT WITH LASER LIGHT SECTION

PROFILE MEASUREMENT OF LONG PRODUCTS BASED ON THE SHADOWING METHOD

STRAIGHTNESS CHECK

CALIX XL

Articulated shafts

and all articulated drive shaft components are available at all times, thanks to the storage by Wichmann. Another advantage is the warranty. As the customer no longer needs to store the articulated drive shaft in his own warehouse, he will not experience technical failure on account of excessive storage times (if an articulated drive shaft is stored for more than three years, the lubrication effect is no longer present). Thanks to the just-in-time delivery by Wichmann, the warranty remains active.

Wichmann will also inform about its special service for the preventative maintenance of articulated shafts.

The service comprises the collection, examination, repair and shipping back of the shafts. Work performed includes inspections for deformations, functional testing, inspection of the welding seams, replacement of defective components and balancing in conformity with DIN ISO 1940.

Wichmann GmbH Hall 5, stand E03 (METEC) www.wichmann-os.de

HEAVY DUTY NON-CONTACT INLINE EASY TO RETROFIT INDEPENDENT OF MATERIAL

www.LAP- LASER.com

LAP SENSOR FOR DIFFERENTIAL THICKNESS MEASUREMENT IN ONE HOUSING

52

››› EVENTS

METEC & 2nd ESTAD – European Steel Technology and Application Days The 2nd European Steel Technology and Application Days (ESTAD) 2015 will run in parallel with the METEC trade fair. The Steel Institute VDEh and its partners offer visitors the perfect opportunity to reach their objectives.

Only those who continue to develop their businesses remain competitive.

The prerequisite for this development means being constantly informed about the latest and most sophisticated technological advances, exchanging ideas and initiating and expanding networks with clients, partners and suppliers. The 2nd European Steel Technology and Application Days (ESTAD) 2015 will run in parallel with the METEC trade fair.

The Steel Institute VDEh and its partners offer visitors the perfect opportunity to reach their objectives. At this event, participants will acquire the latest information on new ideas and developments as well as on the state-of-the-art in metallurgical process technologies for iron and steel production, steel materials and steel application.

The conference language will be English. The conference is organized in close cooperation with the Austrian Society for Metallurgy and Materials (ASMET), the Swedisch Steel Producers Association (Jernkontoret), Associazione Italiana di Metallurgia (AIM) and Fédération Française de l’Acier (FFA, this association will be merged soon into the alliance of mining, minerals and metals A3M).

A scientific programme committee of international experts in all fields

Date: 15 – 19 June 2015 Venue: CCD Congress Center Düsseldorf, Germany Host: Steel Institute VDEh, Düsseldorf, Germany Organizer: TEMA Technologie Marketing AG, Aachen, Germany Contact: www.metec-estad2015.com Email: metec@tema.de

MPT International 2 / 2015

of ironmaking and steelmaking processes, steel materials and steel application reviewed the papers. Approximately 640 technical presentations in 135 technical sessions within three days from 16 to 18 June 2015 are given in the fields ▪ ironmaking, ▪ steelmaking, ▪ rolling, ▪ steel materials and their application, ▪ surface technologies, ▪ environmental and energy aspects to inform on and discuss the latest state-of-the-art steel technology.

Plant tours Conference participants are offered plant tours to eight plant locations in Germany and the Netherlands to take place directly after the conference.

Information and explanations during the plant tours will be provided in English. Transportation to the various plants will be by bus from the Congress Center Düsseldorf CCD South.

Plant tour No. 1 will visit the cokemaking site Prosper in Bottrop, Germany, a company of ArcelorMittal group.

Started up in 1985/1989, the coke plant comprises three oven batteries with a combined annual production capacity of 2.0 million t of coke.

Plant tour No. 2 will lead to the Schwelgern coke plant at the site of ThyssenKrupp Steel Europe in Duisburg, Germany. Started up in 2003, the coke plant comprises two oven batteries with a combined annual production capacity of 2.6 million t of coke.

Plant tour No. 3 will give a comprehensive overview of some major production sites of ThyssenKrupp Steel Europe in Duisburg, Germany. Included in the tour are production facilities as following: ▪ sinter plant Schwelgern 3 (modernized in 2002), ▪ blast furnace Schwelgern 2 (hearth diameter 14.9 m; relined in 2014), ▪ BOF steel plant Bruckhausen (two 380 t converter stands, modernized in 2014), ▪ slab caster Bruckhausen (two strands, max. width 2,600 mm), ▪ thin-slab casting plant and rolling plant (two casting strands, max. strip width 1,600 mm), ▪ hot strip mill Beeckerwerth 2.

Plant tour No. 4 will visit Hüttenwerke Krupp Mannesmann, the most compact integrated iron and steel works in Duisburg, Germany. All production facilities are very closely located here, i.e. coke plant (new battery started 2014), sinter plant, blast furnace A (hearth diameter 10.3 m), BOF steel plant (annual production capacity 5.67 million t), continuous bloom caster No. 1 and No. 2 (six stands and five strands, respectively) and continuous slab caster No. 3 (two strands).

EVENTS Attending plant tour No. 5, participants will visit ArcelorMittal Bremen works, in particular the blast furnace No. 2 (hearth diameter 12.0 m), BOF steel plant (modernized in 2011, annual capacity 3.7 million t), hot strip mill (modernized in 2008, max. strip width 2,150 mm).

Plant tour No. 6 will lead to Tata Steel IJmuiden, the Netherlands. The sinter plant (three strands), the blast furnaces No. 6 and No. 7 (hearth diameter 11.0 m and 13.83 m, respectively), BOF steel plant (modernized in 2003, annual capacity 7.2 million t), continuous slab casters No. 1, No. 2 and thin slab caster No. 3 are included in this tour.

Plant tour No. 7 will visit the company DK Recycling und Roheisen located

also in Duisburg, Germany. The plant is specialized in processing residues from steel works to produce foundry pig iron and zinc. The tour stops comprise the sinter plant and the blast furnace (hearth diameter 5.5 m).

Plant tour No. 8 will lead to Georgsmarienhütte GmbH, an EAF based steel works with an annual capacity of approx. 1 million t of long products.

It operates a 140 t DC EAF, a continuous bloom caster and a medium section mill (modernized in 2012).

Get-together and evening event On Monday, 15 June the participants of the conference will have the oppor-

Trust a partner who knows the steel industry from the inside. Contact our experts today. quakerchem.com info@quakerchem.com

© 2015 Quaker Chemical Corporation. All Rights Reserved

53

tunity to meet on the occasion of an evening reception. The opening event will be staged next to the conference rooms and registration office in the CCD South in Düsseldorf. There will also be entertainment and a finger buffet. Accompanying persons will be welcome, too.

All conference participants will have the opportunity to participate in another evening event on Tuesday, 16 June 2015. The conference dinner will take place on the river boat MS RheinEnergie. This extraordinary location will offer a panorama view of Düsseldorf from the river Rhine. The boat will await the attendees within walking distance from the conference centre.

WITH THE TOUGHEST SOLUTIONS FOR THE WORLD’S MOST EXTREME PROCESSES, QUAKERTEK™ SPECIALTY GREASES KEEP YOUR MILL RUNNING SMOOTHLY. With the demands of the modern steel industry, you and your equipment are both feeling the pressure. Taking care of operations doesn’t just mean keeping the mill rolling, but also means finding ways to lower costs, improve performance and extend the life of your machines. Quaker Specialty Greases minimize Total Cost of Ownership while giving you sustainable product solutions that require less volume and reduce energy during use. As the industry-leading provider of process fluids and other chemical specialties, no one else offers the same level of experience and service, and no one else is in more places at more mills. So team up with Quaker, and keep your toughest operations running smoothly.

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54

››› EVENTS

AISTech & ICSTI will be steel’s premier technology event in the USA this year AIST 2015 – the Iron & Steel Technology Conference and Exposition – will take place in Cleveland, Ohio/USA on 3 – 7 May 2015. AISTech 2015 will host ICSTI 2015 – the 7th International Congress on the Science and Technology of Ironmaking.

AISTech 2015 – the Iron & Steel Technology Conference and Exposition – will be held 4 – 7 May 2015 at the Cleveland Convention Center, Cleveland, Ohio, USA, and will offer a program with numerous technical and keynote presentations by today’s business leaders, an expansive exposition and plant tours. More than 8,000 people are expected to attend AISTech 2015. Along with over 500 exhibiting companies, AISTech 2015 allows attendees to meet face-to-face with key individuals involved in the production and processing of iron and steel.

At the conferences, more than 550 technical presentations will provide a very comprehensive technical program for the steel industry. In the exhibition hall, exhibitors will display their products and services. As proven in the years before, the conference and exhibition will be held on three days.

A students’ program is to attract young talents to start a career as a member of the steel community.

AIST foundation golf classic As a preliminary, AIST Foundation golf classic 2015 has been arranged for Sunday, May 3 (sold out already).

Over 280 golfers are expected to participate in the 2015 outing to be held at Firestone Country Club in Akron, Ohio, USA. Being the host of three PGA championships and numerous world golf championships, Firestone has long been synonymous with exciting golf history.

Association for Iron and Steel Technology (AIST), Warrendale, PA, USA Contact: www.aistech.org

MPT International 2 / 2015

Technical program AISTech 2015 will host ICSTI 2015 – the 7th International Congress on the Science and Technology of Ironmaking. ICSTI provides an open forum to present, discuss and achieve solutions to the essential issues ironmaking challenges today and in the future.

Presentations include invited keynote lectures as well as individually submitted papers.

The three-day technical program will showcase more than 550 presentations on aspects of iron and steel manufacturing technology. Highlights include the latest environmental technologies throughout the iron- and steelmaking process; advancements in rolling and coating technologies; safe work practices and procedures for projects, production and maintenance; cutting-edge research and advancements in the processing, product development and application of steel; the latest in automation and control sys-

tems; and discussions on efficient material movement both within the facility and to the customer.

As an additional benefit of conference attendance, one copy of the AISTech 2015 proceedings on USB will be included in the conference registration fee and will be available on-site.

Additional copies of the AISTech 2015 proceedings in softbound book form or USB may be pre-ordered when registering at AISTech.org.

Howe memorial lecture The Howe memorial lecture was established in 1923 to honor Henry Marion Howe, who helped turn steelmaking from an art into a science with his gift of observation and deduction.

The lecturer is selected in recognition of outstanding individual contributions to the science and practice of iron and steel metallurgy or metallography.

This years lecturer will be Yakov M.

56

››› EVENTS

Gordon, technical director, ironmaking, Iron and Steel Business Unit, Hatch Ltd. His lecture will be entitled “The role of engineering consultancy in the transformation of a technology idea to a working process plant”.

Iron and steel technology exposition The exposition offers individuals a chance to meet face-to-face with key individuals who specify, purchase, design and operate a variety of plants and facilities associated with the production and processing of iron and steel.

The 2015 exposition is slated to be the largest yet, with 25,000 square meters of exhibit space and more than 500 U.S. domestic and international companies for an unrivaled display of global steel technology.

President’s award breakfast The President’s award breakfast is one of the signature events of AISTech 2015. Hosted by the AIST president, Glenn A. Pushis, Steel Dynamics Inc. – Flat Roll division, the President’s award breakfast program will consist of the presentation of prestigious awards, including AIST’s steelmaker of the year.

Lourenco Goncalves, chairman, president and chief executive officer, Cliffs Natural Resources Inc., will present a keynote address titled “Global iron and steel outlook”.

Town hall forum Leading steel executives debate industry’s key issues at the town hall forum. A panel of the steel industry’s most influential executives will take part in a moderated discussion at the AISTech town hall forum on Wednesday, 6 May in the Grand Ballroom at the Cleveland Convention Center, Cleveland, Ohio, USA. Panelists will discuss the guiding theme “Steel 2015: Building, Innovating, Growing” and will provide their insight on workforce development, production advancements, natural gas and DRI processes, market development and regulatory issues in regard to steel imports and public advocacy. Panel members will include: ▪ Andrew S. Harshaw, president and chief executive officer, ArcelorMittal USA, MPT International 2 / 2015

▪ George J. Koenig, president, Berry Metal Co., ▪ Michael D. Lee, vice president and general manager, Nucor Steel – Decatur LLC, ▪ David J. Rintoul, senior vice president – tubular business, United States Steel Corporation, ▪ Richard P. Teets Jr., president and chief operating officer – steel operations, executive vice president, Steel Dynamics Inc.

furnaces which can feed two steelmaking facilities capable of producing 3.8 million tons of raw steel annually. Products made at this location are hot rolled, cold rolled and hot-dip galvanized sheet and semi-finished (slabs).

