MPT International 6/2015 (Dec)

Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

Tailor-made refurbishments of ArcelorMittal’s rolling mills

December 2015

Feralpi upgraded the billet caster at Elbe-Stahlwerke, Germany

We transform ... the world of profiles.

3-roll PSM ®

Precision tolerance

3-roll cassette

PSM® – Advanced 3-roll technology The 3-roll Precision Sizing Mill (PSM ® ) for SBQ and wire rod production meets today’s demands for high flexibility and maximum process transparency. In combination with the MEERgauge® profile measuring device, the 3-roll PSM ® can be operated in fully automatic mode – the system adapts automatically to different rolling conditions and immediately optimizes the process for maximum output and close tolerances.

It also reduces energy consumption by 10 kWh/t, which is why PSM ® was awarded the Ecoplants mark as a sustain able process from the SMS group. Quality unites – a fact that our customers and we discover time and again with every new project. Together we develop production concepts that give our partners the competitive edge in their business. Thanks to this good cooperation, the SMS group is a leading international company heavy machinery and plant engineering.

SMS GROUP GMBH

Ohlerkirchweg 66 41069 Mönchengladbach, Germany

Phone: +49 2161 350-0 Fax: +49 2161 350-1667

communications@sms-group.com www.sms-group.com

EDITORIAL

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Modernization of plants and production facilities Traditionally, we publish the short range outlook by the World Steel Association presented at their annual meetings in October in every year’s last issue of MPT International.

Also this year we stick to this custom. However, there is much more uncertainty about how things will develop. The steel associations around the world have been constantly updating their forecasts for the next months to come. No doubt, the steel industry has been facing headwinds, in particular from overcapacities, market turbulences and geopolitical conflicts. Worldsteel states: “There is an increasing risk associated with this economic slowdown [in China] and the consequent financial market volatility, which has become a global concern.” All this has already led to production cuts and, in some cases, even to the idling of works. While having to cope with these challenges, the steel producers have lacked incentive to invest. Nevertheless, there is always need to improve, for example, the need to reduce resource consumption, save energy or improve quality. The challenge is how to achieve the best in times of scarce budgets.

Dipl.-Ing. Arnt Hannewald

Plant suppliers have prepared for the current scenario by focusing more on modernization than on greenfield projects. So-called Technological Packages are en vogue, as they offer good value for a restricted investment budget. In this issue of MPT International, we feature several examples of technological solutions that may fall in this category and case studies illustrating the benefits of tailor-made modernization projects. It is most fascinating to see how plant suppliers of all sizes have immersed themselves in the modernization strategies of the steel industry to understand what is really needed. It is also good to know that there are reliable and proficient technology providers around, capable of offering high-value solutions even under the prevailing harsh market conditions.

MPT International 6 / 2015

WE ARE PRODUCING IN ENDLESS MODE FROM ULTRA-THIN TO THICK.“ Giovanni Arvedi · Cavaliere del Lavoro

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Rizhao Steel 5 China · 06/2016 Rizhao Steel 4 China · 03/2016 Rizhao Steel 3 China · 09/2015 Rizhao Steel 2 China · 04/2015

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The new standard in Hot Strip Production To meet the requirements of todays steel industry, innovative technologies are needed. ESP is the proven technology to meet todays requirements in producing ultra-thin steel products and high quality steel grades. This technology revolutionizes the flat-steel production the same way LD converters and continuous casting did in the previous century. Operating with a combined, continuous and uninterrupted casting and rolling process brings a lot of advantages: • Lowest operating costs • Outstanding geometrical, metallurgical and surface quality • The only plant type to produce ultra-thin 0.8 mm gauges in large quantities at full width and at full productivity • Industrial API production proven by certificate • Low carbon footprint proven by certificate • Low energy consumption proven by attestation

supplied by

G. Arvedi

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››› CONTENTS

International industry news 22

World Steel Association 2015 annual conference held in Chicago, USA This year’s annual conference heard from high-level speakers on topics including China’s economic prospects into the future and steel’s role in the global economy

Company profile 26

Danieli to remain on track despite adverse market conditions

Coverphoto: Quantum EAF from Primetals Technologies at the minimill meltshop of Talleres y Aceros S.A. de C.V. (Tyasa) in Ixtaczoquitlan, Mexico Primetals Technologies, Ltd., London, UK Contact: www.primetals.com E-Mail: rainer.schulze@primetals.com

In the financial year 2014/2015, the Danieli Group again achieved a notable net profit. The trend shows a decrease in sales both for the group’s plant making sector and for the steelmaking sector, even if linked to different aspects

Steelmaking

Continuous casting

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Precision measurement system increases GHĆ‚EKGPE[ QH UVGGN RTQFWEVKQP CV VJG %%/ To minimize material loss in cutting-to-length operations, precise measurement of the strand is indispensible. However, the steel producer faces allowances, the smaller the better.

The newly developed “Melt Expert� system contains automatic melting profiles and adapts process parameters when required. This increases productivity

Modernization

Cold rolling

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The German steel producer modernized the billet production plant in order to improve the internal and surface qualities of the billets, and to increase the production capacity by 20 percent

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Tailor-made drive train upgrade for the TQNNKPI OKNN QH #TEGNQT/KVVCN &WPMGTSWG Due to the higher rolling forces required to produce high-strength grades, drive trains of hot rolling mills are exposed to higher loads. Innovative solutions have been developed to upgrade the mill drive system with powerful and reliable components

40 * QV CPF EQNF UVTKR OKNN TGHWTDKUJOGPVU CV #TEGNQT/KVVCN 6GOKTVCW The work on the hot strip mill involved the geometrical re-alignment of the finishing stands. The tandem cold mill was upgraded to be able to roll greater strip widths

MPT International 6 / 2015

Outokumpu Nirosta to upgrade rolling-oil treatment technology Clean oil for bright coils: in the framework of the modernization of its 20-roll cold mill, Outokumpu will revamp the existing rolling-oil treatment plant

Environmental protection 45 ' PGTI[ GHĆ‚EKGPE[ PGVYQTM VQ UWRRQTV VJG VTCPUKVKQP VQ TGPGYCDNGU German steel producers ThyssenKrupp Steel Europe and HĂźttenwerke Krupp Mannesmann have established an energy efficiency network “Steel energy+â€?.

Steel production measures already generate huge savings of energy and greenhouse gas

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Columns 10 +PVGTPCVKQPCN KPFWUVT[ PGYU

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Literature service

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Technical innovations

52

In the next issue

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Cartoon

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Imprint

Advertisers’ index ABB AB Hannover Messe Ankiros Fuarcilik A. S. Arabian German for Exhibition Ltd. Associazione Italiana di Metallurgia Badische Stahl-Engineering GmbH Combilift Ltd. Co.

31 39 49 35 29 47

Josua CORTS Sohn CORTS Bearing Technology Danieli S.P.A. Fabris Inc. Maschinenfabrik Köppern GmbH & Co. KG Lechler GmbH

13 8, 9 11 15 17

Primetals Technologies Austria GmbH SMS group GmbH TML Technik GmbH

4, 5, 54 2 43

Verlag Stahleisen GmbH

39, 53

PAUL WURTH S. A.

19, 20

MPT International 6 / 2015

Original design and superior quality manufacturing, single and two-stand reversing mills, four and six-high tandem mills, Z-high mills featuring advanced flatness control systems, high-speed hydraulic automatic gap control and Confined Jet Dryer for superior strip cleanliness.

Four main references out of total 116 ACCIAIERIA ARVEDI ITALY Continuous six-high tandem cold mill for thin gauge material for superior thickness control performances (0.2x1500 mm strip).

Flat product casting, rolling and processing

MARCEGAGLIA ITALY The most compact two-stand cold rolling mill to achieve top level performances in productivity and material yield.

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

DANIELI WEAN UNITED COLD ROLLING TECHNOLOGY TO BREAK NEW RECORDS: 0.2 X 1500 MM STEEL STRIP

MMK METALURJI TURKEY A two-stand reversing mill able to produce prime quality sheet at a speed close to 1,600 mpm.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

OUTOKUMPU FINLAND The new generation of Z-high tandem mill breaking all the records of stainless steel annual productivity.

www.danieli.com

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››› INTERNATIONAL INDUSTRY NEWS

Africa Algeria Arcelor Mittal to transfer shareholdings in its Algerian subsidiaries. ArcelorMittal and IMETAL, an Algerian state-owned company, have reached an outline agreement for a restructuring plan which will see ArcelorMittal transfer its minority shareholding in both ArcelorMittal Algeria and ArcelorMittal Tebessa as well as its majority participation in ArcelorMittal Pipes & Tubes Algeria. This will result in the state of Algeria controlling the full shareholding of these entities. The restructuring is aligned with ArcelorMittal’s strategy of asset portfolio optimization. Furthermore, ArcelorMittal will continue its technical support for the successful implementation of the El Hadjar Complex development plan.

project. The plant will be fueled with blast-furnace and coke-oven gas. It will also be possible to use natural gas. The steam produced will be fed to the customer’s existing turbine which generates electricity for internal consumption.

The Americas Brazil Usiminas to idle activities. Usinas Siderúrgicas de Minas Gerais has decided to temporarily interrupt the activities of the primary areas of its Cubatão plant.

The deactivation process will be gradual and involve sinter and coke plants, blast furnaces and steelworks, as well as all associated activities. The Cubatão plant will cease to produce slabs, but its hot and cold rolling lines will remain active, as well as the activities related to its port terminal. The heavy plates rolling line will remain temporarily suspended.

Algeria Tosyali to build new steel complex. Sinosteel MECC will supply a new 2.3 million t/year steel plant to be built in Algeria by the Turkish company Tosyali. Tosyali already operates an EAF-based steelworks in western Algeria in the region of Oran. The new steelmaking and rolling mill complex will be installed close to Algier and will consist of a meltshop with a 240 t EAF, a ladle furnace, an eight-strand billet caster and two rebar rolling mills. Sinosteel MECC is responsible for the complete turnkey supply for all technological and auxiliary equipment. Plant commissioning is planned for 2017.

South Africa ArcelorMittal to install new steam boiler plant. KPA Unicon will deliver a 50 t/h steam boiler plant to the Vanderbijlpark works of ArcelorMittal South Africa. The turnkey delivery will include all process equipment, transportation to South Africa, all installation work, commissioning and training of the operational personnel. KPA Unicon also arranged the financing of the MPT International 6 / 2015

Canada ArcelorMittal Montreal to upgrade bar mill. To strengthen its position as a local producer of high-quality steel, ArcelorMittal Montreal has announced a major investment to update the finishing line at its Longueuil bar mill. The project, to be completed in 2017, will boost the mill’s production capacity to 500,000 t/year and make new added-value products available to customers. The Longueuil bar mill currently converts about 400,000 t/year of steel billets into special quality and merchant quality bars, rebar and various other semi-finished products for customers in North America and Mexico. The new finishing line will secure additional outlets for billets from the two ArcelorMittal Montreal steelworks in Contrecoeur and will increase the bar mill’s capacity by 100,000 t/year.

Mexico ArcelorMittal to invest in tubular facility. ArcelorMittal has announced a major investment in

ArcelorMittal Monterrey. The investment will allow for the construction of an additional tube mill and downstream value-adding processing equipment to enable the facility to supply high-quality straight and formed tubes used in the production of automotive seating and head rest applications. Monterrey will be capable of producing electric resistance welded tubes ranging from 11 mm to 165 mm diameter in a variety of steel thicknesses and steel grades, from mild carbon to advanced high-strength steels.

Construction will be completed in the spring of 2016.

USA Nucor Yamato Steel to apply quenching and self-tempering technology. Nucor Yamato Steel has selected Danieli to supply the QST quenching and self-tempering package for beams to the Blytheville plant.

QST involves intensive cooling applied to the entire surface of the section after rolling. This increases the mechanical properties of the beams with reduced quantities of expensive alloys, such as vanadium and niobium, and achieves top quality grades with fine grain structure, excellent weldability, high yield stress and low temperature resilience. The new technology will allow Nucor Yamato Steel to achieve substantial savings in terms of material and transformation costs for a wide range of product applications, such as beams used in high-rise buildings, long span bridges, seismic areas and offshore structures.

Asia China Shijiazhuang orders cut-off machines. Braun Maschinenfabrik has received an order for the supply of six high-performance abrasive cut-off machines with associated equipment to Shijiazhuang Iron & Steel. The machines will be installed as part of a major plant relocation and modernization project. At present, the steel

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››› INTERNATIONAL INDUSTRY NEWS

News in brief Hyundai Steel, South Korea, has successfully started up the RH plant supplied by SMS Mevac. The quick-change plant has been added to Hyundai Steel’s secondary metallurgy facilities in Dangjin.

ABS, Italy, has started up the Danieli Rotoforge plant, a breakthrough innovation in rolling mill technology offering a remarkable high reduction ratio (>3:1) and high internal quality, comparable to that of forged products.

Deutsche Edelstahlwerke, Germany, has successfully completed the revamp of its cooling bed. The cooling bed modernization was carried out by SMS group.

NLMK Verona, Italy, has commissioned its upgraded press, which is now able to forge ingots in three planes. The new manipulator, which rotates the ingot during forging, was supplied by Dango & Dienenthal.

Ferriere Nord, Italy, has brought on stream the new rolling mill built at Osoppo. The bar mill is able to produce hot-rolled wire for reinforced concrete in 5 t coils.

Nokra, Germany, specialists in high-precision inline laser measurement technology, have expanded their presence in the Far East. In Japan, they will from now on be represented by K. Brasch Co. Ltd., and in Taiwan by Taiwan Sunshine Industrial Corporation.