Charter Steel is a producer of high-quality carbon and alloy steel rod, bar and wire. This site utilizes state-of-the-art technology in equipment and manufacturing systems to

Sunday, 3 May Golf classic Student plant tour Technical sessions Young professionals’ reception

Noon – 7 p.m.

Noon – 4 p.m.

1 – 3:30 p.m.

5 – 6 p.m.

Monday, 4 May Howe memorial lecture Exhibit hall open Technical sessions University-industry relations roundtable AIST welcome reception Steel to students reception

8 – 9 a.m.

9:00 a.m. – 6 p.m.

9:30 a.m. – 5 p.m.

Noon – 1:45 p.m.

5 – 6 p.m.

6 – 8 p.m.

Tuesday, 5 May President’s award breakfast Technical sessions Exhibit hall open Exhibit hall reception

8 – 9:45 a.m.

10 a.m. – 5 p.m.

9:30 a.m. – 6 p.m.

5 – 6 p.m.

Wednesday, 6 May Town hall forum Technical sessions Exhibit hall open

8:30 – 11:15 a.m.

2 – 5 p.m.

11:30 a.m. – 3 p.m.

Thursday, 7 May Plant tours

start at 7:30 a.m.

AISTech 2015 events at a glance (This schedule may be subject to change.)

Plant tours Three plant tours will be held in conjunction with AISTech 2015. ArcelorMittal Cleveland, Charter Steel Cleveland and TimkenSteel Corp.

Faircrest plant, Pittsboro, will host the tours.

ArcelorMittal Cleveland is recognized as one of the most productive integrated steelmaking facilities in the world, producing one ton of steel for slightly more than one worker hour. The plant operates two blast

optimize steel cleanliness, precision rolling tolerances and coil handling.

At the Faircrest plant, TimkenSteel develops some of the strongest alloy steels in the world. The plant’s new jumbo bloom vertical caster is the biggest continuous vertical bloom caster globally and the only one of its kind in North America. The caster uses an optimized tundish design and advanced clean steelmaking technology to help create answers to customers’ toughest engineering challenges.

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SOLUTIONS THROUGH TECHNOLOGY www.vesuvius.com

58

››› STEELMAKING

World champions 2015 of the 9th virtual steelmaking challenge The World Steel Association announced the new world champions of the 9th steeluniversity challenge. In both – steel industry employees as well as students – category participants from China achieved the best results.

The grand finals of the 9th virtual steelmaking challenge took place in Brussels in February. On 11 February, John Ferriola, chairman of the worldsteel education and training committee, announced the new world champions, who successfully accomplished the first round, the regional championships. Ye Wang from China’s Baosteel Group as well as Yongping Wei and Yongxu Wang from the Chongqing University of Science and Technology submitted the best results in the grand finals. Teams were tasked to produce a grade of steel meeting technical requirements of high strength structural steel for construction at the lowest total costs. The aim was to produce steel within the time of two hours and by using a basic oxygen steelmaking simulation.

This simulation is a simplified model of complex real-life processes, using a grade of steel especially designed for the challenge. Ye Wang won the industry category. In this category employees of the steel processing industry compete against each other, who have less than five years of work experience in this industry. Yongping Wei and Yongxu Wang were the most successful participants amongst those from universities.

Steeluniversity is an institution of the steel industry, delivering education and training to current and future employees of steel companies and related businesses. Executive John Ferriola explains the target of the initiative: “Steeluniversity and steelchallenge are not only at the core of worldsteel’s effort to advance knowledge about steel but also the critical connection to young people in the industry and students who might consider a career in

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

MPT International 2 / 2015

Industry world champion is Ye Wang, Baosteel Group Corporation, China (left).

Student world champions are Yongping Wei and Yongxu Wang, Chongqing University of Science and Technology, China

steel,” the Nucor CEO said. “Going forward, we will look to complement our manufacturing and metallurgical learning with developing skills in business and leadership. In the steel industry we need people with a range of knowledge and abilities. Above all, we need young leaders in our industry.”

“The steel industry is fundamental for a sustainable society. The industry requires the best people to continuously innovate, bring creativity in finding

solutions, and apply the best modern technologies to steel production,” adds Wolfgang Eder, chairman of worldsteel and chairman and CEO of Voestalpine.

Edwin Basson, director general of worldsteel, comments on the challenge: “More than 1,500 teams from 34 countries worldwide competed for the title of regional champion last year. I am particularly proud to learn that 811 teams successfully completed the simulation. I hope these brilliant young engineers and students will join the steel industry and push our industry to become more sustainable and help our customers imagine a new future with steel.” The world champions of the industry and student catego9CVEJ VJG XKFGQ QH VJG ITCPF ƂPCNU QP ;QW6WDG ries were awarded trophies, XKC JVVRU YYY [QWVWDG EQO WUGT YQTNFUVGGNQTI prizes and certificates.

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First Gas Cleaning Assistant systems were installed at Kardemir (Turkey) and Jindal South West, India

'PGTI[ GHĆ&#x201A;EKGPV ICU ENGCPKPI VJTQWIJ KPVGNNKIGPV EQPVTQN Gas cleaning systems in steelworks are responsible for the extraction of dust-laden offgases. For the control of the gas extraction process, SMS Siemag has developed a new system which models the existing gas cleaning network. It has shown in practice that with the same or better gas cleaning quality, considerable energy savings can be reached.

Energy costs account for a significant portion of the steel production costs. Aside from the unavoidable use of energy directly connected with the melting and shaping of steel, also auxiliary plants such as for gas cleaning contribute significantly to energy consumption.

Secondary gas cleaning in particular is often less efficient and there is great potential for improvement in this area. Gas cleaning has been a somewhat neglected auxiliary unit in

Dr. Jesper Mellenthin, Electrical and Automation department, SMS Siemag AG, DĂźsseldorf, Germany Contact: www.sms-siemag.com E-mail: jesper.mellenthin@sms-siemag.com Yusuf Cakir, Director Electrical Engineering, Kardemir A.S., Karabuk, Turkey E-mail: ycakir@kardemir.com

MPT International 2 / 2015

the past. However, in order to comply with environmental specifications, be able to receive an operating license for plants and ensure economy of operation, todayâ&#x20AC;&#x2122;s plants have to be made significantly more efficient and must be optimized as regards energy consumption. In order to comply with the statutory limit values for dust concentration at the workplace, the number of extraction points has been continuously increased. The growing amount of exhaust gases produced is extracted with energy-intensive fixed-speed induced-draft fans.

However, the fixed-speed fans lack flexibility. Only by controlling the negative pressure at the gas inlet to the filter house it is possible to control the overall system so as to ensure the required extraction capacity at all extraction points. As a consequence, at remote points only a reduced extraction capacity is available. This effect can only be reduced by constantly increasing the fan speed, which in turn

will lead to a noticeable increase in power consumption and therefore energy costs.

The X-PactÂŽ Gas Cleaning Assistant is a patented new product developed by SMS Siemag. The system implements an algorithm in the gas cleaning control unit which provides for dynamic flap control at each extraction point, ensuring maximum extraction performance without unnecessarily increasing the speed of the fan. Gas cleaning quality is increased while energy consumption is lowered.

Typical layout of gas cleaning plants A gas cleaning plant ususally consists of a large number of extraction points connected in a complex network which can be controlled to some extent by electrically adjustable flaps.

The exhaust system can be divided into three areas. Dust is sucked in at various extraction points in the steel mill. The

‹‹‹

'08+410/'06#. 2416'%6+10 dust is then conveyed through a piping system to a filter house. Induced-draft fans generate the required negative pressure.

▪ The desired volumetric flow rates are determined at the extraction points (typically up to twenty).

Negative pressure measurement upstream of the mixer/filter house, together with the volumetric flow rate, allow for an optimal control of the fans.

▪ The level measurement at the filter hopper (and at further potential points where dust is collected in the system considered) serves to monitor the occurring amount of dust.

▪ Differential pressure measurement at the filter house serves to determine the degree of clogging of the filter.

▪ Depending on the process requirements, the speed of the fan can be increased or reduced.

Conventional control of gas cleaning plants The required flow rate at any given extraction point can be influenced by the corresponding flap setting, but also depends on the other extraction points in the network. The correlations are highly complex and largely non-linear. They can barely be calculated manually. They are roughly deter-

61

Filter house

Extraction points

Dampers Fans

Schematic diagram of a gas cleaning network

mined experimentally during commissioning, saved in a multidimensional matrix and then only adjusted if necessary. In newer plants the overall pressure is controlled by the fan. The fan, however, sometimes runs continuously and independently of the actual need.

A matrix contains the settings for all flaps, for all combinations of process phases and for all extraction points.

The number of extraction points required to operate simultaneously results in additional pipe resistance.

The matrix is accordingly complex and difficult to determine. The extraction capacity at the individual extraction points is often too high or too low.

The negative pressure in the dust extraction system is kept at a constant,

high value and is not further adjusted. This results in a high power input.

In summary, extraction quality is not optimal and the energy requirement is too high.

Intelligent control of the gas cleaning system The SMS group has used its experience in designing and constructing gas cleaning plants that optimize the control of the flaps and fans. This makes it possible for new plants to achieve optimum gas cleaning quality with lower energy needs. Controlling existing plants is of particular interest, as it is often possible to make better use of the installed extraction capacity and

Conventional control

X-Pact® Gas Cleaning Assistant

Comparison of conventional control and the Gas Cleaning Assistant MPT International 2 / 2015

62

››› '08+410/'06#. 2416'%6+10

to improve the cleaning quality. In addition, with the use of the intelligent control unit, investing in fans with a frequency inverter pays off and thus energy requirement can be significantly reduced. SMS Siemag ensures the high quality of the mechanical equipment by cooperating with renowned fan manufacturers offering specialized products for this type of application.

The gas cleaning network is mapped in a mathematical model and loaded directly into the control unit. Whereas previously the flap setting was determined experimentally and saved manually, the model now calculates the required flap settings and flow rates in the individual network segments in real time and controls them dynamically. The default parameters for gas cleaning decouple from a complex matrix to the flow rates at the individual extraction points. They now depend only on the relevant process phases and can be determined and adjusted independently of what is happening in the rest of the plant. The number of input parameters is drastically reduced, adjustments are simplified and gas cleaning is more efficient overall. Non-linearities are calculated iteratively and highly accurately in the model, which makes it possible to optimally adjust the flap settings. The negative pressure actually required is derived from the simulation of the plant.

It is adjusted individually for each process requirement, which can now also be adjusted dynamically and therefore with lower output, in turn reducing energy needs. Because the fans are always working at the best possible operating point, service life is extended and maintenance overhead reduced.

It is worth noting that the Gas Cleaning Assistant does not need any pressure measurements at the extraction points themselves to work. The calculations are so accurate that the flap position can be determined based on the results of the model. This makes the control process much faster and it is not subject to settling processes as a control system which sets the flaps based on pressure measurements would be.

In addition to improving gas cleaning quality and minimizing energy needs, the Gas Cleaning Assistant can also be used for other purposes. Modelling the network makes information available that would otherwise be difficult or impossible to determine. For MPT International 2 / 2015

Pipeline network

Mathematical model

Result:

Required negative pressure in main sewer for each process step

Required damper position for every damper in network

The Gas Cleaning Assistant maps the network of the gas cleaning plant in a mathematical model and calculates the required set points in real time

example, sometimes extraction output is kept artificially high out of concern that otherwise dust could accumulate at critical points and clog the lines. With the Gas Cleaning Assistant, the flow rate at these points can be calculated and also placed under control.

Monitoring will ensure that the flow rate does not fall below a certain critical minimum value, independently of the flow rates required at the other extraction points.

Another example is commonly found in existing plants that have grown over time. Additional extraction points have been added to the network one after the other so that extraction capacity is no longer sufficient in certain situations. If even the optimization of the Gas Cleaning Assistant is not sufficient to make adequate extraction capacity available, it can still prioritize extraction points.

It detects the inadequate extraction and reduces extraction output at less relevant points to make output available specifically at points that are relevant for environmental or health reasons.

Furthermore, the X-Pact® Gas Cleaning Assistant includes intelligent process monitoring. The monitoring functions ensure reliability in long-term planning for operation and servicing of the plant. In this way, the system recognizes premature wear of the exhaust air flaps, for example, or provides a forecast for the amount of dust present in the filter compartment.