Chinalco, China, has hot commissioned its new Steckel mill for special alloys and stainless steels built at its Shenyang plant. The mill was supplied by Danieli.

MPT International 6 / 2015

plant is located in the urban area of Shijiazhuang, Henan province. The plant will be relocated to a new site 70 km outside of Shijiazhuang. At the same time, the production facilities will be brought to the latest state of the art. Amongst other measures, Shijiazhuang Iron & Steel is investing in completely new rolling mills which will incorporate the abrasive cut-off machines supplied by Braun. Commissioning is scheduled to be completed by the end of 2016.

ly efficient low-NOx burners. In order to guarantee maximum cooling rates, the furnace plant uses the new fast cooling system DRJC (differential rapid jet cooling) patented by Andritz Metals. The system provides highest cooling rates with constant and controlled cooling across the entire strip width, while adjusting to the respective strip width. The scope of supply also includes automation equipment and key process components, such as the zinc stripping air-knife system and shears.

China China Tangshan to expand galvanizing capacities. Tangshan Iron and Steel has awarded Primetals Technologies an order to supply two continuous galvanizing lines to expand coating capacities of the cold rolling mill No. 2 at its Tangshan plant in the Hebei Province. This will increase the production capacity for high-strength, coated metal sheets by 650,000 t/year.

The sheets will mainly be used by the automotive industry. Continuous galvanizing lines Nos. 5 and 6 will be installed in a newly built bay alongside the existing cold rolling mill, which was also supplied by Primetals Technologies and has been in operation since the beginning of 2015.

The two new continuous galvanizing lines are scheduled to come into operation in 2017. On one line a special aluminium-silicon coating technology package will be implemented.

Primetals Technologies will be responsible for the engineering, manufacturing and supply of the mechanical, electrical and process technology equipment for the lines. Galvanizing line No. 5 will have a capacity of some 250,000 t/year. It will process cold strip in widths ranging from 850 to 1,300 mm and thicknesses from 0.18 to 1.5 mm. Galvanizing line No. 6 will be designed to galvanize 400,000 t/year of cold strip in widths ranging from 850 to 1,600 mm and thicknesses from 0.5 to 3 mm. Primetals Technologies will supervise the assembly and commissioning of the lines.

Andritz Metals will supply the continuous furnace plants for the two new continuous galvanizing lines.

The furnaces will be fitted with high-

Tiancai to install flatness measurement system. Tiancai Technology Developing is going to install a Shapeline Flex flatness measurement system at their plant in Tianjin. The Shapeline system, based on the new product platform ShapeCAT, will be used primarily to certify the quality of special stainless steel sheets for the mobile phone industry. The new product platform ShapeCAT is built around a new camera technology, enabling the very high resolution and accuracy required to meet the measurement challenges at Tiancai.

China Shandong places order for greenfield project. Shandong Iron and Steel Rizhao has contracted the SMS group to supply a complete flat steel complex. The complex will comprise a hot strip mill, a pickling tandem mill, a hot-dip galvanizing line and two annealing lines. SMS group will supply the electrical and automation systems for the entire equipment. Operation is scheduled to commence in 2017.

The hot wide strip mill will be designed for an annual capacity of 4.8 million t of strips in widths of up to 1,900 mm.

The slab sizing press will allow width reductions of up to 350 mm. A major part of the hot strip produced will be processed in the pickling tandem mill to obtain high-quality cold strip.

The two annealing lines and the hot-dip galvanizing line will feature

INTERNATIONAL INDUSTRY NEWS high-performance Drever radiant tube furnaces equipped with ultra-fast cooling systems to ensure high cooling rates. The total of two million t of surface-finished cold strip will come in widths between 900 and 1,850 mm and in final gauges of 0.3 to 2.5 mm.

Production will comprise material grades such as CQ, DQ, HSLA, HSS, DP and TRIP, with tensile strength values of up to 1,000 MPa. The scope of supply will also include the implementation of the PQA (product quality analyzer) quality assurance system.

South Korea Posco Pohang installs flatness measurement systems. Shapeline has commissioned the two plate flatness measurements systems installed on Posco’s No. 3 plate line. The two systems are based on Shapeline’s new platform, ShapeCAT, a high-performance optical solution. Almost 12,000 measurement points cover the width of the

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plates, allowing for flatness measurement close to plate edges and corners.

In cooperation with Posco, Shapeline has developed new principles for flatness defect detection, classification and evaluation. The measurement data is also used for feedback upstream to improve the production.

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News in brief NLMK, Russia, has signed an agreement with Novatek for the supply of natural gas to all of NLMK’s natural-gas-using facilities in Russia. The contract has been signed for a term of five years.

India SAIL orders reheating furnaces for new hot strip mill. Primetals Technologies Japan has entrusted Fives Group with the design and supply of two walking beam furnaces for reheating high-quality steel slabs at a rate of 300 t/h. The furnaces will serve a new 3 million t/year hot strip mill to be installed at the Rourkela Steel Plant, part of Steel Authority of India Ltd. (SAIL).

The new hot strip mill, scheduled for commissioning in 2018, will provide high-quality coils for a proposed autosheet joint-venture with ArcelorMittal.

CORTS Engineering

AM Industeel, Belgium, has commissioned its slab caster after a successful revamp by Danieli.

The modernized caster allows AM Industeel to expand its product range and produce larger sizes of up to 355 mm thickness.

Industrie Riunite Odolesi (I.R.O.), Italy, has given a final approval and sign-off to Tenova Goodfellow for meeting performance targets with the recently implemented iEAF® system.

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››› INTERNATIONAL INDUSTRY NEWS

India JSW Steel orders new bloom caster. JSW Steel has awarded Danieli the order for a new three-strand bloom caster to be installed in the existing steel plant in Salem. The caster will be equipped with stopper rod control, mould electromagnetic stirring equipment and air-mist cooling, and will be prepared for the future installation of final electromagnetic stirring and dynamic mechanical soft reduction. The new caster will process the additional steel that will be produced in the steel meltshop following the planned expansion of iron and steelmaking at the Salem plant.

Pakistan Amreli Steels to build new bar mill. Primetals Technologies has received an order to supply a bar mill to Amreli Steels, a rebar steel producer based in Karachi. The rolling mill will be designed to produce around 400,000 t/year of reinforcing steel and round bars. The new bar mill will more than triple the production capacities of Amreli Steels. The finished products will be rebars with diameters ranging from 8 to 40 mm. They will meet national and international standards.

Commissioning of the rolling mill is scheduled for early 2017.

Pakistan Taybah places order for greenfield project. Taybah Group is going to enlarge its business in the Asian region by producing rebars for internal and foreign markets. The group recently ordered a continuous casting-rolling, compact micromill from Danieli.

The plant, which represents the first phase of a two-stage investment programme, will have a rated capacity of 500,000 t/year of rebars. Start-up is scheduled for early 2018. The second phase of the investment includes the duplication of the mill capacity to allow the overall facility to produce 1.0 million t of finished products. The second phase is to be completed in 2019.

The micromill, traded under the brand MI.DA®, is characterized by a singleMPT International 6 / 2015

strand continuous casting-rolling process featuring a high-speed FCC® PowerMold caster, inductive inline heating of the billets, a bar quenching and tempering (QTB) system, and a direct rolling bundling system (DRB®). All these plant components will be arranged in an extremely compact layout.

panies within the Steel Europe business area. ThyssenKrupp Steel Europe plans to standardize the system landscape in the entire business area with the rollout of the software PSImetals.

The two partners will agree upon a joint long-term strategy that will especially take into consideration the areas of project development and process support.

Australia Germany Australia BlueScope reaches agreement on cost reduction measures. BlueScope has reached a memorandum of agreement with unions and employees at Port Kembla on a “game-changing approach” to its workforce structure and a new three-year enterprise agreement. The agreement is considered a significant and essential step to achieving BlueScope’s cost reduction target. It includes a three-year wage freeze and new streamlined provisions for the introduction of workplace restructures.

TKSE orders boom feeder. Samson Materials Handling, part of the Aumund Group, has received an order from ThyssenKrupp Steel Europe to provide equipment for their coal stockyard facility in Duisburg. Samson will supply the new BF0415T boom feeder.

This represents one of the many Stormajor® boom feeders that Samson has installed worldwide in almost 50 years of service in the bulk materials handling industry.

Italy

Europe Czech Republic Vítkovice shuts down steelworks. The converter steelworks of Vítkovice Steel has been shut down.

The plant, with a production capacity of 950,000 t/year, used to produce continuously cast slabs and ingots.

Heavy-plate production will continue with slabs procured from suppliers in the European Union and Russia.

Vítkovice Steel had ended its pig-iron production in 1998. Since, the company had been supplied with hot metal from ArcelorMittal Ostrava.

Germany ThyssenKrupp Steel Europe to standardize systems software.

ThyssenKrupp Steel Europe and PSI Metals have concluded an agreement that will see PSI become the standard software provider for all the com-

Ilva to bring blast furnace to latest state of the art. In March 2015, following a decision by the Italian government, Ilva had to shut down No. 5 blast furnace, the largest blast furnace at its Taranto works. In order to meet latest environmental standards, the plant will be upgraded by EUdefined best available technologies.

Paul Wurth has been awarded several packages for engineering, supply and installation of technologies for the upgrade. For example, the four existing Krupp-Koppers units will be completely replaced by a group of three one-dome hot blast stoves with external combustion chamber. The latter will feature Paul Wurth’s patented waste gas heat recovery system. Performance and maintainability of the BF top gas cleaning plant will be improved by replacement of the existing dust catcher and by modification of the scrubber system. At the slag granulation plant, a new, sea-water-based steam condensation system will eliminate the release of sulphur-laden steam to the atmosphere. Finally, the furnace’s stockhouse will be equipped

INTERNATIONAL INDUSTRY NEWS

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15

with a new dedusting system rated for a suction capacity of 2 million m3/h, which will ensure a maximum of 5 mg/ m3(stp) dust content in the air leaving the stack. The project is to scheduled to be completed within twelve months.

Italy AST renews mill services contracts. ThyssenKrupp-owned Acciai Speciali Terni (AST) has renewed the contracts for several Harsco Metals & Minerals mill services performed at the Terni stainless steel works. Harsco has been providing continuous onsite services to the AST works for more than two decades.

Spain ArcelorMittal to refurbish coke oven batteries. ArcelorMittal Asturias will re-construct two 45-oven batteries at its coke plant in Gijón, including the installation of a state-ofthe-art emission collection and scrubbing system, and implementation of efficient by-product management systems. The refurbishment work will start in mid-2016, and the coke oven batteries are expected to reach full capacity in 2019. Once operational, the Gijón coke oven batteries will be able to meet the coke requirements of the blast furnaces at the site. The project will ensure compliance with the environmental requirements defined in the current integrated environmental authorization granted for this facility and will include the implementation of the best available techniques as defined in the applicable reference document that will come into force in 2016.

We agglomerate your valuable dusts and fines

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

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

Köppern – Quality made in Germany.

Sweden

• State of the art technology • Process technology know-how

Voestalpine Precision Strip to install flatness measurement system. Voestalpine Precision Strip has ordered a third Shapeline 500 flatness measurement system for one of its hardening lines at the Munkfors mill. The system will be mainly used

• High plant availability • Quick roller replacement

www.koeppern.de

MPT International 6 / 2015

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››› INTERNATIONAL INDUSTRY NEWS

to optimize process and quality primarily for valve steel. For this specific purpose it will be equipped with Shapeline’s double-line laser projector, which provides very high resolution and accuracy.

Sweden SSAB to close production lines.

As part of the ongoing efficiency and flexibility programme in connection with the combination of SSAB and Ruukki, SSAB has announced plans for changes in production in Borlänge. These plans entail the closure of the galvanizing and colourcoating lines and transferring the manufacture of the products made on these lines to other units in Finland and Sweden. Also the tube production in Borlänge has been announced to be transferred to other units within the group.

Finland SSAB initiates negotiations to reduce workforce. SSAB has initiated employer-employee negotiations regarding a potential reduction in the workforce at SSAB Europe’s production site in Raahe and in the Ruukki Construction division. These negotiations are being initiated due to reasons related to production, financial situation and operational restructuring. The negotiations at the Raahe site affect the entire personnel in production and support functions at SSAB Europe, SSAB Special Steels and group functions. The plans will mean a reduction of a maximum of 210 jobs. For SSAB Europe, these plans are a necessary part of the efficiency and synergy programmme the group announced earlier as a consequence of the combination of SSAB and Rautaruukki.

Sweden and Finland Ovako implements restructuring programme. Ovako plans to implement a restructuring programme over the next two years to adapt to the MPT International 6 / 2015

current and expected future market demand. The main structural initiatives include the closures of the rolling mill in Hällefors and of the Forsbacka production and distribution unit. In both cases production volumes will be moved to other Ovako units. It is also planned to close the distribution centre in Turenki and consolidate Ovako’s distribution in Finland to the newly acquired facilities in Tampere. Shifts at the steel and rolling mill in Hofors will be reduced from four to three. As previously announced, the tube mill in Hofors is moving to three shifts during the fourth quarter of 2015.

Sweden Ovako signs slag supply contract. Ovako and NCC Roads have signed a ten-year contract on the supply of steel slag. Steel slag is used as aggregate in asphalt production. Slag asphalt is superior to ordinary asphalt in applications with very high loads and tyre rotation. It also contributes to noise reduction. During the first three years of the agreement, NCC Roads will purchase Ovako’s annual steel slag production in Smedjebacken (approx. 50,000 t/year). Over the remaining seven years, NCC will purchase approximately 85,000 t/year, which also includes slag that is currently stockpiled.