Implementation of the Gas Cleaning Assistant The Gas Cleaning Assistant is used in all new gas cleaning plants of SMS Siemag AG, thereby optimizing their operation as an integral part of gas cleaning control. Since it is very flexible and widely configurable, it can also be retrofitted into existing plants. In this case it provides a special added value, since it is able to optimize and prioritize the extraction output of the plant without great investment. To retrofit the Gas Cleaning Assistant, the existing gas cleaning network is analyzed, mapped in a mathematical model and loaded into the Gas Cleaning

Process savings – examples 17%

Charging / Idle

39%

Tapping / Idle

12%

Charging / Charging

21%

Charging / Tapping

Actual energy savings depend on the process phases, with 21% in average

‹‹‹

'08+410/'06#. 2416'%6+10 Assistant. The control unit can be offered as a standalone solution and installed on an industrial PC. It communicates with the existing gas cleaning control unit.

Commissioning costs are therefore low and only short downtimes are needed.

No other measurements are required, which eliminates the cost of electromechanical components.

It is also easy and convenient to extend the gas cleaning plant with the Gas Cleaning Assistant. The model simply has to be adapted to the new layout of the network and loaded into the control unit. In order to ensure that the operating personnel can obtain a good overview of the technical status of the plant at any time, special emphasis is placed on a transparent and clear presentation of the processes. The HMI 2015 developed by SMS Siemag is used here. The operator interface is characterized by an intuitive design, so that the operators only need a short training phase to become familiar with the interface.

innovative product has been demonstrated in two plants in normal operation. First, the Gas Cleaning Assistant was retrofitted in an SMS Siemag gas cleaning plant at Kardemir in Turkey.

This is a converter steel plant with two converters and annual production of 1.3 million tons. The control unit was converted with a commissioning time of just five days including fine-tuning.

A plant shutdown was not required.

As the plant was previously already operating in a stable and manually optimized manner, it was possible to demonstrate the advantages of the Gas Cleaning Assistant very clearly.

Savings depend on the process phases. Overall savings were 21%, which amounted to several hundred thousand euros a year.

At Jindal South West, Toranagallu in India, the Gas Cleaning Assistant was installed directly on the gas cleaning control unit from the beginning. The simplified configuration made it possible to reduce commissioning time. It was not possible to compare the energy requirement, but the accuracy of the model was thoroughly verified. Volume flow measurements are conduct-

Reference plants Beyond various tests and simulations, the functioning of the new and

63

ed at the extraction points so that the calculated flow rate can be compared with the measured value. Deviations of less than 20% were determined, which demonstrates the accuracy of the model and underscores how the results of the model can be used for example to prevent accumulations of dust.

Summary The Gas Cleaning Assistant is an intelligent control unit for secondary gas cleaning that optimizes gas cleaning quality, thereby reducing energy needs. The control unit is used as standard in all new SMS Siemag gas cleaning plants, but it is also easy to retrofit and offers great advantages in modernization projects. The Gas Cleaning Assistant has already been used successfully in two reference plants. Calculations were compared with measurements over a long period in a modern new plant. It has been demonstrated that the calculations are very precise. Savings of 21% on energy costs in an existing plant were demonstrated in a before and after comparison.

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The latest generation laying head for HÂł high-speed wire rod mill

Progress in loop laying head technology saves costs in highspeed wire rod mills The â&#x20AC;&#x153;Twin pipe rotorâ&#x20AC;? designed by Danieli is an alternative to the traditional singlepipe rotor. The results obtained with this technology were even better than expected, SURYLGLQJ WKH HQG XVHU LPPHGLDWH EHQHĆ&#x201A;WV LQ WHUPV RI HTXLSPHQW OLIHWLPH FRLO SDWWHUQ VXUIDFH TXDOLW\ DQG KHDG DQG WDLO IRUPDWLRQ 0RVW UHFHQWO\ 'DQLHOL GHYHORSHG WKH 7XUERORRS OD\LQJ KHDG IHDWXULQJ D Ĺ&#x201D;SLSHOHVV URWRUĹ&#x2022; WKDW RIIHUV QXPHURXV DGYDQWDJHV PDLQO\ IRU WKH SURGXFWLRQ RI VPDOO GLDPHWHU SURGXFWV Innovation means implementing a new product or a product that has undergone significant improvement over

Andrea Taurino, Massimo Vasi, Antonello Mestroni, Andrea De Luca, &CPKGNK % 1HĆ&#x201A;EKPG /GEECPKEJG S.p.A., Buttrio (Udine), Italy Contact: www.danieli.com E-mail: info@danieli.com

MPT International 2 / 2015

time, in terms of method, form and performance. Innovation encompasses all the scientific, technological, organizational, financial and commercial steps that need to be taken to put it into operation.

The origin of the â&#x20AC;&#x153;headâ&#x20AC;?

Everything has a beginning from which it evolves. In this article we have an extraordinary story to relate.

It is about the evolution of processes in the steel industry by way of the example of wire rod production, which has seen significant increases in production speed (from 30 m/s at the beginning of the 1970s to 130 m/s today) and an ever wider range of steels produced.

Over the years, Danieli has developed a wire rod mill technology, covering all aspects from rolling to coil forming through the transformation process.

LLHPlus 2 pipe rotor installed at Ferriere Nord â&#x20AC;&#x201C; Italy

The first steps occurred at the beginning of the 1970s with the first Edenborn coilers. These were top-fed machines mounted on a frame, consisting of a funnel/bell with a rotating pipe inside it and a rotating plate underneath it for optimum coil forming. For coil removal, the machine was fitted with a lateral hydraulic pusher, which transferred the coil to a shutter conveyor.

The coil was then taken to the tying and storage areas.

Persistent market demand for ever larger and heavier coils made it necessary to further develop the Edenborn coiler so that it could process coils weighing more than 300 kg at speeds greater than 30 m/s. The first coil stability problems arose with the 700 kg coils, since they were higher than the ones previously produced using other methods. Consequently, the coil had to be contained both during forming and while it was being transported on the conveyor. As a partial remedy to this problem, pins were added to the forming system, but once the coil was transferred to the conveyor, it was free to move, thereby compromising its stability.

This made it necessary to install a different type of conveyor at the exit of the Edenborn coiler; the new conveyor was equipped with rollers and had a dual function, namely: â&#x2013;Ş to provide a controlled heat treatment to the entire wire rod coil, resulting in a final product with uniform, optimum mechanical properties; â&#x2013;Ş to collect the loops and form a wellshaped, compact coil weighing more than the required 700 kg, in order to improve material yield and make the plant itself more efficient.

That is how the first controlled cooling conveyor for wire rod came to be. It has seen continuous improvements over the years through the application of more and more technologically advanced devices. Markets and steelmakers became more and more demanding and competitive, and consequently this also affected machine manufacturers, who were required to supply increasingly innovative technologies. The first plants to use this technology at the beginning of the 1970s were Sudacier in France, Lech-Stahlwerke in Germany and others in South America and the Far East.

6JG Ć&#x201A;TUV GXGT NQQR NC[KPI head in operation: 1975 Given that market demand was veering towards higher rolling speeds, heavier coils, increased wire rod diameters, better shape, etc., coil forming using the Edenborn method was no longer efficient. Switching from vertical to horizontal coil forming had practically become a reality, especially since the new layout configuration enabled all heat treatments to be performed in line, as well as providing a better coil shape.

One of the first new loop laying facilities was installed at ALFA Acciai in Brescia; these machines ran uninterruptedly for 30 years before being replaced by more modern ones. They were designed with roller bearings and for years they were market leaders, measuring themselves against similar machines developed by competitors.

Technological solutions were then created and patented to reduce the vibrations caused by the increased finishing speed and wear, with design and materials optimized to reduce maintenance.

What revolutionized the loop forming system at the end of the 1990s came MPT International 2 / 2015

66

››› HOT ROLLING

from the market, which because of exThe OFB laying head features a ing speeds of over 100 m/s were quickponential speed increases (110 m/s and unique patented design, which uses ly reached. more) in industrial operation and sig- oil-film bearings for rotor support (inIn the next ten years, more than 70 nificant wear of the forming pipes, stead of traditional roller bearings). loop laying heads with oil-film bearwas turning its attention to the pipe This provides absolute stability during ings were successfully installed and path, which was completely reformu- operation, lower wear, and extended started up all over the world. These malated and enhanced mathematically life of the laying pipe, as well as mini- chines produced increasingly impresthrough the use of cutting-edge com- mized maintenance. Its advanced de- sive results in terms of quality and perputers and simulation software.

60000 Through research on this new path by 50000 the Danieli Research Centre, the lifetime 40000 of the former generaverage ations of pipes (500 30000 min t of 5.5 mm rounds 20000 at 100 m/s in 1995) max saw a significant in10000 crease (with a production of more than 0 5,000 t), thus makASTM A213M - T22 Duplex Duplex Plus Stainless steel (standard material) stainless steel stainless steel ing it economical to produce wire rod at LLHPlus 2 pipe lifetime comparison diagram that speed. The new path – referred to as 2nd generation – was tested for the first sign ensures an optimal response even formance. Then followed the 4th and time on the loop laying head installed in highly unbalanced conditions, and 5th generation machines. at Acciaierie e Ferriere Caleotto in 1998 vibration-free operation at full speed. and immediately became the standard This 3rd generation with the oil-film bearing was fitted with all the im“Twin pipe rotor” laying that Danieli applied to that machine.

But the high rolling speed forced provements and refinements it needhead technicians to deal with another tech- ed to operate in the new working conToday, the latest developments in nological constraint, which came in ditions: loop laying technology ensure a suthe form of vibrations. Through in- ▪ 150 m/s in industrial operation and perior coil pattern and an optimized laying pipe wear rate with absolute optensive studies it became possible to 170 m/s in no-load conditions, design the 3rd generation laying head ▪ vibrations reduced to a minimum erating stability and vibration-free opand manufacture it on an industri(kept below 2 mm/s), eration at production speeds of up to al scale. From 1975 to 2002 Danieli ▪ 3D modelling to develop the new supplied more than 108 laying heads pipe shape needed to optimize the worldwide. coil path, ▪ research and application of wear-resistant materials, Loop laying head with oil ▪ use of a “smart” pinch roll (active pinch roll) to handle the head and ƂNO DGCTKPI The need to extend the lifetime of tail of the rolled stock, the rotor support bearings because ▪ use of advanced automation sysof the high number of revolutions tems designed to properly centre and the vibrations that were generatand lay the loops on the conveyor. ed, led us to look for and use another In the first months of 2003, SN Lonkind of bearing. We eventually opt- gos in Portugal was first to use the 3rd ed for oil-film bearings – OFB, a tech- generation loop laying head. Within nology supported by the long experi- the framework of its wire rod mill reence in cantilever stands and wire rod vamping project, the company wantblocks. The first tests on these bear- ed to be the first to install two laying ings were done in 2002. The bear- heads with oil-film bearings because ings could withstand a high number they were convinced that this was a of revolutions, or high rolling speeds, reliable machine with potential. The with practically no vibrations, prov- two machines were started only a few ing that an oil film is an excellent weeks after their installation. This shock absorber. was possible primarily because work- TurboLLH in operation at Ori Martin – Italy MPT International 2 / 2015

Rolling mill control PLC

WRL process control PLC Speed correction

Active pinch roll Rolls pressure

Line speed PR-overspeed

& Position control

LH motor

Drive

Drive

Position synchronization controller

Drive

Motion drive

150 m/s. The traditional laying head concept has radically changed with the application of a number of innovative features. This advanced design, researched using 3D kineto-dynamic simulation, provides operating stability and reduced wear at high finishing speeds. The laying pipe’s progressively curved shape gives the wire rod an ideal path inside the pipe, where it is in constant contact with the inner wall along the entire pipe length, for even wear distribution (70% increase in pipe life).

In order to fulfil the requirements to further increase the lifetime of the pipe and reduce the downtime for the rotor change, Danieli designed and put into operation a new “Twin pipe rotor” as an alternative to the traditional single-pipe rotor. The results were even better than expected, providing the end user with immediate benefits in terms of lifetime, coil pattern, surface quality and head and tail formation: ▪ long production campaign – up to 80,000 t before changing the rotor pipes, ▪ unbeatable performances with small-size product mix (based on >60% of small sizes from 5 to 12 mm), ▪ internal pipe diameter optimized for small products, ▪ excellent performances with lower pipe wear, ▪ pipes made of duplex stainless steel for long pipe life, even for alloyed steel grades, ▪ perfect head and tail pattern, ▪ no operators needed on the roller conveyor, ▪ special head/tail device excludes the need for human intervention on the roller conveyor/reforming pit, ▪ vibration-free during rolling (less than 1.5 mm/s at 120 m/s) thanks to patented oil-film bearings, ▪ low pipe wear thanks to optimized pipe shape and material (five to six times longer life than conventional laying heads), ▪ optimum formation of the last ring and head positioning in synchronization with the high-speed shear, ▪ special Danieli design for processing of large sizes (up to 27 mm).

PR motor Encoder HSS motor

Active gap adjustment

Line speed correction and front-end positioning control diagram (principle)

6.* 6WTDQNQQR NC[KPI JGCF (patent pending) With the 3rd generation laying head/rotors we achieved an optimized design for very high speeds (170 m/s design speed and 150 m/s in constant operation) with very few vibrations (less than 2 mm/s at a speed of 120 m/s). This proves that thanks to the use of calculations and 3D design of the machines, the loop laying heads can reach unparalleled performances and first-rate finished product quality, with very low wear of the loop laying pipes and less need for spares (i.e. oil film bearings – no need for anti-friction bearings).

Notwithstanding our 3rd generation achievements, Danieli has further developed, innovated and created an additional laying head generation. The Turboloop laying head – THL – features a “pipeless rotor” that offers numerous advantages for operators, for the production of mainly small diameters from 4.5 to 8 mm dia, which can be summed up as follows:

▪ endless life of the rotor, ▪ one rotor in one year corresponding to the use 60 pipes – meaning reduced maintenance and downtimes, ▪ repetitive loop formation with steady, regular laying on the controlled cooling conveyor, ▪ reduced noise level from 110 dB(A) to 86 dB(A), ▪ diminished vibrations due to imbalance and axial-symmetrical wear as well as predictable and controllable wear, with no cobbles due to unexpected pipe wear.

This innovative technology is today fitted onto all of Danieli’s new laying heads and can be easily applied to upgrades of existing units. The machine’s special design coupled with an advanced automation/control system enables regular formation and laying of wire rod tail loops onto the roller conveyor in a perfectly round shape.

This means it is no longer necessary to remove the deformed wire rod tail loops from the roller conveyor manually, making this operation much safer.

MPT International 2 / 2015

68

››› HOT ROLLING

Automation systems for the loop laying head The most challenging targets for the automation and drives system controlling the laying head are the formation of a perfect coil shape and the positioning of the head front end on the cooling conveyor. For a good coil shape, the laying head rotation speed should follow precisely and with high dynamics the real speed of the material. Thanks to the introduction of proper automation algorithms, the loop size is now perfect even at bar head and tail. In detail, for big sizes, speed wobbling is used to reduce the end size of the coil while at the tail a synchronized speed-up cycle of the twin-module block (TMB), pinch roll and laying head is applied to push the material out of the pipe and to have a regular diameter on the last loop. The use of full regenerative drive and proper main motor sizing is mandatory to perform such high-demanding speed cycles.

A great help for the perfect shape of the loops comes from the introduction of the active pinch roll that grants reliable and precise real rod speed measurement. The measured speed is then used to correct the laying head set speed. The correction is useful during high-speed rolling of small-size rods in wire rod lines with TMB when the tail end runs in – and in wire rod lines connected to two-strand rolling mills.

Amazing precision of head end positioning on the cooling conveyor is

Ferriere Nord wire rod line supervision system with the world speed record of 126.2 m/s

now possible with the introduction of the high-speed shear upstream the laying head. When the material head runs in, the rotor of the high-speed shear is maintained in constant phase synchronism with the laying head rotor.

For each turn of the laying head, the high-speed shear makes exactly two turns and when it performs the head cut, the position of the laying head is exactly the one expected. The result is that the error in positioning of the front end of the rod is less than 20 degrees at 120 m/s rolling speed.

Conclusions It took years of research, continuous improvement and teamwork to achieve the record speed of 126.2 m/s as in the

Ferriere Nord plant. Obviously, this was possible only thanks to the mutual trust and collaboration between the plant manufacturer and the plant operators. Over the years the market has become more and more aggressive and competitive, demanding increasingly tight machining tolerances, excellent quality of materials, high-quality and diversified products. The suppliers of processes and technologies must take into account every aspects of a machine and not only individual details.

The task is to analyze each and every possibility and combination in relation to the mechanical, hydraulic and electronic aspects, but above all with a view to the technological process. This approach will ensure outstanding results for all parties involved.

Nucor Darlington H3 wire rod line MPT International 2 / 2015

70

››› HOT ROLLING

Intermediate blocks

“Pocket Mill” – an investmentsaving solution for small and medium-capacity long product rolling mills In cases where a low-capacity rolling mill is required, the plant maker has to provide D VROXWLRQ WDLORUHG WR WKH VSHFLƂF QHHGV 7KH 3HUW 3RFNHW 0LOO 330® was developed to reduce the overall investment as much as possible, while providing highly cost-effective VWHHO SURGXFWLRQ Due to the current critical situation of the global steel market, the initial investment costs for new plants have to be as low as possible in order to allow

Nicola Tomba, Matteo Tomba, Pert srl, Tavagnacco (Udine), Italy Contact: www.pertengineering.com E-mail : info@pertengineering.com

MPT International 2 / 2015

a fast return on investment. In smaller plants, the operational costs must be reduced to a minimum to achieve low production costs as they do not profit from the economies of scale that characterize large plants. To effectively address and respond to the fast-changing market needs, Pert has proposed a non-conventional solution by developing new equipment and a layout specifically engineered for small and medium-size rolling mills.

The PPM® Pert Pocket Mill has been developed for production capacities ranging between 100,000 and 250,000 t/year, serving regional markets in developing economies or in countries where, due to their specific geography, it is advisable to establish various small plants distributed over the territory rather than a few large-size plants, especially in order to reduce the transportation effort and the related environmental impact.

HOT ROLLING

‹‹‹

71

General layout

The main target to be achieved is to reduce the initial costs of a plant.

When considering the costs allocated to a plant, the steelmaker must be careful because they may include not only the costs of the equipment, but also the civil works, buildings, auxiliary plants, etc. These are quite often taken into account far too late in the cost evaluation process.

These costs account for more than 50% of the total investment costs; therefore, it is crucial to understand that it is highly preferable to invest in a technological solution that provides significant cost savings not only in the steel mill equipment but also on the auxiliary equipment and infrastructures.

Much attention has been paid to the volume of civil works to achieve two benefits, namely a reduction of the costs related to civil works, formwork, reinforced concrete, etc., and most importantly a faster installation of the equipment. In fact, most of the delays in a plant start-up process are due to issues related to civil works. Moreover, efforts have been dedicated to reducing the dimensions of the buildings by providing solutions based on making the rolling mill line smaller, using blocks in place of single stands and cooling beds of shorter lengths.

Once the solutions for a reduced initial investment had been identified, the next step was to keep the costs as low as possible. Over the past five years, the engineers have strived to keep the operational costs to a minimum by reducing the number of spare parts required, since these are often quite expensive and not always immediately available.

In the following, the main components of a PPM® Pert Pocket Mill will be presented by way of the example of a mill for an annual rebar production of 150,000 t with a diameter range from 8 to 32 mm, and with a starting billet

size of 130 x 130 x 4,000 mm. The main equipment of the plant consists of: ▪ reheating furnace, ▪ triple-stand roughing mill, ▪ intermediate block (GEZ 420 and GEZ 340), ▪ rebar finishing block, ▪ cooling bed, bar discharging devices and finishing area, ▪ electrical system, ▪ water treatment plant.

Reheating furnace The reheating furnace is a 25 t/h pusher-type furnace, oil or gas fired, depending on the customer’s choice.

This type of furnace is the most adequate solution for small and medium-size plants, since it provides ▪ evenly heated billets (temperature difference between the billet top and bottom – or head and tail – of approximately 30 – 35°C), ▪ reduced fuel consumption (approx. oil consumption 30 – 32 kg/t, or natural gas consumption 35 – 37 m³/t) and ▪ ease of use,

with an initial investment far lower than that required for walking-hearth or walking-beam furnaces.

Pusher-type furnaces are a wellknown technology; therefore, the primary focus was shifted towards a more rational design of the furnace and, above all, towards the design of a combustion system with low levels of fuel consumption and emissions.

For specific applications or in order to comply with certain legal requirements, it is possible to use state-of-theart regenerative burners with alumina balls or honeycomb-type burners, which ensure consumption levels reduced by 60% and limited NOx emission levels (flameless operation).

3-high stand roughing mill This is a well-known and widely used technology, whose latest advancements are: ▪ elimination of flywheels, ▪ roll gap regulation performed by a hydraulic system from the main control pulpit,

Finishing block MPT International 2 / 2015

72

››› HOT ROLLING

▪ reduced on-board piping, ▪ new chock group design for fast and easy roll replacement.

To allow an automated rolling process without any operator intervention, the tilting table has been replaced by a very simple chute system that conveys the rolling bars into the respective grooves.

The 3-high stand has been engineered for rolling two billets simultaneously, to achieve a maximum hourly production rate of 40 t/h. The main technical characteristics are the following: ▪ roll diameter: 600 mm, ▪ barrel length: 1,500 mm, ▪ rolling speed up to 2.5 – 3 m/s, ▪ designed for 5 or 7 passes.

For low production capacities, the 3-high stand may replace a continuous roughing stand because inside it the bar being rolled is torsion-free; therefore, the 3-high stand replaces a roughing mill of single stands in H/V arrangement, providing equal performance at reduced costs.

The 3-high stand is not directly connected to the rest of the mill; therefore, in case of cobble in the intermediate rolling mill, the plant downtime is reduced since the rolling mill can be easily inspected and it is conveniently accessible for operators carrying out maintenance operations. The chance of cobble on the 3-high stand is minimal compared to a roughing stand. Moreover, the head and tail of the bar are swapped at each pass in the 3-high stand, so the chances that the bar head may split (usually due to the low quality of the billet) are rather low.

In a 3-high stand, the time required for a roll replacement is approximately two hours, i.e. almost the same as required in a continuous roughing mill without any available spare stands.

Moreover, while in the continuous roughing stands it is always necessary to align the guides, in the 3-high stand such operation is not required.

Spare parts for the 3-high stand are more expensive than the ones required for a single continuous roughing stand; however, the 3-high stand replaces six continuous roughing stands, therefore it is possible to achieve considerable cost savings for the spare parts required – i.e. six bearings instead of 24, a reduced number MPT International 2 / 2015

Bar discharging device

of guides, spindles, gearboxes and motor couplings, no hydraulic clamps, etc.

Intermediate block GEZ 420 and GEZ 340 In order to reduce the costs, a new type of blocks for use in the intermediate train has been developed. The intermediate blocks GEZ 420 and GEZ 340 represent a further application of the Pert BS spindleless® stands and have several innovative features: four stands are mounted on a common baseplate and driven by one motor. Rolling ring diameters are 420 mm or 340 mm, respectively. The rolling rings are mounted on a heat-treated alloyed-steel shaft. It is therefore possible to use cast iron or carbide rings to extend the grooves’ working life.

While common cast iron rolls must

be scrapped at the end of their life, the steel shafts can be indefinitely re-used, with only the worn rolling rings being replaced.

The use of cast iron or tungsten carbide rolling rings provides for a much longer groove working life compared to common cast iron rolls. Moreover, they allow uniform groove consumption, which decreases tensioning of the rolling stock between the block stands, since it is not possible to set the speed of each single pass.

The shafts are mounted on a double support and an eccentric roll gap regulation system. The high stiffness of the equipment reduces mechanical yielding. Further technological features include the absence of spindles (5% less electric energy consumption), horizontal arrangement and no on-board piping. The intermediate blocks allow the rolling mill dimensions and the re-

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››› HOT ROLLING

Cooling bed

quired number of electric motors to be reduced to a minimum.

4GDCT ƂPKUJKPI DNQEM The use of the rebar finishing block in the finishing mill allows to considerably reduce the required equipment, maximizing cost savings. In the here described case, the finishing block has cantilevered ring-holder shafts, the stands are in horizontal/vertical arrangement and the block has been developed specifically for the production of rebar.

Compared to traditional blocks, the main feature of this block is the use of standard roller bearings instead of oil film bearings; therefore, it is neither necessary to have a big lubrication unit or a water-oil separator nor is it necessary to use an expensive oil or an oil different from the one used for the lubrication of the other stands. The main technical data are: ▪ max. speed: 35 m/s, ▪ cast iron or carbide rings diameter: 250 mm, ▪ stand centre-to-centre distance: 650 mm, ▪ 4 or 6 passes.