Turkey Erdemir to build continuous galvanizing line. Erdemir has awarded Primetals Technologies an order to supply a turnkey continuous galvanizing line for its (UHÛOL plant on the Black Sea coast. The project includes erection and civil works and will be handled in an open consortium with a local Turkish company. The line will process 350,000 t/year of IF steel and high-strength cold strip for use in the automotive industry with a focus on exposed parts. Primetals Technologies will lead the project execution, engineer and supply the entire mechanical and electrical equipment, as well as the automation and process technology. The project is scheduled to be completed in the second quarter of 2018.

Ukraine ArcelorMittal Kryviy Rih orders further coil compactor. ArcelorMittal Kryviy Rih has placed an order with SMS group for the supply of a further horizontal coil compactor for its two-strand wire rod mill. After successful commissioning of a new coil compactor in 2013 and a second one in 2014, ArcelorMittal has now placed an order with SMS group for the supply of a third coil compactor of type HP 4700-PWT2. In addition to the mechanical equipment, the scope of supply includes the electrical equipment, machine automation and the complete hydraulic systems. SMS will integrate the new compactor into the existing plant environment and optimize all process interfaces. One of the technological benefits provided by the new compactor is that it will turn the coils automatically. This will make it possible to produce coils with eight straps positioned at equal distances from one another by four strapping units. This strapping method is particularly suitable for higher-strength grades. Delivery of the third coil compactor is scheduled for the end of 2015.

United Kingdom SSI UK shut down Teesside facilities. Sahaviriya Steel Industries UK mothballed its iron and steel making facilities on Teesside. This decision has had to be taken against a continuing background of poor steel trading conditions across the globe and the consequential severe deterioration in steel prices experienced during the course of 2015, together with the view that this is unlikely to change in the short term.

United Kingdom Tata Steel to restructure Long Products Europe business. In response to a shift in market conditions caused by a flood of cheap imports, particularly from China, a strong pound and high electricity costs, Tata Steel has been forced to make changes to its Long Products Europe busi-

ness. Plate mills in Scunthorpe, Dalzell and Clydebridge will be mothballed while one of the two coke ovens at the Scunthorpe steelworks will be closed.

Companies Air Liquide expands business in Turkey. Air Liquide is accelerating its growth in the Turkish market with the acquisition of Messer Aligaz Sanayi Gazlari, a subsidiary of Messer Group. Messer Aligaz provides industrial, medical and specialty gases to a range of industries in Turkey. With this acquisition, Air Liquide will now be present in the three main industrial areas of the country: Ankara, Istanbul and Izmir.

Inteco acquires Swedish engineering company. Inteco has acquired 70% of the shares in the engineering company SPT Swedish Process Technology AB. The deal also includes the acquisition of the company’s intellectual property rights. SPT has a long history and profound expertise in the field of ingot casting technology and has made a fair share of contributions to today’s state of the art technology, such as complete solutions for advanced teeming systems, flexible scrap loading system, and production and maintenance systems. The company has been renamed Inteco SPT Swedish Process Technology AB and will be the prime contact in Scandinavia for all production processes offered by Inteco.

Danieli acquires Fata. Fata, established in 1936 with headquarters in Pianezza, operates worldwide in the field of industrial plant engineering and construction with its subsidiaries in the USA (Fata Hunter), India (Fata Engineering), China (Fata Shanghai) and the United Arab Emirates (Fata Gulf). Fata is divided into two main businesses: Fata EPC and Fata Hunter.

Following the integration of the resources of Fata EPC and Danieli Construction International, the company

DESCALING

INTERNATIONAL INDUSTRY NEWS will remain independent and be free to operate in the markets. The acquisition of Fata Hunter will further broaden Danieli Centro Aluminum’s product range, also, the acquisition of Fata Hunter will complement certain areas of Danieli competences in steel processing lines.

Outokumpu divests shares in Chinese and Mexican joint ventures. Outokumpu has signed an agreement with Lujiazui International Trust Co., Ltd regarding Shanghai Krupp Stainless Co., Ltd. (SKS) in China. SKS is a Shanghai-based cold rolling joint venture between Outokumpu and Baosteel, who have been holding shares of 60 and 40% respectively. According to the recent agreement, Outokumpu will divest 55% of SKS shares to Lujiazui International Trust and retain the remainder of 5%. It is planned to continue operation of the cold rolling mill.

Outokumpu will also divest its 50% stake in the joint venture Fischer Mexicana to F.E.R. Fischer Edelstahlrohre. That joint venture, originally formed by ThyssenKrupp Mexinox and Fischer, has become the largest stainless tube producer in Mexico.

SSAB to increase share of women in top management. In pursuit of improved gender equality, SSAB has announced a new group-level target for women to hold 30% of top management positions in the company by the end of 2019 (up from 21% in 2015). With a presence in more than 50 countries, SSAB is striving to greatly increase its focus on diversity and equal opportunities for everyone in the organization. To accelerate this process, the company will develop a mentoring programme focused on female leadership and will require that at least one female candidate be considered for every managerial position going forward.

NLMK steel supplied to Vyksa Steel. NLMK (Russia) has supplied over 2 million t of steel featuring superior chem-

‹‹‹

17

The new Nozzle System

SCALE MASTER

HP

®

S U P E R I O R

I Improved surface quality of the product due to increased spray impact I Lower water flow I Energy savings due to reduced cooling of the product

New brochure and check list for nozzle configuration available under

www.lechler.de

Lechler GmbH Precision Nozzles · Nozzle Systems P.O. Box 13 23 72544 Metzingen / Germany Phone + 49 (0 71 23) 962-0 Fax + 49 (0 71 23) 962-333 info@ lechler.de · www.lechler.com

MPT International 6 / 2015

18

››› INTERNATIONAL INDUSTRY NEWS

ical composition and structure standards to Vyksa Steel Works (VMZ), which belongs to OMK. In 2012, NLMK and OMK had set up a high-tech supply chain from mining of iron ore at Stoilensky, the production of steel slabs at NLMK’s Lipetsk site through to the manufacture of large-diameter pipes at VMZ.

Outotec partners with GIW Industries. Outotec has agreed with GIW Industries to enter into a partnership to sell and market GIW® slurry pumps and related services to metal mining customers globally.

TMEIC introduces new business unit. TMEIC Toshiba Mitsubishi-Electrical Industrial Corporation has formed a new operational unit, the Industrial Systems business unit, which combines two of the company’s key technology segments, namely those serving the metals and material handling industries.

TES to be integrated into Tamini.

An agreement has been reached between Terna and shareholders of TES Transformer Electro Service concerning the integration of TES into Tamini, a member of the Terna group. The integration will be executed through an exchange of shares. Both TES and Tamini are specialized in the design and manufacture of transformers.

Eurofer market outlook. Revised data on the EU steel market suggest that demand could grow by 1.5% in 2015, on a par with the expected rise in activity of the EU steel consuming sectors.

Third countries’ imports have increased to the highest quarterly level since the second quarter of 2011. According to Eurofer director general Axel Eggert, this ballooning of imports confirms fears that third country suppliers are the main beneficiaries of current market conditions. EU steel companies will continue to be exposed to difficult conditions, even as imports are predicted to experience some moderation in 2016.

MPT International 6 / 2015

Output in EU’s steel using sectors rose by 2.1% year-on-year in the second quarter of 2015. As expected, output growth picked up some speed following a rather muted start in the first quarter of this year. In spite of slowing demand from the emerging markets, the weaker euro also helped Eurozone exporters to benefit from robust demand in the US, South Korea and India. Total activity in EU steel consuming sectors is predicted to rise by 1.9% in 2015 and by 2.5% in 2016.

Worldsteel announces 10th Steel Challenge. 2016 will see the 10th edition of the Steel Challenge championship organized by the World Steel Association. It will begin with the regional championship round on 20 January 2016 and will finish with the world championship round on 11 April 2016. The task will be to produce a specific grade of steel at the lowest total cost, while meeting the steel quality requirements, using the electric arc furnace steelmaking simulation at steeluniversity.org.

Wickeder sells cold rolling assets. Wickeder Westfalenstahl has taken additional steps toward focusing on its core business activities in the fields of clad materials and thermostatic bimetals by divesting its cold rolling assets. The company sold USbased Wickeder Steel Company to Voestalpine Precision Strip and signed an agreement with the Waelzholz group on the acquisition of Wickeder’s Cold-Rolled Steel Strip product group.

Wickeder Westfalenstahl is a member of the Wickeder group, which also includes the companies Auerhammer Metallwerk, Deutsche Nickel, micrometal, and Engineered Materials Solutions. The group has its strategic focus on specific technically demanding niches and product groups.

Materials Chemistry, RWTH Aachen University, has been appointed Max Planck Fellow at the Max Planck Institute for Iron Research in Düsseldorf, Germany. Jochen M. Schneider will be leading a research group developing self-reporting materials, which indicate a change in performance during application through property changes. Max Planck fellowships are awarded to outstanding university professors, offering the opportunity to establish and lead a Max Planck research group.

Jochen M. Schneider

Management change in ThyssenKrupp Industrial Solutions business area. Jens Michael Wegmann has taken over as CEO and chairman of the ThyssenKrupp Industrial Solutions business area management board, with responsibility for strategy, communications, technology, innovation, sustainability, quality and processes, and compliance. Hans Christoph Atzpodien will be concentrating fully on the management of marine systems in the future as a member of the business area management board.

Jens Michael Wegmann

Personalities Max Planck fellowship for research on self-reporting materials. Jochen M. Schneider, chair of

Schmolz + Bickenbach appoints new head of investor relations.

Schmolz + Bickenbach has appointed Ulrich Steiner as new head of investor

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INTERNATIONAL INDUSTRY NEWS relations and corporate communications. He succeeds Stefanie Steiner who will pursue a career outside the company. Ulrich Steiner joins Schmolz + Bickenbach from specialty chemicals group Clariant.

Ulrich Steiner

Salzgitter reappoints executive board chairman. Salzgitter AG has appointed Heinz Joerg Fuhrmann as chairman of the executive board for a second five-year term of office, commencing in July 2016. Heinz Joerg Fuhrmann has held senior positions at the Salzgitter Group since 1995.

Heinz Joerg Fuhrmann

New member on Ovako’s board of directors. Joakim Olsson has been elected as a new member on Ovako’s board of directors. He is senior industry expert at Triton Partners with extensive experience in leading and developing major international organizations.

Changes on Outotec’s executive board. Jari Ålgars has joined Outotec as chief financial officer and member of the Outotec executive board. He succeeds Mikko Puolakka, who will continue working for Outotec until 31 January 2016, ensuring smooth tran-

sition of his responsibilities to his successor.

Outokumpu appoints new president and CEO. Roeland Baan has been appointed as president and CEO of Outokumpu and chairman of the leadership team as of 1 January 2016.

Baan is currently the executive vice president and CEO of Aleris Europe and Asia. Mika Seitovirta left his position as president and CEO of Outokumpu and his position on the Outokumpu leadership team in October 2015. Reinhard Florey, chief financial officer and deputy to the CEO, has been acting as interim CEO.

Roeland Baan

New chief financial officer at Quaker Chemical. Mary Dean Hall has been appointed as vice president, chief financial officer and treasurer of Quaker Chemical.

Mary Dean Hall joins Quaker from Eastman Chemical Company, where since 2009 she was vice president and treasurer.

Derek C. Hathaway dies. Derek C. Hathaway, former chairman, president and chief executive officer of Harsco, died in October 2015 at the age of 71. In 1966, Derek C. Hathaway founded Dartmouth Investments Limited, building a group of engineering businesses into a public corporation acquired

by Harsco in 1979. Joining Harsco’s world headquarters in 1984, he became involved in the wider management of the company. In 1994, he was elected chairman, president, and chief executive officer. He retired from the company at the end

‹‹‹

21

of 2007 and from the board of directors in early 2008.

Events ›

16 – 17 February 2016 Düsseldorf, Germany Organizers: Euroforum Deutschland www.handelsblatt-stahlmarkt.de

Stahlmarkt 2016. Keynotes, presentations, discourses and discussions at the 20th Handelsblatt annual conference “Stahlmarkt” will be looking at the future of the steel market from different angles. Topics covered will include current developments and trends, Industry 4.0 and digitization, the European steel market, regulatory framework, investment policy, etc.

›

17 – 20 May 2016 Beijing, China Organizers: CIEC Exhibitions www.mm-china.com

Metall + Metallurgy China 2016.

This key event for the hot metal processing industries will again combine four complementing international Chinese exhibitions under one roof: the metallurgical industry exposition, the foundry exposition, the industrial furnaces exhibition and the refractories and industrial ceramics exhibition.

›

25 – 27 May 2016 Venice, Italy Organizers: AIM Associazione Italiana Metallurgia www.aimnet.it/eec2016.htm

EEC 2016. The 11th European Electric Steelmaking Conference and Expo will provide a forum for information transfer among those active in the field of electric steelmaking, including steel producers, steel users, plant engineers, researchers and academia.

MPT International 6 / 2015

22

››› INTERNATIONAL INDUSTRY NEWS

World Steel Association 2015 annual conference held in Chicago, USA In October 2015, the World Steel Association met in Chicago for its 49th annual conference. This year’s annual conference heard from high-level speakers on topics including China’s economic prospects into the future and steel’s role in the global economy. The leaders of 75 steel companies around the world have signed the worldsteel Sustainable Development Charter. The conference also featured a discussion on the challenges facing the steel industry and the impact of those on the industry’s future.

The World Steel Association (worldsteel) is one of the largest and most dynamic industry associations in the world. It represents approximately 170 steel producers (including 9 of the world’s 10 largest steel companies), national and regional steel industry associations, and steel research institutes.