Due to the use of the FLUR® Fast Locking-Unlocking Ring system, the ring replacement time is reduced to a minMPT International 2 / 2015

imum and the set-up time for the finishing block amounts to approximately 20 minutes. For these reasons, it is advisable to use a finishing block instead of independent stands.

Cooling bed, bar discharging FGXKEGU CPF ƂPKUJKPI CTGC A 30 x 6 m Wimler-type cooling bed allows a production rate of 25 t/h and a maximum speed of approximately 20 m/s. The reduced cooling bed dimensions are due to the use of two tail brakers and a twin-channel system, which are today largely used in plants all over the world. The hydraulic-driven twin-channel system has been developed for a bar diameter ranging from 8 to 32 mm, with dedicated “shells” for small and large diameters specifically engineered to allow a fast change from the production of small to large diameter bars and vice versa, whenever required.

According to the requirements of the mill operator, the cold shear can either be of the static or flying type.

The finishing area, including tying and bundle evacuation, is fully automated. However, the option of a manual tying procedure to provide additional cost reduction may be considered.

Electrical system The entire production process is completely automated (level 1). Due to the use of the above described equipment, the number of the main electrical motors is reduced to four: the motor sizes of the triple stand and of the finishing block are the same (~ 1,200 kW), so are the two motors of the intermediate blocks (~ 800 kW); therefore, there are four main motors of only two different sizes. With this arrangement, the installation and start-up times of the electrical system are drastically reduced.

From an economic perspective, instead of keeping in stock two large-size motors as spares, it is possible to adopt a solution that foresees the use of two motors for each type of equipment, i.e. two motors of 600 kW each on the triple stand instead of one of 1,200 kW, and two motors of 400 kW each instead of one of 800 kW. This solution allows to keep only one motor with the largest size (600 kW) as spare, to be used to replace the other motors in case of failure. In order to allow for the interchangeability of motors, it is necessary to take this option into consideration from the early stages of the project design (foundations and frames for the electrical motor, axis height adjustment, etc.).

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Water treatment plant

Water treatment plant Being an auxiliary plant, the importance of the water treatment facility is still not given due attention. It is in fact crucial to ensure high operational efficiency, production continuity of the rolling mill and the adequate quantity of cooling water to achieve high durability of the rolling ring grooves. Moreover, the quality of the circulating water is fundamental to maximizing the effectiveness of the overall equipment.

The water treatment plant is composed of two circuits: a “direct” circuit for roll cooling water and for the quenching process, and an “indirect” one for cooling the lubrication/hydraulic units and other devices.

It is crucial to effectively perform the removal of scale from the water. First, solids settle in a scale pit. The water is then delivered to a hydro-cyclone to achieve additional settling. The hydro-cyclone is installed at ground level in order to reduce civil works. A settling basin is installed for further scale separation. To remove solids from the water and finalize the treatment process, the water is then pumped into a filtering station composed of a self-cleaning filtering battery.

MPT International 2 / 2015

After filtering, the re-conditioned water is collected in a basin. From there it is pumped first to the cooling equipment and then to the respective users. For certain climatic conditions (e.g. water scarcity), a customized plant configuration has been engineered to reduce the required make-up water by approx. 60% by using hybrid cooling towers and drains recovery.

Conclusions Focus has been placed on the design and engineering of a state-of-the-art rolling mill, while keeping the overall investment and operational costs as low as possible. The adoption of a single-strand rolling process, instead of a multi-slitting process is the result of a careful analysis of various technical and economical factors, as following.

The multi-slitting technology was developed in the past to ensure high production rates per hour, since the maximum achievable speed was relatively low. Nowadays, the multi-slitting technology is also used in low-capacity plants in order to reduce the initial investment costs by reducing the number of required stands. The operational costs related to

the rolling mill train are equal to those of high-capacity plants. The investment required for guides and related spare parts is higher, since torsion guides and a slitting box are needed. Cobble may occur more often. The multi-slitting technology requires more time for groove replacement and guide aligning, possibly resulting in an increase in plant downtime.

For newcomers with no specific expertise in the steel production, the single-strand process is much easier to implement. Better quality tolerance can be achieved, specifically in the production of plain rounds. Fewer issues due to misaligned and overlapped bar in the finishing area will occur.

The key advantages of the PPM® Pert Pocket Mill consist therefore in the low investment and operational costs required, and in the maximum efficiency in the plant management. The solution proposed is only one of various solutions that can be engineered for low-capacity rebar rolling mills. In fact, these solutions may be “customized” to fully respond to the specific needs of the steel producer, such as the annual production capacity required, the operator’s level of expertise, the product mix and the final quality of the product.

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78

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş HOT ROLLING

NLMK Kaluga produces angle sections on its rebar mill 1/0. .DOXJD RSHUDWHV D Ć&#x192;H[LEOH UROOLQJ PLOO IRU UHEDU DQG VHFWLRQV ,Q WKH SODQW VWDUWHG WR SURGXFH VPDOO DQG PHGLXP VHFWLRQV W RI DQJOHV ZHUH VKLSSHG ODVW \HDU The EAF steel works NLMK Kaluga significiantly expanded its product portfolio. In 2014 the plant has started to supply 25 x 4 and 75 x 6 angles as well as #10 rebar to its customers in the Russian central and Volga regions.

At the beginning of 2015, also 63 x 6 angles were added to the product portfolio. By the end of the year, the plant plans to introduce 50 x 5, 100 x 9 and 90 x 8 angles. Alongside sections, the plantâ&#x20AC;&#x2122;s product mix includes #12, 14, 16, 18, 20, 22 and 25 rebar.

NLMK Kaluga is able to roll rebars at high speed and produce small and medium sections on the same line. Specific process solutions installed at NLMK Kaluga allow for swift readjustment of the rolling mill. It consists of a 150 tons per hour walking beam reheating furnace, 18 stands, two finishing blocks and three thermoprocessing lines. Six of the 18 stands are convertible for the readjustment according to customer requirements or market conditions.

In 2014, the facility fulfilled orders totalling 288,400 t of billets, 625,000 t of rebars and 2,800 t of angles. In August 2014, NLMK Kaluga produced its one millionth ton of steel. The steelmaking and long product capacities of the Kaluga plant are 1.5 million and 0.9 million t/year respectively.

The plant is located in the Central Federal District of Russia, a region with a large market for long steel products.

The central region accounts for approximately 30% of the long steel consumption in Russia and â&#x20AC;&#x201C; according to NLMK â&#x20AC;&#x201C; for 9% of the groupâ&#x20AC;&#x2122;s production. â&#x20AC;&#x153;Under the current market conditions, NLMK Kaluga is making full use of its competitive advantages,â&#x20AC;? says

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

MPT International 2 / 2015

Since 2014, NLMK Kaluga has also been producing angle sections; 2,800 t were shipped last year.

Roughing mill (picture courtesy of SMS Meer)

Alexander Burayev, general director of NLMK Long Products. â&#x20AC;&#x153;The plant is supplying the Russian construction sector with high-quality steel products that are in great demand, thus promoting import replacement.â&#x20AC;?

The launch of NLMK Kaluga in July 2013 was based on the mini mill concept of locating EAF steelmaking and rolling operations in close proximity both to sources of raw materials and consumers of finished goods.

NLMK Kaluga is part of the NLMK groupâ&#x20AC;&#x2122;s Long Products division. Investment in the construction of the plant totalled more than RUB 38 billion, of which around RUB 7.5 billion were spent on environmental protection measures, NLMK states. According to the company, the region boasts a surplus of scrap of around 2.3 million t/year. Scrap is supplied by the NLMK groupâ&#x20AC;&#x2122;s in-house scrap collecting network, Vtorchermet NLMK.

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››› MATERIAL FLOW LOGISTICS

The multidirectional ability of the truck enables it to handle bars as long as 10 m

Drivers appreciate the in-cab camera and the automatic fork positioners

Improving the dispatch of stainless steel long products The increased volume of stock carried has meant that Bird Stainless Steel Service Centre has doubled its storage area by building a free standing structure, with bespoke racking, which will accommodate up to a further 1,500 tonnes of stock.

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 firms in the home, European and Middle Eastern markets.

Bird Stainless, headquartered just north of stainless steel’s home city of Sheffield, has taken delivery of its second Combilift 4-way forklift to enable it to cope with increasing demand for its products. Until four years ago the main handling vehicles used to pick and transport free stacked bars were counterbalance forklifts, sometimes used in conjunction with a sideloader. The limited

Combilift Ltd., Co., Monaghan, Ireland Contact: www.combilift.com E-mail: info@combilift.com

MPT International 2 / 2015

manoeuvrability of these trucks was less than ideal when negotiating tight areas with very long loads and locating specific customer orders was a very time consuming process. Following the delivery of the company’s first 8-tonnes Combilift C8000, managing director Nigel Bird saw a considerable improvement in procedures: “This was so much more flexible than our old trucks and in conjunction with a racking system it enabled us to cut time for locating and retrieving bars down to a matter of minutes rather than up to an hour. Aisle-widths between the racking were also reduced for maximum use of space. The multidirectional ability of the truck also enables us to handle longer lengths than before and we can now confidently negotiate all areas of the site with bars as long as ten metres.”

Since the original truck has been in place, 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. The

increased workload is too much for the one machine and Bird has taken delivery of a second C8000 to work in the new facility. “We need reliability from our equipment and this is what we got with our first truck so it was a natural choice to go for the Combilift this time round,” said general manager Bill Innes.

“The new facility was designed around the truck’s capabilities, so this ensures that we have the utmost in space utilization and productivity. We have used all vertical space with racking up to 5.5 m and guided aisle operation again allows aisle widths to be set at a minimum.”

The new diesel powered C8000 has slightly shorter forks of 750 mm, which accord to the depth of the new racking, therefore avoiding any potential problems of forks going through to the next bay and eliminating the risk of damage to racking and stock. Drivers also appreciate the in-cab camera when placing or picking bars to the top beam and the automatic fork positioners which avoid the need for them to get in and out of the cab for manual adjustment.

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82

››› AUTOMATION

Hot strip mill II at ThyssenKrupp Steel Europe AG, Duisburg works, Germany (Courtesy: ThyssenKrupp Steel Europe AG)

0GY QXGTURGGF UYKVEJ VQ HWNƂN increased safety requirements Systems operators are requested to observe increased safety regulations with regard to critical operating statuses. Leading the way, ThyssenKrupp Steel Europe AG installs the overspeed switch EGS(H)® IURP -RKDQQHV +¾EQHU *LHVVHQ 7KLV GHYLFH LV FHUWLƂHG WR highest safety integrity level and performance level as well, to ensure maximum safety.

Humans and machines face extreme conditions in heavy industry in particular. To comply with stringent safety regulations applicable to large industrial systems, operators implement protective measures as part of “functional safety” management procedures. These encompass the safety of the whole plant, which depends on the proper functioning of safety-related systems to reduce risks. Standards such as the international standards IEC 61508 and DIN EN ISO 13849 specify that plant systems must ensure their functions are performed under defined fault conditions with a defined high degree of probability. These functions must be executed flawlessly,

Johannes Hübner Fabrik elektrischer Maschinen GmbH, Giessen, Germany Contact: www.huebner-giessen.com E-mail: info@huebner-giessen.com

MPT International 2 / 2015

in particular with regard to operating statuses such as “safe standstill” and “safety limited speed” as well as when carrying out maintenance on “live” systems.

To guarantee maximum safety for these operating statuses in particular at the stands of the roughing train of the hot strip mill II, ThyssenKrupp Steel Europe AG installed an electronic overspeed switch that operates independently of the closed-loop speed control system. The Duisburg-based company is the first in Germany in which the EGS(H)® 41 ensures an even higher level of plant safety. Produced by Johannes Hübner Fabrik elektrischer Maschinen GmbH, the device functions as a system with an integrated sensor (speed measurement), logic circuitry (speed evaluation) and actuator (speed switch). In this combination it is the first device on the market worldwide certified according to the international standard IEC 61508 up to safety integrity level (SIL) 2 as well as to

performance level (PL) d in accordance with DIN EN ISO 13849. “Functional safety means protecting life and limb by means of safe systems in our plant.

With the introduction of this global innovation from Johannes Hübner Giessen we have responded to increased requirements with regard to safety of personnel, and we are more than meeting functional safety requirements,” explains Svetlana Regner, responsible project manager in the field of Energy/ Asset Management (EA) at ThyssenKrupp Steel Europe AG.

Safe processes when performing maintenance To date, it is only mandatory to install SIL components in new plants and systems. No such obligation applies when upgrading systems such as in the case of the hot strip mill II operated by ThyssenKrupp Steel Europe AG. Nevertheless, the Duisburg-based group decided to install the SIL certi-

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fied EGS(H)® 41. The electronic overspeed switch helps their maintenance personnel to eliminate faults in the system significantly quicker. “We introduced a new safety concept in cooperation with the [German] Employer’s Liability Insurance Association. This safety concept makes it necessary to precisely monitor the system with the Hübner device,” according to Svetlana Regner.

“It is not necessary to de-energize the electrically powered main drives when changing a roll if the operating speed of the system is monitored with the aid of this encoder. This practice protects the electrical components, because we do not have to switch the system back and forth at the contacts,” she explains the procedure. If it were necessary to continuously electrically activate the system, it would also be necessary to constantly switch the power components to and fro. It is expected that switching the electric components less will have a positive effect on contact wear. “The electronic components do not have to be replaced so often since the overspeed switch was installed. That saves both time and costs,” added the project manager.

With the EGS(H)® 41 installed the system supervisor is now able to quickly safeguard the operating modes “safety limited speed” and “zero speed” to minimize risk.

New encoder and overspeed switch combined The overspeed switch was attached to the equally new absolute encoder ASPAH 60 from Johannes Hübner Giessen. The company developed the absolute encoder specifically to fulfil the requirements of systems operating in heavy industry. And because the encoder is equipped with a parallel interface for the absolute value output (terminal box 1) as well as two additional electrically isolated incremental value outputs (terminal box 2) communications between the ASPAH 60 and the EGS(H)® 41 are ideal. The overspeed switch is equipped with four programmable switching outputs and equally two terminal boxes. Moreover, the encoder is housed in a robust casing to which it is possible to attach devices such as the SIL certified overspeed switch without any difficulty.

MPT International 2 / 2015

High switching accuracy offers peace of mind ThyssenKrupp Steel Europe has trusted the reliable and long-lasting products from Johannes Hübner Giessen for more than 40 years. The company installs the encoder technology made in Giessen, Germany, in numerous manufacturing plants and sites worldwide.

ThyssenKrupp Steel Europe became aware of the EGS(H)® 41 overspeed switch during a technical consultation. “As we were sounding out the market for a new encoder solution, Hübner was the only developer that offered a device for use in heavy industry, such as the hot rolling mill in our case. Hübner put in an enormous amount of development work during the following project phase to meet specific demands such as the shaft diameter and SIL 2 rating for the envisaged application.”

The safety device is equipped with two separate electrically isolated switches to monitor speed; they can be programmed independent of one another to monitor overspeeds and underspeeds from 0.5 rpm. Electric isolation means there are two complete switches available. To achieve the same function with mechanical centrifugal switches it would be necessary to install two devices. Thanks to the setting “independent rotation direction” maintenance personnel are able to store different switching speeds for each switching point. To ensure it is possible to continuously monitor the safety functions incorporated in the device, the EGS(H)® 41 offers integrated standstill and slip monitoring functions as well as diagnostics switches.

Internal diagnostics is a precondition for SIL 2 certification. All told, there are three diagnostics switches available: Two switches are fitted in series with both main switches. Another, separate switch is provided to facilitate enabling functions in the customer controls as required. The integrated overcurrent detection and the switching contact status monitoring functions monitor the switching contact current in both directions of flow. “Rapid overcurrent detection protects the switch and the series-connected fuse against damage in the event an inadvertent connection causes too much current to flow across the switch contacts,” confirms Bernhard Herbst, project engineer at Johannes Hübner Giessen.

Before the EGS(H)® 41 was installed, personnel had to reckon with risks to safety time and again, such as the system starting up suddenly or the speed increasing abruptly as they carried out maintenance tasks or system setup work. The high switching accuracy of the device minimizes these risks.

Hence, the first SIL certified overspeed switch produced in-house at Johannes Hübner Giessen fulfils an important objective: the safe operation of machines and systems.

The solution of choice for ThyssenKrupp Steel Europe is the B5 version of the SIL 2 certified overspeed switch, which is flange-mounted to the ASPAH 60 hollow-shaft device. The overspeed switch is available as B5 (flange), B35

The overspeed switch was attached to the equally new absolute encoder ASPAH 60 from Johannes Hübner Giessen

(flange and foot) as well as a hollow shaft version. Furthermore, Hübner customers are able to choose between a supply voltage of 12 to 30 V DC or 100 to 240 V AC and between the versions with a switching voltage 0 to 30 V DC or 30 to 230 V AC/DC. Johannes Hübner Giessen produces other options tailored to customers’ needs. “Our portfolio includes a variety of encoder solutions for heavy industry, all of which are individually adapted to meet specific customer requirements,” explains project engineer Bernhard Herbst. “To achieve the best possible signal quality and a long service life it is important to choose the right devices and ensure optimum mechanical attachment of the devices to the system on site.” The combination of encoder and overspeed switch fulfilled these requirements in the hot strip mill operated by ThyssenKrupp.

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Scope The long-standing co-operation between AIM - Associazione Italiana di Metallurgia - and the IFHTSE - International Federation for Heat Treatment and Surface Engineering - has already led to the joint organisation of significant events, such as the Congresses held in Florence in 1982 and in 1998 and the Congress on automotive applications organized in Riva del Garda in 2005.

Now, our combined resources will be focused on the organization of a Conference that will deal with tradition and innovation in heat treatment and surface engineering. The Conference will join the European Conference on Heat Treatment 2015 and the 22nd IFHTSE Congress.

Conference organisers

ASSOCIAZIONE ITALIANA DI METALLURGIA p.le Rodolfo Morandi 2 · 20121 Milano · Italy phone: +39 02.7602.1132 or +39 02.7639.7770 fax +39 02.7602.0551 · e-mail: aim@aimnet.it Conference website:

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Optical 3D surface inspection is ideal both for the lab as well as demanding industrial use (Photo courtesy of NanoFocus)

Optical 3D surface measuring VGEJPQNQI[ CEEWTCVG RTQƂNG TGRTQFWEVKQP QH VJG ƂPGUV structures For surface inspections, the trend is heading toward smaller and smaller structures that must be reproduced or resolved accurately at nanometre level. Highly precise principles can present the sample topography and roughness structures not only qualitatively, but also quantitatively according to tactile measurement methods that are described in many industry standards.

Surface inspections are indispensable in many of today’s industries.

Optical measurement processes as contact-free and destruction-free

Gernot Hamann, Physik Instrumente GmbH & Co. KG, Karlsruhe, Germany Contact: www.pi.ws E-mail: d.knauer@pi.ws

MPT International 2 / 2015

analysis and test methods are chosen for many applications because they can be applied to almost all materials and are also suitable for sensitive samples. NanoFocus AG, located in Oberhausen, Germany, has pioneered in optical-confocal 3D surface measuring technology for many years. Different product lines cover various areas of application, from fast inline production inspection to flexible, customer-specific solutions and even high-preci-

sion μsurf systems. For rapid wide-area measurements these μsurf systems work with vertical resolutions up to 1 nm, laterally up to 300 nm. This means they are suitable both for the lab as well as for demanding industrial use, such as three-dimensional surface measurements in the automobile industry, materials management and the steel industry. The measurement principle works reliably on metallic surfaces, in rough or polished condition. Further-

®

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The “μsurf expert” measuring system

200 to 400 individual 2D images are converted into a 3D image by the

was launched in 2014 (Photo courtesy of

measurement software (Photo courtesy of NanoFocus)

NanoFocus)

more, layer thicknesses of partially transparent surfaces can be analyzed using special algorithms.

Extremely low scatter and robust signalling The core of each of these μsurf systems is the integrated confocal-optical filter unit that is combined with a highly precise and fast focusing module. The patented multi-pinhole disc (MPD) is used as an optical filter of reflected light rays and distinguishes itself through extremely low scatter light intensity as well as robust signalling with a high light yield. The objective focuses light from a high-performance LED source through the multi-pinhole disc onto the surface. Only the portion of the light that is reflected from one point of the surface and which lies precisely in the focal distance of the objective can pass the point openings of the MPD. In contrast, light that is reflected by a sample area that is not within the focal plane of the objective is blocked. By rotating the MPD, the entire sample surface can be quickly and completely scanned.

By moving the objective vertical to the sample surface, all contour lines of the sample are focused one after the other. The CCD camera used stores the brightness values of the visual field for each objective position. Points MPT International 2 / 2015

with maximum brightness are located on one contour line. Each confocal image is a horizontal cross-section through the surface topography of the sample. The 3D structure of the sample can be determined from the total number of images at different height intervals. This is called the image stack. This stack consists of an average 200 to 400 individual images that are recorded in a few seconds and are converted by the measurement software into a 3D topography representation, accurate to within a few nanometres.

Piezo positioning system for the objective In order to achieve such a high measurement resolution, the objective must be moved in the direction of the z axis with great precision. “This is almost impossible using conventional motor drives,” explains Dr. Georg Wiora, responsible for strategic development and innovation management at NanoFocus. “The positioning system for our objective is therefore based on piezo actuators. They work free of wear and friction with zero play and they are suitable for high recording frequencies due to their dynamics.” Zero play and highly precise flexure guides together ensure high focus stability. This is how travel of up to 500 μm is achieved in

the described application; the position accuracy of the kinematics thus lies in the nanometre range.

The piezo-based, single-axis positioning system used in the μsurf system originates from the comprehensive product portfolio of the company Physik Instrumente, based in Karslruhe, Germany. It was adapted to precisely meet the application requirements, was able to be easily integrated into the objective holder thanks to its compact dimensions and moves the objective at a constant speed. The measurement is performed on the fly. That is why the core requirement of the positioning system is a high velocity constancy in the nanometre range. This is the only way absolutely accurate (down to a few nanometres) roughness measurements can be taken that are compatible with tactile processes and meet the requirements of the corresponding industrial norms. Repeatability is just as important when positioning the objective, so as to prevent a height offset when assessing the stack of individual images.

High-resolution measuring process and applicationURGEKƂE EQPVTQNNGT Repeatability and linearity in highly dynamic and high-resolution positioning systems are inconceivable without

QUALITY ASSURANCE

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The piezo-based single-axis positioning U[UVGO ƂVU GCUKN[ KPVQ VJG QDLGEVKXG holder (Photo courtesy of PI)

the use of measurement processes with the highest possible resolution. Position accuracies of just a few nanometres or lower require precise position measurement methods that are able to detect motion in this range. In the described application, capacitive sensors ensure

this highly precise actual value recording. The high sensor bandwidth also allows closed-loop control in dynamic applications. The capacitive sensors are generally suitable for measurement ranges up to 1,000 μm, for resolutions down to 0.01 nm. The repeatability and

absolute positioning accuracy of the objective are therefore guaranteed.

A controller with an integrated piezo amplifier analyzes the sensor data and controls the positioning system’s piezo actuator. The compact customized electronics can be integrated into the NanoFocus control system seamlessly, both in terms of hardware dimensions as well as electrical interfaces. “In this area, too, Physik Instrumente (PI) has proven to be a competent partner that has contributed decisively to our success,” explains Dr. Wiora. Piezo-based positioning systems have therefore shown once again that they can drive technology.

www.LDV-Systeme.de

LET’S HAVE A LOOK !

Pneumatic dosing systems for steel plant Coal Injection system (1-3 Lances / dispenser) Lime & Aluminum technology for EAF and LF Production of wear-resistent pipes and bends Einblastechnik für Stahlwerke Kohle Einblasanlagen (1-3 Linien / Sender) Kalk & Aluminium Einblastechnik für EAF & LF Kalkzugabe in den Schlackenstrahl Herstellung von verschleißfesten Rohrleitungsteilen Verschleißschutzlösungen Keramik (AL2O3)- & Korundbögen

LF

EAF

LDV Laser- und Lichtsysteme GmbH An der Wethmarheide 36 · D-44536 Lünen Fon +49(0)2306 940 80-0 · Fax +49(0)2306 940 80-33

Koll Anlagenbau GmbH & Co KG 16.-20.06.2015 DÜSSELDORF Schachtstr. 21, 59379 Selm , Tel.:+49/(0) 2592 / 978578 Halle 5 Fax.:+49/(0) 2592 / 978682 Stand D11 E.Mail: Koll@eaf-carbon.de

Please visit us: METEC 2015, hall 4, A19 MPT International 2 / 2015

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Pipe welding line TUBE AND PIPE MAKING CSI Tubular Products (CSITP), of the non-annealed pipe does not meet the quality rea wholly-owned subsidiary of California Steel Industries quirements. The output is therefore higher than with con(CSI), based in Fontana, California, USA, has successfully ventional, stationary seam annealing plants. The mill also commissioned an electrical resistance welding (ERW) pipe features full body ultrasonic lamination testing and ultramill supplied by SMS Meer. The mill, designed to produce sonic weld seam inspection. up to 24” (610 mm) diameter pipes, achieves production speeds of up to 35 m/min and is capable of producing up Contact: to 400,000 t/year of pipe. Coil pay-off can be performed www.sms-meer.com · www.sms-elotherm.com from above and below, meaning better strip alignment within the plant’s forming process, depending on the direction of rolling of the inserted strip. SMS Elotherm supplied the induction HF welding and seam annealing technology. The EloWeld™ 1800 pipe welding plant is integrated into the central section of the pipe mill and ensures reliable welding of the longitudinal seams.