Members represent around 85% of world steel production. Every October, World Steel Association hosts the annual conference for its members, which usually begins with meetings of the executive committee and board. This is followed by a series of presentations and panel sessions. This year the 49th worldsteel annual conference was staged in Chicago, the capital city of the Ohio state, USA.

Short range outlook for 2015 – 2016 In its short range outlook for 2015 and 2016, worldsteel forecasts that global steel demand will decrease by -1.7% to 1,513 million t in 2015 following growth of 0.7% in 2014. In 2016, it is forecast that world steel demand will show growth of 0.7% and will reach 1,523 million t.

The steel industry faces headwinds from various fronts. Commenting on the outlook, Hans Jürgen Kerkhoff, chairman of the worldsteel economics committee said; “It is clear that the steel industry has, for the time being,

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

MPT International 6 / 2015

Dr Wolfgang Eder, chairman of worldsteel and CEO, Voestalpine (right), and John Ferriola, vice chairman of worldsteel and CEO, Nucor Corporation (left)

reached the end of a major growth cycle which was based on the rapid economic development of China. Combined with China’s slowdown we also face low investment, financial market turbulence and geopolitical conflicts in many developing regions. The steel industry is now experiencing lowgrowth which will last for the time it takes for other developing regions of sufficient size and strength to produce another major growth cycle.

We expect the current headwinds to moderate in 2016, but this is based on a belief that the Chinese economy will stabilize. Of particular concern is the vulnerability of the emerging economies to external shocks though we are also expecting some, like India, to show

resilience to the global slowdown. On a positive note, the recovery of steel demand in the developed economies, even though the momentum has weakened a little, remains on track.”

In China, the economy has decelerated as the impact of the rebalancing measures on the investment and real estate sector turned out to be more severe than expected. As a result, activities in the construction and manufacturing sectors have slowed considerably.

China’s steel demand is expected to decrease by -3.5% in 2015 and -2.0% in 2016, following its demand peak in 2013. There is an increasing risk associated with this economic slowdown and the consequent financial market volatility, which has become a global concern.

INTERNATIONAL INDUSTRY NEWS The performance of some key emerging and developing economies started to deteriorate in 2012 due to internal structural issues, lower commodity prices associated with China’s economic slowdown, and in some cases, escalating political instability. For example Russia and Brazil are experiencing severe contraction in steel demand. Geopolitical tensions and political instability in the Middle East, Africa and Ukraine continue to have a negative effect. On the other hand, steel demand in India and Mexico and other countries in the

to currency appreciation and a slowing energy sector. In the EU there is a broadening of the recovery momentum aided by low oil prices, low interest rates, and a weak euro. Developed Asian countries like Japan and Korea are expected to show negative growth due to adverse structural forces weighing on their economies.

In 2015, steel demand in developed economies is expected to contract by -2.1%, but positive growth of 1.8% is expected in 2016. Steel demand in the world excluding China will grow by -0.2% in 2015 and 2.9% in 2016.

Regions

2015

2016

change

European Union (28)

149.8

153.1

+2.2%

Other Europe

40.1

40.6

+1.3%

CIS

49.9

49.9

0.0%

140.8

143.7

+2.1%

Central and South America

45.2

46.1

+2.0%

Africa

38.8

40.9

+6.2%

Middle East

53.9

56.3

+4.3%

995.1

992.8

- 0.2%

1,513.4

1,523.4

+0.7%

404.2

411.6

+1.8%

1,109.2

1,111.8

+0.2%

China

685.9

672.2

- 2.0%

World excluding China

827.5

851.3

+2.9%

NAFTA

Asia and Oceania

World Developed economies Emerging and developing Economies

Short range outlook for apparent steel demand (million tons)

ASEAN and MENA regions is expected to maintain growth momentum despite the adverse external environment due to positive domestic demand and progress in reform.

Steel demand in the emerging and developing economies excluding China will, despite the major slowdown in some countries, grow by 1.7% in 2015 and 3.8% in 2016.

The developed economies see a setback in 2015, but return to growth is expected in 2016. The strong momentum seen in the developed economies in 2014 weakened considerably in 2015. While the US economic fundamentals continue to remain solid, steel demand in the US is expected to show negative growth in 2015, due

Wolfgang Eder re-elected as worldsteel chairman Wolfgang Eder, chairman of the management board of Voestalpine AG, remains chairman of the World Steel Association for another year until October 2016. This is the first time that an incumbent chairman of the organization is re-elected. According to the association’s rules, as incoming vice chairman in 2014, André Gerdau Johannpeter, CEO of the Brazilian steel manufacturer Gerdau S.A., had been designated to succeed Eder. He requested to be released from taking over the office, as he would like to concentrate fully on the challenges of the Brazilian market, which is so important for his company.

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The board of directors of worldsteel elected as vice chairman: John Ferriola, CEO of the Nucor Corporation, USA; as treasurer: Eiji Hayashida, president and CEO, JFE Steel Corporation.

The new officers are elected for one year, until October 2016.

The board of directors of worldsteel also elected the 2015/16 executive committee: Wolfgang Eder, Voestalpine AG; John Ferriola, Nucor Corporation; Eiji Hayashida, JFE Holdings, Inc; Heinrich Hiesinger, ThyssenKrupp AG; Sajjan Jindal, JSW Steel Ltd; Oh-Joon Kwon, POSCO; André Gerdau Johannpeter, Gerdau S.A.; Mario Longhi, United States Steel Corporation; Lakshmi Mittal, ArcelorMittal; Alexey Mordashov, Severstal JSC; Paolo Rocca, Techint Group; Kosei Shindo, Nippon Steel & Sumitomo Metal Corporation; Lejiang Xu, Baosteel Group Corporation; Edwin Basson, World Steel Association.

The 2015 sustainable steel policy and indicators report The sustainable steel policy and indicators 2015 report highlights how steel and the steel industry contribute to and perform in the areas of economic, environmental and social sustainability. It reports about the steel industry’s performance throughout 2014 against eight sustainability indicators, measured annually since 2003. Publication of the report reflects the steel industry’s efforts to continuously improve performance in sustainability, to demonstrate commitment, and to enhance transparency. Reporting is voluntary, and in 2014 a total of 147 companies worldwide participated in the study, up from 42 in 2004. Crude steel produced by companies who reported on one or more indicators for the 2014 fiscal year was 923 Mt, representing 55% of global crude steel production.

Commenting on the industry’s performance, Edwin Basson, director general of worldsteel, said: “Data for sustainability indicators has been collected since 2004 and the industry has improved over that period in many areas. However, there are a number of challenges that we continue to face and in some areas our performance still falls short of our ambitions. We are working to address these as a priority and will not compromise on our commitments.”

MPT International 6 / 2015

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››› INTERNATIONAL INDUSTRY NEWS

worldsteel-49 annual conference was held in Chicago in October 2015

For environmental performance in 2014, average greenhouse gas emissions were at 1.9 tonnes of CO2 per tonne of crude steel cast and energy intensity was at 20.4 GJ per tonne of crude steel cast. Material efficiency indicator results showed that 97.6% of materials used on-site to make crude steel are converted to products and by-products. The environmental management systems (EMS) indicator demonstrated that 94.2% of steel industry employees and contractors worked in EMS registered production facilities, e.g. with ISO14001 certification.

For social performance, the lost time injury frequency rate (LTIFR) was at 1.4 injuries per million hours worked in 2014 while the employee training indicator showed that employees (at both production & non-production facilities) received an average of 6.5 training days during the year.

For economic performance, investment in new processes and products in 2014 was at 7.5% of revenue while economic value distributed (EVD) reached 954 billion US$ globally or 97.3% of revenue.

Worldsteel reaffirms its commitment to sustainable development announcing the industry’s 2015 Sustainable Development Charter. Seven principles highlight the steel industry’s commitments to improving the social, economic and environmental performance of member organisaMPT International 6 / 2015

tions. Edwin Basson, director general of worldsteel, said: “Our members are committed to the future of sustainable steel, for a sustainable society.

Our collective belief is that sustainable development must meet the needs of the present, without compromising the ability of future generations to meet their own needs. Quite simply, we each need to take responsibility and act with purpose to achieve the targets we have set for the coming years.”

Safety and health excellence Worldsteel has recognised excellence in six safety and health programmes from Arrium, Essar Steel, Gerdau, Hadeed, NatSteel and Tenaris. Wolfgang Eder, worldsteel’s chairman, said: “The 2015 safety and health submissions and implemented programmes once again show that leadership of the CEO or chairman of an organization is a key element of any successful safety and health initiative. Leadership is undoubtedly essential in building a sound, safe and healthy work environment. We are very proud of the companies recognized this year for the improvement they have made for their employees, but also the positive impact they have made on the industry. There is no better way to improve safety performance than sharing the knowledge and experiences among peers.”

Arrium, South Australia, launched the ‘Swear By Safety’ campaign, a comprehensive cultural change process to shift belief around achieving Goal Zero and injury prevention behaviours at its mining and steel business as well as the broader community in Whyalla, South Australia. The campaign was well supported with unique and appealing materials through multimedia including TV, radio, print advertisements and social media. Overall, 800 people within the workplace and community took the ‘Swear By Safety’ oath, including the local mayor.

Essar Steel, India, launched a ‘Process Safety Management’ (PSM) project in December 2010 with a baseline external audit by a third party, which was followed by further audits in 2012, 2014 and 2015. The project incorporates a number of different safety initiatives and aims at involving all employees and contractors. The initiatives include an online PSM portal, PSM campaigns, screening of PSM video films and a ‘Safety Rally’ which gathered over 3,500 employees. As a result, the PSM culture score evaluated by the third party audit has improved from 55% in 2010 to 92% in 2014.

Gerdau, Brazil, developed a ‘Leader’s Proactive Index’ (LPI) which monitors and evaluates the execution and control of leaders’ safety activities.

The LPI approach encourages lead-

INTERNATIONAL INDUSTRY NEWS

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25

Representatives from the winning companies of the safety and health excellence recognition programme 2015

ers to demonstrate their commitment through managing safety on a daily basis while successfully carrying out their activities at the same time. The initiative, based on regular evaluations of the company’s leaders, has produced both qualitative and quantitative benefits and has resulted in a notable improvement in injury frequency rate and severity rate in 2014.

Hadeed, Saudi Arabia, built a new user-friendly online ‘Environment Health Safety and Security’ (EHSS) reporting system, with investigation and action tracking features aiming to make the process of producing near miss reports accessible to all. An overall near miss analysis is carried out every month and every near miss is subject to a detailed analysis by the company’s safety department. The near miss analysis report helps the company to identify areas of concern that require attention and encourages employees to adopt a culture of EHSS reporting. As a result of this initiative, the number of near misses reported has increased almost tenfold, from 1,579 in 2009 to 15,433 in 2014.

NatSteel Holdings, Singapore, implemented a ‘Total Workplace Safety and Health’ (TWSH) programme, a holistic approach to integrate its safety, health and well-being activities in 2014. This is a continuation of the safety excellence journey to cultivate a

safety and health culture in the workplace embarked on in 2008. The TWSH approach recognises that the work environment and the overall health, safety and well-being of employees are interrelated. With the implementation of various programmes, such as the ‘Occupational Hygiene’ programme, the ‘Wellness’ programme and ‘Health’ programme, the health of the employees has improved significantly and has resulted in the reduction of chronic diseases.

Tenaris launched the ‘Safety Work Instructions’ project in 2010 to define best practices focusing on development, availability, training, adherence control and updating. The aim was to standardize behaviours among different teams and encourage management leadership through direct involvement in the approval and control process. The company developed 4,000 safety work instructions, available to all those working in operative areas, and around 8,000 inspections were performed in 2014. As a result, the total number of injuries in 2014 was reduced by 36% compared to 2010.

Steelie awards The 6th Steelie awards winners were announced at the annual dinner to close the 49th worldsteel conference.

The trophies, known as Steelies, were

awarded in seven categories this year.

The categories and winners were: ▪ Steel industry website of the year: TMK (www.tmk-group.com), ▪ Innovation of the year: POSCO for lean duplex stainless steel with super ductility using a strip-casting process, ▪ Excellence in sustainability: ArcelorMittal for their 10 sustainable development outcomes, ▪ Excellence in life cycle assessment: Tata Steel Europe (again, as last year) for the use of LCA to demonstrate the impact of the reuse of steel in a world class circular economy building in Holland, ▪ Excellence in education and training: Tata Steel Europe for developing a blended learning course for young people transitioning to management, ▪ Journalist of the year: Joseph Innace (Platts), ▪ Industry communicator of the year: John Ferriola, Nucor.

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

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

MPT International 6 / 2015

In 2014/2015 Danieli Group invested 45 million euros in direct and indirect research activities and more than 155 million euros in the management of innovative job orders

Danieli to remain on track despite adverse market conditions ,Q WKH Ć&#x201A;QDQFLDO \HDU WKH 'DQLHOL *URXS DFKLHYHG UHYHQXHV RI PLOOLRQ HXURV DQG D QHW SURĆ&#x201A;W RI PLOOLRQ HXURV 7KH JURXSĹ&#x2019;V RUGHU ERRN DV RI -XQH DPRXQWHG WR PLOOLRQ HXURV 7KH WUHQG VKRZV D GHFUHDVH LQ VDOHV ERWK IRU WKH 3ODQW 0DNLQJ VHFWRU HQJLQHHULQJ DQG FRQVWUXFWLRQ RI PHWDO PDNLQJ SODQWV DQG IRU WKH 6WHHOPDNLQJ VHFWRU HYHQ LI OLQNHG WR GLIIHUHQW DVSHFWV The Danieli Group runs two main businesses: the first (Plant Making) is in the field of engineering and manufacture of plants â&#x20AC;&#x201C; including turnkey plants â&#x20AC;&#x201C; for the production of metals.