The downstream EloSeam™ 3000 pipe seam annealing plant allows for post-annealing, where necessary, thanks to its ability to be traversed longitudinally. This is required if, for example after a standstill of the plant, a portion Electrical resistance welding line at CSI Tubular Products

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STEELMAKING ROLLING ENVIRONMENTAL AND ENERGY ASPECTS STEEL MATERIALS AND THEIR APPLICATION, SURFACE TECHNOLOGIES

Host

Organizer

Steel Institute VDEh | Dr.-Ing. Hans Bodo Lüngen Sohnstr. 65 | 40237 Düsseldorf | Germany Phone: +49 211 6707- 444 | Fax: +49 211 6707- 440 www.stahl-online.de

TEMA Technologie Marketing AG | Carsten Scheele Aachener-und-Münchener-Allee 9 | 52074 Aachen | Germany Phone: +49 241 88970- 300 | Fax: +49 241 88970- 999 Email: metec@tema.de | www.tema.de

MPT International 2 / 2015

www.metec-estad2015.com

IRONMAKING

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New range of oil sealed pumps SPECIAL EQUIPMENT With the newly launched range of single-stage oil sealed rotary vane pumps, Edwards can now offer pumping solutions from atmosphere down to ultra-high vacuum (UHV). The ES range of pumps can be used individually or with mechanical booster pumps to increase both performance and

Keep your plant safe.

Oil sealed pumps

ultimate vacuum. The pump mechanism on the new ES pump has been refined to produce a better quality of vacuum. The pumping speed is maintained even at lower pressure, extending the operating pressure range.

Powerful solutions for the metal industry

Contact: www.edwardsvacuum.com

As a global provider of automation solutions, Endress+Hauser has the necessary expertise to deliver safe, robust and reliable field devices as well as customized solutions and services. Our industry-optimized packages enable you to lower energy and process costs efficiently and comply with environmental requirements.

High-capacity ×N@S@SHNM BDKK SPECIAL EQUIPMENT Suitable for all flotation applications, the new flotation cell launched by Outotec is designed to meet the market demand for increased capacity combined with improved production and energy efficiency. The Outotec TankCell® e630 is the latest addition to Outotec’s flotation portfolio.

With a diameter of 11 m and a lip height of approximately 7 m, it has an effective volume of 630 m3 as standard and volumes of close to 700 m3 achievable depending on the chosen configuration.

The new cell incorporates proven innovations such as the Outotec FloatForce® mixing technology, which enables superior pumping performance, better air dispersion and mixing capability, improved efficiency and longer component life. The capital investment and operational costs are lower compared to multiple smaller units.

Contact: www.outotec.com/tankcell

www.endress.com/metal

Endress+Hauser Instruments International AG Kaegenstrasse 2 4153 Reinach Switzerland info@ii.endress.com www.endress.com

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Plate mill refurbishment HOT ROLLING Within the framework of a major refurbishment project at Eastern Europe’s largest heavy plate mill, Corts Engineering adjusted the rolling geometry of the finishing stand to the original gap dimensions and tolerances by machining, reengineered the work roll change mechanism and replaced key components. The scope of the work also comprised the redesign of the work roll clampings, installation of a new greasing system and protection of all relevant surfaces of the mill housing and related back-up and work roll chocks by linear bearings made of stainless compound steel.

Over the years, the rough operating environment prevailing in the reversing heavy plate mill had taken its toll on the accuracy of the stand’s rolling geometry. The result were large gaps

between the chocks and the housing liners, allowing an unwanted movement of the entire roll set during rolling. Previous attempts to refurbish the mill by resin injection behind the liners had proved to be ineffective and even worsened the condition of the mill.

With the approach adopted by Corts Engineering, the finishing stand of the 40-year-old plate mill was refurbished and upgraded to its original performance level in the course of an eleven-day shut down and about four months of preparation. Corts Engineering utilized state-of-the-art laser measurement technology for mill audits, as a detailed survey is the key to determining the current condition of the geometry of a mill window and the related chocks. The obtained values were

A New Era In Technology ROLLTEX EDT (electro discharge texturing) machines for cold strip mill rolls

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Refurbishment of mill windows by new liners

carefully studied and compared to the original manufacturer’s drawings by skilled and experienced rolling mill engineers. All results were presented to the mill operators in a detailed, easyto-read survey report. Based on this report, the target values for machining, new liner thicknesses and the desired gaps between the chock and the housing were calculated and agreed in the basic engineering documentation.

The experienced surveying team used unique measurement techniques, allowing them to act fast and achieve accuracies down to 0.05 mm.

The reference surfaces of the mill had progressively worsened over the years.

Once there was a gap between the liners and the mounting surfaces on the housings, water intruded causing severe corrosion and wear. During rolling and slimming of the mill stand, water was sucked in and pumped out during each rolling campaign. This exponentially increased the size of the crevices leading to inaccurate window gaps between the chock and the housing liners.

In any mill application, the gap between the housing and the chocks is calculated by the mill builder in such a way that it is as tight as possible, while allowing for slimming during rolling.

This has an immense influence on the mechanical performance of the mill.

Once that gap increases, bearing failures, cross rolling, broken clampings, excessive wear part consumption, frequent mill outages and poor product quality are the result.

TECHNICAL INNOVATIONS For the here described rolling mill, a refurbishment by Corts Engineering was the only solution to regain the mill’s capability of producing high quality steel sellable in today’s highly competitive markets. After the remaining resin, broken bolts and screws had been removed, two milling machines with a vertical stroke of over 5 m were installed, for simultaneously milling the entry and exit sides on both the operator and drive side.

All machines were set up using stateof-the-art laser surveying technology, allowing the window dimensions to be brought back to the original design specifications.

Milling machines specially designed for this kind of application provide for fast and accurate repairs in any location of the mill. At the same time, the back-up roll change system was upgraded with Corts quenched and tempered solid stainless steel liners. This material withstands the heavy weight of the roll set and the constant presence of cooling water without problems.

The recently added fixed rails used for the work roll change had been damaged

by the hydraulic system and were to be replaced. The two 7-m-long rails weighing 8 t each were secured in the mill stand by tight-tolerance fitted locking keys which carry the weight and set the rails accurately in position and exactly level from the operator to the drive side.

Now, after machining, the window geometry of the mill is true to tolerances and, in combination with the liners made of Corts compound steel, a hard, stainless surface has been created. With this solution, extensive rolling guarantees can be offered.

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The chocks were reintroduced into the mill and perfectly fit. The mill window gap is now optimal, the patented lubrication system has been activated and the chocks have been locked in place by the updated clamping system. In addition to the optimal mill window, the gaps between the chocks and the housing are now as designed by the mill builder over 40 years ago. This puts the mill in an excellent condition for decades to come.

Contact: www.corts.de

Dino Capitanio - AIC Founder

40 years learning, listening and solving our Customers’ needs.

We want to offer the steel industry excellence and constant attention to details in the design of complete systems including command, control and monitoring components.

The result leads to a better performing, safer and more efficient production process.

The worldwide experience in engineering metal automation process is all in your hands.

AIC Automazioni Industriali Capitanio sites: ® Italy (Headquarters & Workshop) - Phone +39 0365 826333 ® United States of America (Sales & Service) ® India (Sales & Service)

aic@aicnet.it - www.aicnet.it

Mill housing with refurbished window

www.metec.com www.tbwom.com

New industrial valve for processing abrasive and corrosive substances SPECIAL EQUIPMENT A new slurry knife gate product designed to enhance current pipeline equipment and processes using enhanced technology for fluid control has recently been launched by Flowrox. The SKW (slurry knife wafer) valve was developed for use in the oil and gas, mining, minerals and metallurgy, power and waste water industries, where abrasive or corrosive slurries, powders or coarse substances are processed. Flowrox has engineered its SKW valve at full-bore with no flow restrictions, allowing processes with abrasive or corrosive fluids to move without compromising performance.

The main benefit to a full-bore design is that the SKW valve itself becomes an integral part of the pipe and allows it to process the same fluids in the harshest of conditions. In addition to its strength and resistance to aggressive slurries, Flowrox’s new SKW valve is designed as a full port fluid control device that allows a more efficient process, requiring less pumping energy to operate.

It incorporates a cast single-piece body, which eliminates any potential leak paths from the body and offers a versatile tower construction that will accept manual, electric, hydraulic or pneumatic forms of actuation. In the “open” position, the SKW valve’s rubber ring sleeves are the only parts in contact with the medium as a way to reduce any potential corrosion.

worldwide

Contact: www.flowrox.us

Tap hole cleaning manipulator 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!

STEELMAKING Since September 2014, at TenarisTamsa in Mexico, the eccentric bottom tap hole of the 170 t EAF has been cleaned by a manipulator supplied and installed by More. The swivelling movements of the Estrop EBT cleaning manipulator are actuated electrically, the lifting movements hydraulically. The manipulator is a stand-alone piece of equipment which can be installed on the bottom shell either on the left or on the right side of the EBT tap hole. The cleaning operation is performed either from the main control room or from a local control box installed in a safe position close to the EBT area.

One of the main challenges of this project was to design a structure capable of coping with the heavy heat loads since the manipulator arm is constantly above the ladle during tapping. TenarisTamsa recently ordered an additional Estrop unit for the spare shell.

Contact: www.more-oxy.com

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

www.messe-duesseldorf.de

WELDING A new laser welding machine developed by Guild International creates complete edge-to-edge welds without the need for start and stop tabs on strip as thin as 0.076 mm. The machine, named LHMA laser welder, utilizes a fibre laser to deliver the necessary energy for welding via a fibre optic cable

Edge-to-edge welding

connected to a focusing head. The focusing head concentrates the energy to a very fine spot to achieve excellent weld results on steel, stainless steel, cooper and brass alloys and aluminium. The machine includes a camera and large HMI touchscreen allowing the operator to view the strip fit-up prior to welding. In just two minutes, the process of shearing, aligning and welding the two coil ends is complete. Weld schedules can be stored for quick retrieval and the parameters are easily set with the HMI touchscreen. An interlocked safety enclosure provides the required safety for the operator.

Contact: www.guildint.com

EAF optimization system STEELMAKING Kanto Steel has signed off on performance savings on its steelmaking process using Tenova Goodfellow’s EFSOP® holistic optimization system. The system was installed at the 90 t EAF No. 1 at the Kanto steel plant in Tsuchiura City, Ibaraki, Japan. Consumption savings attained were 0.5% on electricity, 8% on oxygen, 20% on kerosene, with an 0.5% increase in yield. Total overall consumption savings amounted to slightly more than 190 JPY (approx. 1.38 euros) per t.

Contact: www.tenovagroup.com MPT International 2 / 2015

VISIT US AT METEC | HALL 04, BOOTH 4E18

Coil end welding on ultra-thin strip

www.alpinemetaltech.com

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GLOBAL ONE STOP SOLUTIONS FOR CASTING & ROLLING UNDER WORLD LEADING BRANDS

TECHNICAL INNOVATIONS

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Perspectives for steel and aluminium in automotive engineering LIGHTWEIGHT DESIGN Based on independent consultation with steel, aluminium and automotive experts, World Steel Dynamics concludes that steel can easily deliver the weight savings required to meet fuel economy targets for most vehicles. According to a report presented to steel executives at the worldsteel annual conference in Moscow, advanced high-strength steels will offer more than sufficient lightweighting opportunities to automotive companies in the next decade, and from 2021 – 2025, automotive designers will be implementing an array of higher-strength steels.

Once engineers decide to redesign steel-intensive vehicles from the ground up, they will implement sizable and relatively low-cost weight savings with advanced high-strength steels. Advanced high-strength steels, even if priced substantially higher than other auto sheet, are quite attractive given their weight savings relative to aluminium. It is anticipated that automakers will not widely adopt aluminium or other alternative materials during their next round of design.

Contact: www.worldsteeldynamics.com · www.autosteel.org

FMG RESULTS TAKING THE CENTER

PRECISE FROM END …

… TO END

Flattness measurement up to the product‘s edges.

Experience for yourself: METEC 2015 hall 03 | booth A35

www.surfiles.com

Cloud solution for strategic purchasing METALLURGY A cloud solution for the strategic purchasing of master alloys, alloys and unalloyed materials is provided by the start-up Alloys2b. With the independent Alloys2b tendering platform, a new procurement channel for raw materials is available to small and medium-sized enterprises (SME). The platform, which specializes in master alloys, alloys and unalloyed materials, is free of charge for buyers. They are also under no obligation to buy. The process followed in a call for tenders differs from the usual procedure in which the lowest bid is automatically the winning one. Instead, the buyer is at any time free to choose a bid and the associated supplier. The decision as to the purchase and the supplier remains in the hands of the buyer. The goal of the platform is to enable steel mills and foundries to conduct their mission-critical purchasing process more efficiently, reliably and cost-effectively.

It is possible to achieve fair market pricing using the cloud solution from Alloys2b and the known procedure based on the tendering principle. A call for tenders is created within less than five minutes and the subsequent bidding procedure starts automatically. The Alloys2b cloud solution can be deployed in any environment without the complexity and cost of a time-consuming IT project. The platform can also be used on mobile end devices such as smartphones and tablets.

Contact: www.alloys2b.com

Variable frequency drive with improved features DRIVE TECHNOLOGY A new medium voltage drive introduced by TMEIC supports higher voltage motors without the need for an output transformer, and avoids many problems associated with older variable frequency drive designs, such as low efficiency, low input power factor, and output harmonics. The new TMdrive-MVe2 family of drives gives the user a choice of voltage output and power levels. The different drives available range from 3 kV to 11 kV at power levels up to 3,860 kW. The drive uses pulse width modulation to create a voltage sine wave output by means of several inverter power modules. To create the required medium voltage output to the motor, the inverter modules are connected in a series so the output is the sum of the module outputs. Only two modules in series per phase are required for the 3 kV output, only three for the 6 kV output, and only 5 for the 11 kV output. The benefits of the new

TECHNICAL INNOVATIONS drive include energy savings, as regenerative braking puts energy back into the supply when the load is slowing down.

High electrical conversion efficiency of 97% results from the low switching losses of the main circuit elements and the low input side harmonic currents, which also eliminate the need for harmonic filters or power factor improving capacitors. Stable speed control is achieved without requiring a motor speed sensor since the drive accurately calculates

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motor speed from the motor current and voltage. The multilevel pulse-width-modulated control produces an output waveform close to a sign wave, so an output filter is not required, and motors do not require surge protection. Using the drive to soft start the motor controls the starting current and reduces the inrush current.

Contact: www.tmeic.com

Millmate Strip Scanner. The leading edge technology.

Improved accuracy leads to better margins, both financially and in the process.

Keep track of your strip edges in your mills and process lines using the Millmate Strip Scanner System (MSS), a well-proven robust sensor with negligible maintenance costs.

Based on ABB’s patented Pulsed Eddy Current technology, it is a non-contact sensor with no moving parts. The measurement is extremely stable, even during the worst conditions.

Mill coolant, steam, heat and dust do not affect the measurement.

By using the MSS system you will achieve better strip position control resulting in better flatness control possibilities, reduced scrap, improved threading and better coiling. www.abb.com/pressductor

ABB AB Force Measurement Phone: +46 21 32 50 00 Fax: +46 21 34 00 05

MPT International 2 / 2015

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››› TECHNICAL INNOVATIONS

High-resolution ICP-OES spectrometer for elemental analysis ANALYTICAL EQUIPMENT Designed for use in the most demanding elemental analysis applications in industry, science, and academia, the new Spectro Arcos, introduced

by Spectro Analytical Instruments, provides improved sensitivity, stability and precision, while lowering operating costs with the introduction of innovative components, unique capabilities and optimum flexibility. It establishes a new ICPOES performance class for complex analytical tasks. Features of the new Spectro Arcos include the possibility of axial or radial plasma observation. The CCD optic system delivers a matchless resolution of 8.5 picometers in the wavelength range from 130 to 340 nm. A new solid-state generator design provides the highest plasma power available for extreme or quickly changing plasma loads. The sealed optical chamber ends the need for the purging of argon or nitrogen gases. Aircooled interface technology and the completely air-cooled generator eliminates the need for an external cooling system.

Contact: www.spectro.com

Spectrometer for complex analytical tasks

STEEL MANUAL ISBN 978-3-514-00745-1

24.90 € Published by the Steel Institute VDEh Edition 2008 · 20.0 x 24.0 cm 186 pages including many multi-colour illustrations and a flow chart showing the production routes from ore to steel For many years the STEEL MANUAL has been the undisputed reference for those looking for a general description of the material steel, from the raw materials and the various iron and steelmaking routes through to technologies of the first processing stage, steel industry related topics and environmental and climate protection issues – the STEEL MANUAL leaves no aspect of steel out.

Verlag Stahleisen GmbH P. O. Box 10 51 64 · 40042 Düsseldorf, Germany · Fon: +49 211 69936-264 · Fax: +49 211 69936-266 e-mail: annette.engels@stahleisen.de · www.stahleisen.de

MPT International 2 / 2015

TECHNICAL INNOVATIONS

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Integrated infrared pyrometers with LED focusing MEASURING EQUIPMENT A new series of fully integrated infrared pyrometers providing high accuracy, flexibility and ease of use has been introduced by Ametek Land. The SPOT product line uses a patented, pulsed green LED to confirm spot size and focus, eliminating the safety concerns found with laser-based sighting. There are eight models spanning temperatures from 250 to 1,800°C with wavelengths ranging from 1.0 to 1.6 Οm.

The choice of measuring range and wavelength makes them suitable for numerous applications in iron and steel production, metal forging and heat treating. The pyrometers combine Ethernet, Modbus TCP, analogue inputs and outputs, and alarm contacts within a single device. No separate processor is required. Configuration settings and readings are available on a rear display, remotely via a web browser, or through proprietary software. They are designed for simple installation and are interchangeable with older spot pyrometers.

Fibre optic versions allow the optic head to be mounted in a hostile environment, with the detector and electronics enclosure located several metres away. This permits viewing of targets that are inaccessible or in areas with high radio frequency interference or ambient temperatures where water cooling is not possible. The software allows users to

configure, display and log data for up to 254 different pyrometer locations. The software permits effective use of the pyrometers in smaller operations where traditional process control systems are absent.

Contact: www.ametek.de

Infrared pyrometers available for temperatures ranging from VQ Â&#x152;%

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››› LITERATURE SERVICE Cast, forged and welded parts and constructions 16 pages, English, German A brochure outlining the range of activities and services provided by Cast-Con Engineering, which is specialized in the construction, optimization and supply of castings, welding constructions and forgings for plant engineering applications, melting plants, etc.

Contact: E-mail:

www.cast-con.de info@cast-con.de

Oil-sludge separation

Oil-sludge separation with mobile gas-tight decanters

6 pages, English A brochure featuring Filtratec’s mobile gas-tight three-phase decanter plants for the separation of combustible and harmful substances. With this technology, sludge is separated in one step into the three phases of oil, water and solids. The brochure explains the technology, applications and benefits. > FILTRATEC FILTRATEC, with its well-trained personnel and high-grade equipment, provides services in the sector of sludge treatment, filtration and oil-sludge separation

filtratec.com

Contact: E-mail:

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

Control systems for water-hydraulic presses 12 pages, English, German A company brochure describing the core competences of Hauhinco, suppliers of water hydraulic operating systems. The company develops and manufactures the complete range of controls and drives for water-hydraulic presses, from high-pressure pumps and valves to hydraulic and electronic controls.

Contact: E-mail:

www.hauhinco.de info@hauhinco.de

Cooling tower construction 8 pages, English, German, French This brochure summarizes the spectrum of activities and expertise of M-CTI Mumme–Cooling Tower International. The company offers engineering, installation, maintenance and reconditioning services for standard wet cooling towers, cell cooling towers and natural draught cooling towers.

Contact: E-mail:

www.m-cti.com info@m-cti.com

Mill service 12 pages, English A concise brochure outlining the range of mill services offered by Morgårdshammar. The company assists with services such as process and pass design, maintenance, education and training, spare and wear parts, design, revamps and project management.

Contact: E-mail:

MPT International 2 / 2015

www.morgardshammar.se; www.mh-guides.de mh@morgardshammar.se; office@mh-guides.de

LITERATURE SERVICE

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Refractories 20 pages, English, German In this company brochure, RHI presents its activities, service offer and company history as a globally operating supplier of high-grade refractory products. The company offers the full range of refractory products used in the primary industry.

Contact: E-mail:

www.rhi-ag.com rhi@rhi-ag.com

%QORCP[ RTQƂNG 6 pages, English, German A brochure presenting Saar-Metallwerke and the other group companies. The products and services range from copper fittings for the iron and steel industry, turning, milling and hardening of parts for the automotive industry as well as open-die forging of parts made of high-conductivity copper and copper alloys.

Contact: E-mail:

www.saarmetall.de info@saarmetall.de

Blasting plants 8 pages, English A comprehensive brochure about blasting equipment supplied by SLF Oberflächentechnik.

It includes detailed descriptions and various illustrations of blasting robots, blast rooms, automatic blasting systems, hand blasting cabinets and lifting platforms.

Contact: E-mail:

www.slf.eu info@slf.eu

Process engineering Information leaflet, English Concise information on waste gas, exhaust air and flue gas cleaning solutions provided by Standardkessel Baumgarte. Explained are the processes of condensation, catalysis and a combination of both as examples of sustainable concepts for the reduction and avoidance of pollutants.

Contact: E-mail:

An idea ahead Innovative suction and filtering technology

www.standardkessel.de info@standardkessel.de

5WEVKQP CPF ƂNVGTKPI VGEJPQNQI[ 46 pages, English, German A brochure presenting the portfolio of suction and filtering solutions offered by Teka Absaugund Entsorgungstechnologie. The detailed brochure describes mobile, stationary and central suction and filtering systems; gas cutting, welding and grinding benches; collecting elements; fans and ducting; as well as soundproofing and visibility protection.

We set air in motion

Contact: E-mail:

www.teka.eu info@teka.eu

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››› IN THE NEXT ISSUE…

Environmental protection An industrial scale, transparent venturi scrubber for testing performance improvement strategies Today, there is a serious trend to increase energy efficiency and overall collection efficiency of gas cleaning systems. To meet the latest environmental regulations, many existing gas cleaning systems have to be upgraded. A full scale test rig was developed to better understand the physical phenomena inside the throat section. Experimental findings help to derive modifications to improve efficiency.

Continuous casting – Hot rolling Rizhao Steel counts on the ESP thin slab technology for high-quality production With actually five Arvedi ESP lines, the Chinese steel producer Rizhao Steel is now focusing on the highly attractive local and export markets for high-quality, thin-gauge strip products. The new casting-rolling complex is designed for a total annual production capacity of 11 million tons of high-quality, ultra-thin, hot-rolled strip products with widths of up to 1,600 mm and thicknesses down to 0.8 mm. The first line began operations in spring 2015.

Strip processing Spray modules shorten pickling time In spray pickling modules, the pickling liquor removes the scale much more effectively from strip surfaces than in conventional turbulence pickling lines. Thus, carbon steel strip can now be pickled in markedly less time, and newly built pickling lines can be designed with a shorter length. Moreover, it will be possible to flexibly adapt the pickling parameters from coil to coil.

Quality assurance Fully automated laboratory system accelerates sample processing and process control Taiyuan Iron & Steel (Group) has implemented a fully automated system for the dispatch, preparation and testing of samples taken from hot metal and liquid steel. The analysis is now faster, more precise and can be better reproduced, and it contributes significantly to improved control and regulation of the steelmaking process.

Events Final preview on Europe’s main metallurgy expo and conference METEC & 2nd ESTAD 2015 METEC is coming closer and closer and it is apparent that the event from 16 – 20 June 2015 will once again be providing a complete picture of the international market. ecoMetals 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.

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

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

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MPT International 2 / 2015

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