Its principal operating companies in the Plant Making segment are in Europe and in Asia, with service centres around the world. In the Plant Making sector, Danieli is one of the top three

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

MPT International 6 / 2015

manufacturers in the world for metal making plants and machines, market leader in meltshops and plants for the production of long products, and second in the manufacture of plants for flat products.

The second business (Steelmaking) concerns the production of special steels through the companies Acciaierie Bertoli Safau S.p.A. (ABS) and ABS Sisak d.o.o. (ABS Sisak). ABS is the number one steelmaker in Italy and among the leading ones in Europe in its field.

Danieli Plant Making has largely achieved the set production targets, as the consolidated revenues show the

effect of a decrease resulting from the cancellation of nearly 85 million euros linked to the â&#x20AC;&#x153;intercompanyâ&#x20AC;? invoicing of the Rotoforgia plant to the subsidiary ABS S.p.A. (an activity which occupied the Italian workshops for most part of 2014/2015).

Sales of ABS Steelmaking show the effect, with equal production volumes (approx. 1 million tons), of a decrease in sales prices linked to a parallel drop in the costs of raw materials, and during the financial year maintained a satisfactory level of margin and plant use.

The groupâ&#x20AC;&#x2122;s consolidated profit for the period has improved compared to

Danieli provides 65,000 hours per year of technical support and consultancy for productivity and quality improvement

the previous financial year, even if it shows a lower operating margin which is however substantially in line with the forecasts made at the beginning of the year. This is mainly due to the group’s financial management which, even if with a prudent approach, has obtained a very satisfactory result thanks to the good currency management. Moreover, the group’s net financial position has improved.

As regards capital expenditure, in the Plant Making sector the development plan of the Danieli workshops in China and Thailand was substantially completed during the year, while the production ramp-up of the new factories in India and Russia is under completion. In the Steelmaking sector (ABS), after the conclusion of the first phase of investments at Sisak in Croatia, investments went on at Pozzuolo in Italy with the completion of the new reversing mills, the technological upgrading of the continuous casting machine MCC3, and the start-up of the new Rotoforgia rolling mill in September. The important investments made at ABS have a high innovative content which will enable the company to sig-

nificantly improve quality and widen the range of its products, thus covering new market segments in a competitive way.

The group’s order backlog was in line with year-end figures of the previous year and well diversified by geographical area and product line. The number of employees of the Danieli Group

decreased by 470 units compared to 30 June 2014.

Acquisition of Fata In October 2015, Danieli acquired Fata, a referenced player in the field of industrial plant engineering and construction. This acquisition will fur-

Plant Making

Steelmaking

Total

vs. 2014

2,039.6

726.3

2,765.9

- 6%

EBITDA

180.0

70.8

250.5

- 19%

Net profit

145.1

16.7

161.8

+ 5%

Order book

2,986

169

3,155

+ 2%

Employees

9,543

1,411

10,954

- 4%

Sales

Forecast for 2015/2016 Sales EBITDA Order book

2,050 / 2,100

650 / 750

2,700 / 2,850

180 / 190

60 / 70

240 / 260

2,950 / 3,100

150 / 200

3,100 / 3,300

(million euros) (KIWTGU QH VJG &CPKGNK )TQWR HQT VJG ƂPCPEKCN [GCT CPF HQTGECUV HQT VJG current period MPT International 6 / 2015

28

››› COMPANY PROFILE

ther strengthen Danieli project execution and construction capability, and broaden Danieli Centro Aluminium products and stainless steel range. Fata, with headquarters in Pianezza, Italy and a workforce of approximately 200 employees, has a yearly turnover of about 150 million euros. Fata is divided into two main businesses: Fata EPC has experienced activity in the field of turnkey plant engineering, procurement and construction, with a first-class track record in the aluminium, chemicals and power markets. The second business, Fata Hunter has distinctive capabilities in the aluminium, steel and stainless steel processing industries.

The acquisition of Fata Hunter will further broaden Danieli Centro Alu-

minium’s product range. This move will also integrate certain areas of Danieli competences in steel lines, with particular focus on stainless steel. The recent partnership agreement entered into between Danieli and Alcoa for the worldwide marketing of the Micromill™ technology will put Danieli Centro Aluminium on the cutting edge of technology in the aluminium market.

Outlook and strategies for the Danieli Plant Making segment The world steel market is undergoing a period of restructuring in 2015, with a forecast of stabilization for 2016 and improvement for 2017. Quantities in

some markets are increasing, but prices remain low due to the competition of China, Russia and Ukraine. It is clear that there is a need for a shared and joint strategy above all in Europe, in order to reduce evident differences in development, eliminate the inefficiency present in some countries, and promote a greater competitiveness in the weaker economies. Some countries are already showing clear signs of recovery, while others are still penalized by delays in the reforms required to modernize their structures. This confirms the need for a greater global coordination to sustain growth through medium and long term development plans to foster new investments in infrastructures and the upgrading of the existing ones. The prospects of global growth for 2016 show an improvement with a foreseen GDP (gross domestic product) development of 3.8%.

The Danieli Group will continue to consolidate and expand its activities to ensure an increased competitiveness in terms of innovation, technology, quality, costs, productivity and customer service; Danieli is renowned not only for its plant-making capabilities but also for its manufacturing ones: in Europe with noble and high-tech products, in Asia with the design and manufacturing of consolidated and tested products with the same European quality. Danieli is defining a new organizational model of the group to develop its present structure in a way which better reflects the emerging needs of the markets. In particular, to consolidate these strategies, the group has decided to strengthen the Danieli Academy for the development of the juniors, the updating of the seniors and the management and enhancement of talented youths.

Danieli continues to pursue high rates of innovation, efficiency and quality of customer service; it follows that the team excellence plays a very important and strategic role for the company’s success. The importance of managing with great attention the enhancement of people’s potentials and skills to ensure that the group staff training is in line with the best practice is therefore confirmed.

Started-up in September 2015, the new Rotoforgia mill provides a reduction ratio of 3:1 MPT International 6 / 2015

harald-wehrle.de

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Have a glance at what our Open Courses Programme 2016 has to offer – and book your training now at bse-kehl.de!

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€ 3,950.–

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€ 3,950.– * Fee per person plus German VAT.

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

30

››› STEELMAKING

New electrode control system offers decrease in energy consumption and increase of OGNVKPI GHƂEKGPE[ 7KH QHZO\ GHYHORSHG Ŕ0HOW ([SHUWŕ V\VWHP FRQWDLQV DXWRPDWLF PHOWLQJ SURƂOHV DQG adapts process parameters when required. This increases productivity. To ensure a high degree of reliability in a rough industrial environment, robustness and operational safety were a main focus during development.

A novel touch screen design allows simple and fast access to process relevant data

With „Melt Expert“, Primetals Technologies offers a new electrode control system for operators of electric arc furnaces and ladle furnaces. Melt Expert has been developed based on more than 35 years of experience with the Arcos and Simelt electrode control systems. The new system unifies the advantages of the previous solutions. New features like KPI (key performance indicators), plant monitoring, customer orientated interfaces as well as sophisticated control strategies ensure most efficient production. Auto-adaptive regulation algorithms reduce energy

Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 6 / 2015

consumption and increase melting efficiency. The system contains automatic melting profiles and adapts process parameters when required. This increases productivity. To ensure a high degree of reliability in a rough industrial environment, robustness and operational safety were a main focus during development. Amortization of Melt Expert may be achieved within less than nine months. For existing melt shops, Primetals Technologies offers upgrade kits to convert Arcos and Simelt systems to the new technology.

Embedded controller platform Melt Expert is based on an embedded controller platform, in which the system is split in a PLC part and a PC part. This new concept unifies the advantages of both platforms concern-

ing flexibility, robustness and computing power, which is necessary for fast and complex calculations as well as high dynamic HMI. Control signal handling is done within the PLC part which simplifies the integration into the automation environment. Intelligent signal interface modules ensure very fast and accurate data sampling with on-board signal preconditioning.

Acquired data from hydraulics, mechanics and electrics is put in relation to actual operating conditions. In this way the electrode control system itself and its auxiliary systems are permanently monitored. So called health checks are performed automatically in regular intervals in which the functionality of measurement loops and output circuits are verified without disturbing the process. Continuous signal collection in combination with long-term-trend analysis allows the detection of shifts, deviations and creeping in malfunctions in a very early stage with the aim to predict a possible event or damage, before it happens.

Based on actual process conditions, control parameters such as set points or controller gains are automatically adapted by the system. Arc length will be modified according to process needs. This results in a higher melting efficiency and reduced energy consumption. A new algorithm is avoiding arc extinction and increase the power input during boring phase. An integrated loop gain linearization model transforms individual mechanical furnace characteristics and uniforms the control loops. Thus the parameter setup will be simplified which results in faster performance run ups and less

STEELMAKING time needed for optimization. Standard state of the art protection functions are included as well as more advanced modules like countermeasures against electrode oscillation.

Screens provide conditioned information for different user needs Target group orientated screens provide conditioned information for different user needs like melt shop management, electrical/mechanical maintenance, operators, etc. Designated screens support optimization

and parameter tuning for process experts. Regularly revisions are simplified by a special maintenance mode. A novel touch screen design allows simple and fast access to process relevant data and displaying key values such as actual consumption figures, melting time or regulation quality in the form of bench mark reports. Should there be a significant deviation from normal process parameters, related information comes alive and will be indicated. For fully automated process control additional packages like foaming slag control, melt down control and thermal furnace balancing are available.

‹‹‹

31

Conclusion Benefits of the new electrode control system for EAF and ladle furnaces are reduced energy consumption and increased melting efficiency due to auto-adaptive regulation algorithms.

Higher productivity is ensured by automatic melting profiles and process parameter adaptation. The system is highly reliable due to main focus on robustness and operational safety in an industrial environment. Process quality is ensured due to target group orientated screens and highly sophisticated data recording and evaluation. Amortization can be within less than nine months.

Stressometer® Systems. Extended actuator teamwork.

The long standing problem with flatness control in multi actuator mills is now solved

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

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

Stressometer Systems. www.abb.com/stressometer

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

MPT International 6 / 2015

32

››› CONTINUOUS CASTING – SPECIAL EQUIPMENT

Precision measurement system KPETGCUGU GHƂEKGPE[ QH UVGGN production at the continuous caster To minimize material loss in cutting-to-length operations, measurement systems are indispensible. However, due to the inaccuracy inherent in the working principle of many systems, caused for example by slippage, wear or dirt, producers often have to add a VLJQLƂFDQW VXUSOXV TXDQWLW\ WR WKH PLQLPXP SURGXFW OHQJWK JXDUDQWHHG WR WKH FXVWRPHU 7KLV PHDQV WKDW ZLWK HDFK FXW WKH SURGXFHU ŔJLYHV DZD\ŕ D FHUWDLQ TXDQWLW\ RI PDWHULDO LSV measurement system positioned above the cast strand in front of torch cutters (left)

In continuous steel casting plants, torch cutting is performed at strand speeds (i.e. casting speeds) ranging between 0.5 and 5 m/min. In every continuous casting plant, the mould is the core equipment as it determines the format of the strand. The liquid metal is poured into the mould, cools down and solidifies as the strand moves on.

The strand speed and the cooling pattern both have an effect on the cooling and solidification process. The strand speed is crucial to the internal quality of the final product. In the worst case,

Pierre Passarge, Polytec GmbH, Waldbronn, Germany Contact: www.polytec.com E-Mail: info@polytec.de

MPT International 6 / 2015

if the outer skin is not thick enough to provide sufficient strength, the strand will break. These negative effects can be avoided by continuously measuring the strand speed and controlling it in accordance with the process requirements.

How long and how fast is the strand?

When cutting slabs, billets or blooms to length, also the velocity measurement plays an important role as a complement to the length measurement because the strand is constantly moving on while being cut. In order to obtain a clean and straight cutting edge, the speed of the cutting unit must be adjusted to the speed of the moving strand. Otherwise, also the slant of

the cut would have to be taken into account in addition to the minimum length. Therefore, knowing precisely the speed and the length of the strand is an important factor for process optimization and consequently also for cost reduction.

In principle, various methods are available to perform the relevant measurements, however, many of them having severe disadvantages: When the length and the speed of the strand are recorded with measuring wheels, inaccuracies are unavoidable.

Inaccuracies result from the fact that the diameter of the wheel changes because of wear or contaminations such as scale. Therefore continuous maintenance, examination and calibration are required. Moreover, such tactile measurements are always influenced by slippage as the oscillating movements of the mould are transferred to the strand. Therefore, there will be a slight “jerk” from time to time. The same applies when speed and length measurements are derived from the rotational speed of the driving rollers recorded and evaluated by rotary encoders.

Effective solution: optical, non-contact and wear-free measurement Therefore it is not surprising that non-contact optical measurement systems have become the prevailing solutions in steel mills. The Laser Surface

CONTINUOUS CASTING – SPECIAL EQUIPMENT Velocimeters (LSV-2000) from Polytec, for example, have been specifically developed for precise speed and length measurements in rough environments. These systems are wear-free and do not require any maintenance even when in operation around the clock. Moreover, it is easy to integrate the highly reliable measurement data provided by these systems into process control.

The Laser Surface Velocimeter uses the differential Laser Doppler principle and evaluates the laser light scattered back from a moving object. Unlike conventional non-contact methods, the LSV recognizes any standstill of the strand and reliably detects the direction of movement.

The high precision and reproducibility of this non-contact measurement increase quality and reliability.

For the user, this pays off quickly. Just by reducing the allowance of material for cutting inaccuracies by a few millimetres, payback periods of about one year can be achieved. The optical measurement systems are easy to install and commission. The devices are mounted about 1.5 m above the strand and are immediately ready for use. Commissioning is carried out by Polytec experts. Only the application-specific parameters will have to be entered.

The training effort for this task is negligible; once in operation, the LSV does not require any operator input.

A further advantage is that despite the rough environment the measurement system does not have to be protected by additional cooling measures. The protective housing with integrated cooling water pipes is so effective that there is no need for any additional protective measures. This saves the plant operator time and money.

Practice-proven in rough operating environments The measurement system is designed for ambient temperatures of up to 200°C and has proven highly successful in harsh industrial applications. For example, an LSV system was installed in a steel mill at a cross beam near the outlet of the strand, directly in front of the torch cutters. For cooling, process water of 31°C from the water cycle was fed into the housing. Despite the high inlet temperature, the cooling

‹‹‹

33

No additional protection measures are required thanks to a sturdy housing with cast-in cooling water pipes

performance was sufficient to protect the measurement system.

The LSV measurement system was tested to simulate a problem in the cooling water supply. The water supply was interrupted and the temperature development was observed. Only after approximately 15 minutes did the temperature reach a value critical for the sensor. When the cooling water was circulating again, the temperature dropped to a safe level within just a few minutes.

As process water may become too warm, especially in a warm climate, it was tested to use tap water instead.

The temperature in the cooled protective housing never exceeded the level of 25°C. Therefore, the temperature at the measurement head, which should not exceed 45°C, was less than 30°C. The massive housing has sufficient reserves to work reliably in environments of higher temperatures than in the test environment. Due to the robust, high-precision non-contact measurement systems, economic efficiency and process safety can be markedly increased in any continuous casting process without requiring additional cooling measures to be provided by the plant operator.

Conclusion In continuous casting processes, as in any production process, material loss must be kept as small as possible in order to guarantee economy of

The Laser Surface Velocimeter (LSV JCU DGGP URGEKƂECNN[ FGXGNQRGF for precise speed and length measurements in rough environments

production. The use of the high-precision, non-contact LSV measurement systems, which are designed to withstand even the rough operating conditions directly above the hot cast strand, a considerable savings potential can be tapped, increasing the overall economic efficiency of the continuous casting process.

MPT International 6 / 2015

34

››› MODERNIZATION

Elbe-Stahlwerke Feralpi upgraded the continuous billet caster The German steel producer modernized the billet production plant in order to improve the internal and surface qualities of the billets, and to increase the production capacity by 20 percent. This was achieved by installing a new machine head, which included DiaMold molds and a retractable DynaFlex oscillator, as well as by optimizing the secondary cooling.

Elbe-Stahlwerke Feralpi GmbH (ESF), a German steel producer and part of the Feralpi Group, has issued the final acceptance certificate for a modernized, five-strand continuous billet caster in its Riesa plant. Primetals Technologies received the order in May 2014. One major reason for winning this order was the good results Feralpi had obtained with the modernized, four-strand continuous billet caster in Acciaierie di Calvisano, Italy, which Primetals Technologies had also modernized at the beginning of 2013.

The aims of the project at the Riesa works were to improve the internal and surface qualities of the billets, and to increase the production capacity by 20 percent. This was achieved by installing a new machine head, which included DiaMold molds and a retractable DynaFlex oscillator, as well as by optimizing the secondary cooling. The new plant has a modular design, and was pre-assembled to keep installation and downtimes short.

The five-strand continuous billet caster owned by ESF in Riesa was installed in 1994 by a third-party supplier. It had an annual production capacity of around one million metric tons of billets with square cross-sections of 130 x 130, 140 x 140 and 160 x 160 millimetres. The plant has a machine radius of six metres and reaches casting speeds of up to 3.8 metres per minute.

It casts low and medium-carbon steels, which are further processed in a wire rod mill in the Riesa plant.

Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 6 / 2015

Five-strand continuous billet caster at Elbe-Stahlwerke Feralpi GmbH (ESF)

Improvements to the machine head and secondary cooling Retractable DynaFlex mold oscillators were installed to increase capacity. This solution enables the mould on a strand to be exchanged without interrupting the casting process, increasing both the productivity and the flexibility of the casting plant. All mechanical connections are released hydraulically at the touch of a button. The complete machine head, including mold and oscillator, is moved from the casting position to the maintenance position on a mobile platform.

The time between stopping and restarting the strand to change a mold is between just 15 and 20 minutes. In this time, the mold is exchanged, the dum-

my bar is brought in, and the mold is prepared for casting. The existing secondary cooling was converted and extended by adding a fourth zone to ensure optimal cooling even at higher capacities.

To increase product quality, the casting plant was equipped with new DiaMold molds. The technical features of the oscillators include stroke adjust capability during operation, and the option of selecting from a range of sinusoidal and non-sinusoidal oscillation parameters. An OsciMon system monitors the movements of the molds, and visualizes the measured values of frequency and stroke in all three dimensions. The equipment installed during the course of the modernization was designed to keep downtimes as short

MODERNIZATION as possible. The modular design concept was selected for its focus on ease of installation. System parts were also pre-assembled and tested according to the proven “Connect & Cast” plant conversion philosophy to shorten installation times on site. As agreed, the

plant was converted during the 2014 Christmas stoppage.

Conclusion Technical improvements to the machine head and the secondary

‹‹‹

35

cooling result in a higher quality of the billets. Production capacity increased by 20 percent to 1.2 million metric tons per annum. Modular design and pre-assembly of components shortened installation and downtimes.

11TH EUROPEAN

ELECTRIC STEELMAKING CONFERENCE & EXPO

Venice (Italy) • 25-27 May 2016 Organised by

ASSOCIAZIONE ITALIANA DI METALLURGIA

Patronised by

www.aimnet.it/eec2016.htm After the successful events in Florence (1986) and Venice (2002), AIM hosts the Electric Steelmaking Conference & Expo 2016.

The total world steel production coming from electric arc furnaces is today up to 35% and there is a ceaseless technical development of EFC process and of its auxiliary equipment. In addition, the combination of such technology with new plants based on direct reduction of iron ores makes electric furnace an interesting solution not only for the production route based on steel scrap recycling but also for a flexible usage of mineral resources.

The 11th European Electric Steelmaking Conference & Expo aims at providing a forum for information transfer of the latest techniques and applications in electric furnace steelmaking and at bringing together steel producers, research and academics active in steelmaking industries, energy production and plant supply concerns.

ZZZ Technical Focus Z State of the art aspects • Operational results • Process control, automation and modeling • Metallurgy aspects • Quality aspects Z Raw Materials • Scrap • DRI/HDRI/HBI • Pig iron Z Equipment • Consumables • Refractories • Auxiliary equipment • Maintenance • Injection • Electrodes • Robotics & Automatized Operations Z Future Trends - Innovative Furnaces Z Efficiency • Fast melting • Energy Efficiency • Materials Recovery • Heat Recovery • Chemical Energy Z Environment & Safety • Slag foaming and environmental impact • Emission trading • Safety Z Market outlook

ZZZ Conference chairman Giuseppe Pasini - President of Feralpi Siderurgica ZZZ Conference venue The Conference will be held at the Giorgio Cini Foundation, located on the Island of San Giorgio Maggiore in Venice.

ZZZ Exhibition & Sponsorship As an integral element of the event, EEC 2016 will feature an Exhibition that will enable excellent exposure for company products, technologies, innovative solutions or services. At this opportunity the Organizers will set an area strategically located. This area will be a focal point of the Conference, so that enough time will be available to guarantee a perfectly targeted potential customer’s environment.

Companies interested in exhibiting and/or sponsoring the event may contact:

e-mail: commerciale@siderweb.com ZZZ Important dates Information on Acceptance Opening of the online registration Deadline for Full Paper Submission

January 15, 2016 January 15, 2016 March 7, 2016

AIM is looking forward to welcoming you in the unique city of Venice!

EEC 2016 Organizing Secretariat AIM - Associazione Italiana di Metallurgia u P.le R. Morandi, 2 20121 Milan - Italy u Tel. +39 02 76021132 u Fax +39 02 76020551 E-mail: aim@aimnet.it u Website: www.aimnet.it/eec2016.htm

MPT International 6 / 2015

36

››› MODERNIZATION

Layout of the ArcelorMittal Dunkirque hot strip mill

Tailor-made drive train upgrade for the rolling mill of ArcelorMittal Dunkerque Steel markets have been demanding increasingly higher-strength rolled products. Due to the higher rolling forces required to produce these grades, drive trains of hot rolling mills are exposed to higher loads. Within the framework of a study, the mechanical and electrical components of existing drive trains have been analyzed. Innovative solutions have been developed to upgrade the mill drive system with powerful and reliable components.

ArcelorMittal Dunkerque has recently upgraded the drive system of its hot strip mill. The objectives of this investment were to improve the reliability of the plant and expand the product mix towards higher-strength grades. The upgrade was initiated by a study provided by SMS group covering the overall capabilities of the hot

Klaus Lazzaro, Dr. Gerhard Hansberg; SMS group, Hilchenbach, Germany Contact: www.sms-group.com E-mail: Klaus.Lazzaro@sms-group.com

MPT International 6 / 2015

strip mill. The study had analyzed the existing product mix and the failure statistics of the existing drive components and had provided a load prediction based on the planned future product mix.

From 2010 to 2014, the main gears of both the roughing mill and the finishing mill were replaced. New gear units were manufactured in the SMS group workshops. All upgrading measures were performed during scheduled annual shutdowns in order to minimize production losses. Thanks to the preassembly of the gear units, the time frame for the installation on site could be kept very short.

ArcelorMittal Dunkerque integrated iron and steel works The integrated iron and steel works in Dunkerque (France) is part of ArcelorMittal Atlantique. It makes flat steel products. The process route comprises a coking plant, a sinter plant, blast furnaces, BOF converters, continuous casters and a hot strip mill.

The 2,040 mm wide hot strip mill went on stream in 1963. It is a fully continuous mill comprising five roughing stands, seven finishing stands and three downcoilers. The nominal production capacity amounts to 5 million t/year of coil.

MODERNIZATION Roughing stands of the hot strip mill are continuous stands. Their drive trains comprise a main gear and a pinion gear.

Study of options for modernization After more than 40 years of operation and due to increasingly higher loads, the reliability of all drivelines had been dramatically decreasing.

The gear units required high maintenance efforts. It was doubtful whether the drive units would be able to cope with any further increasing loads that would result from future requirements.

At that point, ArcelorMittal Dunkerque awarded SMS group the order to systematically analyze the drive trains of the roughing mill and the finishing mill. For almost one year, SMS group studied in detail the operating conditions of the mill. Based on the mill data (e.g. pass schedules, material specifications, stand loads) and measurements of the actual rolling torques, forces and speeds, the dynamic behaviour of the complete drive train from the motor via couplings, gears and spindles to the work rolls was simulated. By this approach, it was possible to determine the torques acting on the drive components, assess the mechanical limits of the gears and evaluate different measures for the improvement of the situation.

A second part of the study was a rolling simulation of the current and a future product mix. This involved the comparison of the mill concept based on continuous stands with roughing mill concepts using reversing stands.

The evaluation proved that the current configuration would also suit ArcelorMittal’s future demands. As a result, the study recommended the installation of new main drive motors and the upgrade of the main gear units of the roughing mill and the finishing mill.

Maintenance cost savings would be achievable above all by a suitable rating of the new drive components. In order to save costs on spare parts, the design of the drive components was to be unitized wherever possible.

The motors for the roughing and finishing mill drives were kept identical so that the number of spare parts could be minimized and their multiple use would be possible.

The bull gears of the drives are expensive equipment and their delivery time is usually very long. Therefore their design was unitized in order to be able to use the gears in various drivelines. The number of coupling types used in the complete roughing and finishing mills could be reduced to only five sizes to be stored as spares.

To minimize the risk of failure, the sequence of replacements was selected such that the weakest drivelines were to be replaced first. The theoretical calculations of the reserves of the existing main gearboxes clearly corresponded to ArcelorMittal’s practical experience as reported in the statistics of failures and damages

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of the drives occurred during the past few years. Accordingly, the decision was made to first exchange roughing stand R5, then, one year later, R2 together with R3 and finally, in 2012, R4 together with the main reducers of finishing stands F2 and F3. Because of an unpredictable failure of the existing gear of finishing stand F1, which occurred during the project, the F1 reducer had to be exchanged during an unscheduled shutdown. The modernization of the drivelines was completed in summer 2014 with the installation of the new main reducers of F4 and F5.

The design of the foundations and site planning were provided by ArcelorMittal Dunkerque in cooperation with SMS group. The installation work was performed by proficient subcontractors and supervised by SMS group specialists.

Every shutdown was a challenge in terms of work sequence planning and coordination of the teams responsible for the electrical drives and the gearboxes. Whereas the installation of the drive components for roughing stand R5 was quite easy to perform, the

Modernization strategy The main target of the modernization project was to maximize the availability of the drivelines. Further targets were to minimize ▪ the maintenance costs, ▪ the costs for spare parts, and ▪ the risk of failures during the project.

Installing a heavy new gear of the roughing stand MPT International 6 / 2015

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complexity grew with each of the following shutdowns for the other drive trains. Successful implementation had only been possible thanks to the very close cooperation between ArcelorMittal Dunkerque and SMS group as well as the suppliers of the main drive motors.

Gear manufacturing The gear units were completely manufactured at the SMS group workshop in Hilchenbach, Germany. All gears for this project are equipped with

double-helical case hardened toothing. The largest case-hardened gear was manufactured for roughing stand R3. That one has a diameter of nearly 4,500 mm, a width of 1,300 mm and a weight of 40 t. Mounted together with shaft, bearings and coupling, the dropin set weighs 75 t. Gear manufacturing in the workshop starts with submerged arc welding the hub and rim to the wheel body. To satisfy highest requirements regarding accuracy, gear cutting is performed in three steps: slotting, rough-cutting and finish-cutting. After case hardening, the

tooth flanks are ground with highest accuracy on a modern profile grinding machine.

Also the gear housings were welded, machined and assembled in-house at the SMS group workshops in Hilchenbach. There, all gear units were pre-assembled and the contact patterns of the gear tooth were preset. After a final check, the units were disassembled into suitable sub-units and transported to the site for installation.

Conclusion The study of the entire hot strip mill provided deep insight into the existing pre-modernization situation and provided the basis for specifying, rating and designing the new drive trains.

Based on those findings, a tailor-made concept for the modernization of the drive trains for the entire hot strip mill could be drawn up. SMS group manufactured all gearboxes in their own workshops in Hilchenbach and delivered them to the ArcelorMittal plant in Dunkerque. All mill stands operated under full production load immediately after erection on site.

Close cooperation between the teams of ArcelorMittal Dunkerque and SMS group

STEEL MANUAL

STEELMANUAL

ISBN 978-3-514-00817-5

26.90 € Published by the Steel Institute VDEh Edition 2015 · 20.0 x 24.0 cm · 219 pages including many multi-colour illustrations

Verlag Stahleisen GmbH Postfach 105164 · 40042 Düsseldorf · Tel.: +49 211 6707- 561 · Fax: +49 211 6707- 547 · E-Mail: annette.engels@stahleisen.de

MPT International 6 / 2015

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â&#x20AC;ºâ&#x20AC;ºâ&#x20AC;º MODERNIZATION

New DanLiner stainless steel wear plates

Hot and cold strip mill refurbishments at ArcelorMittal Temirtau ArcelorMittal Temirtau, Kazakhstan, has revamped a tandem cold rolling mill and the Æ&#x201A;QLVKLQJ VWDQGV RI D KRW VWULS PLOO 7KH VL[ VWDQG WDQGHP FROG PLOO ZDV XSJUDGHG WR EH DEOH WR UROO JUHDWHU VWULS ZLGWKV 7KH ZRUN RQ WKH KRW VWULS PLOO LQYROYHG WKH JHRPHWULFDO UH DOLJQPHQW RI WKH Æ&#x201A;QLVKLQJ VWDQGV E\ RQ VLWH PDFKLQLQJ RI WKH PLOO KRXVLQJV DQG WKH DOLJQPHQW RI D EUDQG QHZ PLOO VWDQG ArcelorMittal Temirtau is the largest steel producer in Kazakhstan and in the central Asian region. For its 1,700 mm wide hot strip mill (HSM 1700),

&CPKGNK % 1HÆ&#x201A;EKPG /GEECPKEJG 5 R # $WVVTKQ +VCN[ Contact: www.danieli.com E-mail: info@danieli.com

MPT International 6 / 2015

the company needed to find a suitable solution to restore the correct geometrical characteristics of the finishing stands in order to guarantee stable strip rolling parameters. While guaranteeing a high performance level of their production equipment, steel producers constantly strive for cost savings, especially in economically difficult times as we are going through at the moment.

On-site machining of the housings of the hot rolling stands With this objective in mind, in April 2014 ArcelorMittal Temirtau chose Danieli as its partner for a project which involved the restoration of the standsâ&#x20AC;&#x2122; geometrical dimensions. The main targets of this project were to improve the quality of the rolled material and to dramatically reduce the failure

Preparation for the installation of new DanLiner stainless steel wear plates

rate of the work roll bearings. Among others, the installation of DanOil oil film bearings was intended to save costs on spare parts and reduce downtimes due to bearing failures. Brand new mill stand housing windows feature very tight tolerances, ensuring that the roll chocks are stably and accurately positioned and the rolls properly aligned. When a mill stand has been in service for many years, the condition and positioning of the mill stands deteriorates due to various factors. This leads to problems due to the incorrect positioning of work and back-up rolls and excessive movement of the roll chocks in the mill stand.

The geometrical re-alignment of the finishing stands was executed by on-site machining. The aim was to reestablishing the originally tight tolerances and achieve an alignment as precise as in brand new mill stands. The scope of that activity encompassed the re-alignment of the mill windows of all seven finishing stands in two phases.

The stands had been in operation since 1959. The first phase was successfully completed in November 2014 during a mill shutdown of only 12 days. The second phase is planned for the end of 2015. The purpose of the activities was to restore the proper roll stack alignment (alignment of work and back-up

rolls) in each stand, between the stands and with respect to the mill’s central axis. The work performed has resulted in an improvement of the quality of the final rolled product. Strip defects caused by roll chattering, swinging and crossing have been eliminated.

Extensive engineering and equipment manufacturing for phase 1 had been carried out in record time, considering that not only the on-site activities had to be prepared but also a great number of high-quality spare parts and improved equipment had to be supplied to the customer, namely: ▪ new bending blocks with DanLiner wear plates, ▪ DanLiner wear plates for housing and chock, ▪ base plates and inter-stand rails, ▪ work roll and back-up roll clamps, ▪ back-up roll sledge with load cell cases, ▪ spherical bearings, ▪ grease lubrication unit with piping.

The project was carried out by a joint team involving staff from the Danieli Service headquarters and the Danieli Volga local branch operating in Eastern Europe. During the shutdown more than 50 persons were involved as well as five on-site milling machines and three laser measurement stations.

Starting at the first shutdown day, a complete 3D finishing mill alignment was performed in order to define the proper reference planes for the milling. To this end, the stands had been stripped off the main components, such as wear plates, bending blocks, inter-stand rails and clamps, and the portable milling machines for vertical surfaces (liners and bending block seats), horizontal surfaces (base plates and inter-stand rails) and front surfaces (clamps) had been put in place. The machining phase included the restoration of existing holes and the drilling of new fixation points where necessary.

When the machining was completed, new, customized stainless steel wear plates were installed and connected to a new grease lubrication unit allowing a dedicated, advanced grease lubrication pattern. After re-assembling the stand equipment, the mill was restarted perfectly on time.

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Finishing train after refurbishment

Along with the above mentioned activities on the hot strip mill (i.e. restoration of finishing stands and chocks) the outdated sealing system had to be converted to the reliable, state-of-theart DanOil solution. The new DanOil sealing for the chocks of the back-up rolls reliably avoids water and scale ingress at the chocks and into the lubrication circuit of the oil film bearings, an additional factor providing for a long service life of the DanOil bearings.

The key facts of the hot mill revamp can be summarized as follows: ▪ Very tight project execution time schedule (five months).

▪ Engineering was completed within a record time of 45 calendar days, with the engineering for long-lead items ready within 72 hours from order confirmation.

▪ 60 t of stainless steel wear plates (DanLiner 1174) were manufactured in less than 12 weeks, with very high dimensional accuracy (max. 0.05 mm parallelism and planarity) and excellent surface finishing (Ra <0.8).

▪ On-time plant restart after successfully completing on-site activities in only 12 days.

%QNF TQNNKPI OKNN WRITCFG RTQXKFKPI HQT VJG manufacture of wider coils Together with Danieli Volga, Danieli Service converted the existing sixstand tandem cold mill at ArcelorMittal Temirtau during a 10-day shut-down in December 2014. Early in January 2015, ArcelorMittal rolled the first wider coil at a width of 1,250 mm. By this “widening” project and the now possible extension of the product mix, ArcelorMittal will be able to enter new markets by offering a broader selection of rolled strip products.

The existing tandem cold mill was first commissioned in 1982 and had not been upgraded ever since.

The QR code links to a video on vimeo showing HSM stands geometry restoration (https://vimeo.com/129701396)

MPT International 6 / 2015

Danieli’s proposed approach to maximize the yield by replacing but a minimum portion of the existing equipment had been the winning point: the highest level of customer satisfaction was achieved with reduced investment costs.

Installation and commissioning activities were concluded on time, two days before Christmas 2014. ArcelorMittal Temirtau greatly appreciated the support and help during the installation, commissioning and test phases rendered by Danieli Advisory Service. The following contractual performance targets have meanwhile already been achieved: increase in entry backtension, the possibility of rolling wider strips, increase in rolling speed, strip centering within an accuracy of ±3mm at the entry into the first stand and improved strip cleanliness .

ArcelorMittal signed the Final Acceptance Certificate later in January 2015, immediately after rolling the first wider strip material for galvanizing. A Stressometer Roll will measure and guarantee strip shape parameters within a tolerance of the 25 I-units.

The improved roll cooling has already proved to be highly beneficial in terms of longer roll lives, decreased

MODERNIZATION

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43

New converters for the drum winch

for milling activities

surface defects and scratches and elimination of improper thermal crown of the rolls.

# UVTQPI CPF TGNKCDNG RCTVPGT HQT VJG UVGGN DWUKPGUU The refurbishment of the ArcelorMittal Temirtau hot strip mill project is a perfect example of Danieli Service’s global capabilities which allows the company to successfully handle and implement large-scale projects

with a limited amount of preparation time and compact shutdowns. Such results can be achieved only thanks to strong engineering and manufacturing expertise, and a global presence through local branches and service centres. On-time delivery at high performance standards and strict observance of contractual agreements are key elements of Danieli’s commitment to customer satisfaction.

The short timeframe of just 10 days agreed for the cold mill upgrade

aimed at expanding the rolling width was maintained, as were all the other contractual parameters. This was possible thanks to the vast experience of Danieli Service in upgrading projects and the company’s extensive competence and expertise in rolling technology.

Danieli Advisory Service with its high level of competence is capable of solving any unexpected issue that may come up due to the unpredictable nature of such revamping activities.

WORKING SOLUTIONS FOR EXTREME CONDITIONS

TML Technik GmbH | A Company of the Fon: +49 (0)2173 - 95 75 100 | Fax: +49 (0)2173 - 95 75 400 E-mail: info@tml-technik.com | www.tml-technik.com

ENGINEERING | PRODUCTION | SERVICE

MPT International 6 / 2015

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››› COLD ROLLING

Rolling-oil treatment plant equipped with a SUPAFINE® ƂNVGT U[UVGO

Outokumpu Nirosta to upgrade rolling-oil treatment technology Clean oil for bright coils: in the framework of the modernization of its 20-roll cold strip mill at the Krefeld (Germany) site, Outokumpu will revamp the existing rolling-oil treatment plant.

The Outokumpu group is a global leader in stainless steel strip with production facilities located in China, Finland, Germany, Mexico, Sweden, the UK and USA, and with a global sales and service centre network. The Outokumpu Nirosta Krefeld site is one of four cold rolling production facilities in Germany. Here, a 45 years old 20roll cold rolling mill “SG 3” in monoblock design was upgraded recently, allowing this mill to be used also for rolling ferritic grades in thin gages and high-gloss quality (2R bright annealed).

SMS group, Düsseldorf, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com MPT International 6 / 2015

In March 2015, SMS group received an order from Outokumpu Nirosta encompassing the upgrade of the rolling-oil treatment plant, making it suitable for the production of these high-gloss grades. A part of the equipment will be retained and continued to be used.

Key equipment to be newly installed includes a dirty-oil tank with automatic pre-separation and the ultra-fine filter system SUPAFINE® developed by SMS. In future, vertical filter pumps will convey the rolling oil containing contaminations from the rolling process out of the dirty-oil tank to the SUPAFINE® filter system, where it will be cleaned. The cleaned oil will be fed to the clean-oil tank and reused in the rolling mill.

The mixture of rolling oil and abrasive material resulting from the backwashing of the oil filters will be treated in a second

filtration stage and the thus recovered rolling oil will be recycled back into the system. The employed backwashable filter elements achieve an extremely high filtration grade without requiring any filter aids – and hence without the otherwise arising high consumables and disposal costs.

The performance and economic efficiency of the SUPAFINE® filter system has been proven by the fact that as many as 210 of these filter units have already been installed worldwide. As requested by Outokumpu Nirosta, SMS will perform and complete the work on the mechanical equipment of the mill stand and on the rolling-oil treatment plant within a very tight time schedule in the course of the year 2015, guaranteeing that Outokumpu Nirosta can start producing the desired grades on this mill before the end of the year.

ENVIRONMENTAL PROTECTION

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

45

'PGTI[ GHĆ&#x201A;EKGPE[ PGVYQTM VQ UWRRQTV VJG VTCPUKVKQP VQ TGPGYCDNGU German steel producers ThyssenKrupp Steel Europe and HĂźttenwerke Krupp 0DQQHVPDQQ KDYH HVWDEOLVKHG DQ HQHUJ\ HIĆ&#x201A;FLHQF\ QHWZRUN Ĺ&#x201D;6WHHO HQHUJ\ Ĺ&#x2022; 6WHHO SURGXFWLRQ PHDVXUHV DOUHDG\ JHQHUDWH KXJH VDYLQJV RI HQHUJ\ DQG JUHHQKRXVH JDV Improving energy efficiency is one of the key aims of the transition to renewables. To achieve this, the German government has launched an initiative to establish around 500 networks.

German steel industry, e.g. in the form of the German Steel Federation (Wirtschaftsvereinigung Stahl), has committed to implement this by 2020.

ThyssenKrupp Steel Europe has now set up its own network â&#x20AC;&#x153;Steel energy+â&#x20AC;? and joined the initiative. In addition to the

work is to intensify the existing, longstanding exchange of experience and ideas to increase energy efficiency. â&#x20AC;&#x153;â&#x20AC;&#x2DC;Steel energy+â&#x20AC;&#x2122; is our active contribution to achieving the governmentâ&#x20AC;&#x2122;s energy savings targets,â&#x20AC;? says Klaus Kurke, head of Technical Services & Energy at ThyssenKrupp Steel Europe.

The company has already carried out a wide range of energy improvement measures to achieve savings during the energy-intensive steel production process. Examples include two top-gas expansion turbines at blast furnaces No. 2 and No. 8, which generate electricity by converting the energy contained in the top-gas pressures, 1.2 bar and 2 bar, respectively. Following design optimization of the expansion turbine at blast furnace 8 at the Hamborn site and an overhaul of the turbine at blast furnace 2 at the Schwelgern site, it is expected that roughly 30,000 MWh The upgraded expansion turbine at blast furnace 8 and 100,000 MWh respecgenerates around 30,000 MWh of electricity per year tively, will be generated sites of ThyssenKrupp Steel Europe AG, each year. That corresponds to the electhe network also includes subsidiaries tricity consumption of around 30,000 ThyssenKrupp Rasselstein, Thyssen- four-person households in Germany.

Krupp Electrical Steel, Hoesch HohenEven seemingly minor measures are limburg, the Schwelgern coke plant and contributing to the overall energy savHßttenwerke Krupp Mannesmann. The ings at the Duisburg works site. For exaim of the new energy efficiency net- ample, an upgrade to the control technology for unit 3 of the Hamborn power plant has made it possible to increase the temperature of the steam discharged from the boiler by 5 degrees to 525°C. ThyssenKrupp Steel Europe, Duisburg, Germany This enhances the efficiency of the unit, %QPVCEV resulting in the generation of an addiYYY VJ[UUGPMTWRR UVGGN GWTQRG EQO tional 100 megawatt hours (MWh) per ' OCKN GTKM YCNPGT"VJ[UUGPMTWRR EQO year on average. Overall, sustainable energy savings at ThyssenKrupp Steel Eu-

rope in the last two fiscal years came to around 600 gigawatt hours, roughly the annual electricity consumption of all households in a mid-size city.

The aim of â&#x20AC;&#x153;Steel energy+â&#x20AC;? is to take this a step further. Through a further intensified exchange of experience with its subsidiaries in the Steel Europe business area of ThyssenKrupp and HĂźttenwerke Krupp Mannesmann, the steel producer will be able to identify and implement new energy efficiency projects. The first areas addressed by the new network will be energy savings potential in hydraulic systems and lighting.

Initiative aiming for around PGY GPGTI[ GHĆ&#x201A;EKGPE[ networks by 2020 At the end of 2014, the German government reached an agreement with numerous German industry associations and organizations on the introduction of energy efficiency networks.

The initiative supports the transition to renewable energies and sees further improvements in energy efficiency through cost-efficient measures as an important tool in also improving the cost efficiency of the overall energy system. Energy efficiency networks â&#x20AC;&#x201C; the voluntary, systematic and targeted exchange of experience among companies in a region or sector â&#x20AC;&#x201C; are regarded as a suitable approach for this. The joint objective of government and industry is to initiate and establish around 500 new energy efficiency networks by the end of 2020. The German government believes this can result in savings of up to 75 petajoules of primary energy and 5 million tons of CO2. The network initiative will therefore make an important contribution to achieving Germanyâ&#x20AC;&#x2122;s climate and energy policy goals.

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››› TECHNICAL INNOVATIONS

Upgrade of turbine blowers in blast furnace plant ENVIRONMENTAL PROTECTION In order to reduce energy consumption at blast furnace No. 5, ArcelorMittal Galati, Romania, has invested in an upgrade of a set of turbine blowers which inject cold air into the blast furnaces.

The new system is based on a state-of-the-art operating system that allows for the two units to be handled, monitored and controlled automatically. The project involved the redesign of the rotors and the diaphragms of the two compressors and turbines, the maintenance of all technological control, balance and command circuits. The blowers are now more efficient, more flexible in the way they

can be deployed, and more reliable. They use only 32 to 40 t/h of steam, compared with 70 t before the modernization. With the steam saved, the company is now able to generate electricity that can be used in the steel production process. A high level of automation has also been implemented, improving the efficiency of the operation. The investment was part of ArcelorMittal Europe’s ‘Energize’ project aimed at reducing energy consumption by 15% over the next five years.

Contact: www.arcelormittal.com

Big data technology to optimize material use in oxygen steelmaking STEELMAKING To optimize the consumption of ferroalloys and supplementary materials during steel production in the oxygen-converter plant, Magnitogorsk Iron and Steel Works (MMK) has signed an agreement with Yandex Data Factory to develop a mathematical model for steelmaking in MMK’s oxygen-converter plant and to use this as a basis for developing related software.

IT specialists from Yandex Data Factory and specialists from MMK are currently analyzing information covering the

oxygen-converter plant operations over previous years. A machine learning algorithm will be incorporated into the mathematical model that is being developed based on corporate information available on the Apache Hadoop platform. The final software solution will receive data on the original composition, original weight and requirements regarding the chemical composition of the steel produced, and the mathematical model will help it indicate the optimal amount of ferroalloys

and supplementary materials to be used during steelmaking. The Sniper project employs big data technologies, processing large sets of data in order to improve management processes and optimize production.

The final stage of the project is expected to include a quality check involving a series of experimental steelmaking processes in which additive composition is based on the system’s recommendations.

Contact: www.yandexdatafactory.com

Signal processing with runtime system AUTOMATION Numerous new functions and an even more intuitive user interface are the new features of the

fifth generation of the ibaLogic PC-based measurement and automation system recently released by Iba. At the core of the system, there is a new development, the so called runtime system based on a programmable automation controller (PAC). Iba has enhanced this architecture which is commonly used in modern PLC systems by the typical properties of a measurement system.

Typical areas of application for ibaLogic are online signal processing in measurement systems, e.g. condition monitoring, implementation of process models for optimizing production as well as interfacing systems from different manufacturers as part of modernizations. The system is also used for modifying and extending automation systems as well as for connecting the basic auto-

Visualization of the measurement and automation system MPT International 6 / 2015

TECHNICAL INNOVATIONS mation with IT systems in the MES world. By combining the features of a powerful controller with the properties of a measurement system, ibaLogic is perfectly suited for the use in automatic test benches. The new ibaLogic version is available in different performance classes. The license-free entry-level version ibaLogic-V5-Lite is suitable for use in less complex plants. The full version offers the complete range of functions with connectivity for iba measurement technology, OPC server, an unlimited number of TCP/IP connections and clock cycle times of

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47

down to 1 ms. In compact machine-oriented solutions ibaLogic can run directly on the communication module of the modular measurement and automation system ibaPADU-S and perform control tasks in real time.

The user can develop his solution using the graphic user interface almost without any prior knowledge and immediately sees the results due to animated connectors and the integrated multichannel recorder ibaPDA-Express.

Contact: www.iba-ag.com

Ladle slide gate valve with three plates CONTINUOUS CASTING The gas-tight three-plate ladle slide gate valve, FT3 GT, offered by Knöllinger Flo-Tec, has been designed for applications with very high demands on the steel quality. The slide gate valve, which consists of three plates, features a closed housing with high-temperature-resistant seals. It can be applied as an inert gas barrier acting as a shielding from the outside atmosphere. The gas is passed through the gate, past the collector nozzle into the funnel or shroud. This produces a combined casting stream and slide gate shield. When developing the FT3 GT slide gate valve, emphasis was also placed on ease of use. To achieve this, the centre plate is mounted in a cassette, which can be swung open to provide free access to the slide plate.

The gate valves are available in two diameters, 65 and 100 mm.

Contact: www.knoellinger-gmbh.de

Three-plate slide gate valve with the centre plate cassette opened

Roll bite lubrication ROLLING MILLS As a result of roll lubrication introduced to its 4-high Steckel mill by Quaker Chemical, Nucor Steel Tuscaloosa has been benefiting from significant extension to roll service life and a notable reduction in mill torque. To further understand the impact of roll lubrication, a trial was performed which yielded the mechanism and advantages of backup roll lubrication in the reversing hot rolling mill: Fewer roll changes are needed with lubricated backup rolls, as the normal pressure and friction traction between the backup and work rolls are reduced. Roll bite lubrication lowers the mill separating force and torques by increasing the slipping zones and counteracting the length of the breaking zone. Bite and roll slippage are no longer factors with the presence of lubrication.

Contact: www.quakerchem.com

Customised 4-Way Handling www.combilift.com

࠮ Space saving, safe and productive handling ࠮ Indoor/outdoor capabilites ࠮ Robust and versatile ࠮ Capacities from 1.5 – 25 tonnes

Maintenance-free couplings SPECIAL EQUIPMENT Gear couplings used in roller conveyor drives or pilger rolling mills require regular lubrication and maintenance associated with stops

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With Combilift

Contact us for: FREE warehouse design service FREE DVD

Combilift Ltd Gallinagh Co. Monaghan Ireland Tel: +353 47 80500 UK: 07870 976 758 E-mail: info@combilift.com

MPT International 6 / 2015

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››› TECHNICAL INNOVATIONS

of the system. Voith CT-P couplings completely eliminate these disadvantages, as they require no lubrication or maintenance and can operate around the clock 365 days per year. Operators save costs when calculating this over the life cycle of a plant. A CT-P coupling usually has a longer lifetime than the units connected to it.

The longer lifetime is achieved thanks to the completely different physical concept employed by Voith. The integrated rubber elements prevent metal-to-metal contact as is customary in a gear coupling. At the same time, they dampen the forces of inertia occurring when drives are switched off.

Another distinctive advantage is that silicone elements can be used if needed, allowing the CT-P coupling to resist heat up to an ambient temperature of 130°C. The couplings are designed for torques of up to 200,000 Nm and speeds of up to 7,200 rpm. They are usually installed directly between the electric motor and the roller conveyor.

Coupling for roller conveyor

Contact: www.voith.com

drives or pilger rolling mills

Online monitoring concept for trunnion bearings in converters STEELMAKING A new comprehensive online monitoring concept for the trunnion bearings and gears of converters has recently been introduced

by Schaeffler. The system incorporates several monitoring concepts, namely acoustic emission measurements, oil particle analysis and grease condition checking. Acoustic emission measurement is an ideal method for slowly rotating trunnion bearings such as those used in converters. The otherwise usual method of measuring vibrations cannot be used reliably here, since the speeds are not high enough to generate sufficient energy to measure the structure-borne noise during overrolling of damaged areas of the bearing. Acoustic emission measurements, on the other hand, utilize the effect that plastic deformation or breakages occur in materials that are subject to loads beyond the elastic lim-

it. This defect leads to a concentration of stresses followed by the formation of cracks and, ultimately, to a sudden release of the tension in the material.

This short process generates an acoustic emission event that moves away from the source in the form of an ultrasonic wave and that can be measured.

Wear in bearings or gearings manifests itself well before impending failure in the form of abraded metal particles. If this abrasion is measured and monitored, damage to gearboxes lubricated with oil circulation and plain bearings can be detected at an early stage. The FAG Wear Debris Check device measures the number of particles in the oil and transmits key values to the upstream monitoring system and records and evaluates the particle concentration according to size and material.

More than half of all rolling bearing

failures are directly attributable to lubrication. Lubrication conditions, physical grease aging, or the proportion of solid and liquid contamination such as water in the lubricant have a decisive influence on bearing life. By using the FAG GreaseCheck sensor and the corresponding analysis unit, it is possible to detect any changes in the condition of the grease during operation, long before any damage to the rolling bearing occurs. This means grease changing can be precisely planned and the operating life of the bearing can be extended. Moreover, it allows switching from scheduled relubrication to relubrication according to requirements. As part of the monitoring strategy, FAG ProCheck monitors over 60 ascertainable key values and the process parameters.

Contact: www.schaeffler.com

Oil particle analysis module and data evaluation unit

TECHNICAL INNOVATIONS

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Low-wear and low-maintenance side guiding system HOT ROLLING Voestalpine Stahl will install additional Eco Slide Disc systems at the entry side guides of coilers 3 and 4 in the hot strip mill. Eco Slide Discs developed and supplied by Primetals Technologies have already been in continuous, successful operation at one guiding side of coiler 3 since August 2014. Eco Slide Discs can be used continuously for four weeks, whereas conventional wear strips usually last only two or three days. The new side guides have an inherent self-cleaning effect. This reduces the risk of material deposits falling on the strip and damaging its surface.

The rotatable Eco Slide Discs are mounted on a maintenance-free, rugged geared beam. They are installed vertically between the table rollers and automatically and synchronously rotate through a selectable angle after a variable number of strips have passed. While, when using conventional wear plates, the strip always cuts into the material at the same point, with Eco Slide Discs the wear is evenly distributed around the entire surface of the circular ring. This does not only extend the service life of the wearing parts, but also the period of continuous operation of the entry side guides from the previous two or three days to four weeks. The periodic and gradual rotation of the discs means that only small amounts of rubbed off material from the guided strip edges adhere to the discs. Such deposits are rubbed off by the following strips. This

self-cleaning effect of the Eco Slide Discs eliminates the manual cleaning of the wear strips required for certain strip qualities to prevent deposits from the strip edges falling off and damaging the surface of the strip.

Contact: www.primetals.com

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Universal encoder system for implementation of safety functions SPECIAL EQUIPMENT When rectifying faults, setting up machines or performing test runs, it may sometimes be necessary to intervene while the machine is running. This poses a safety risk to the operating personnel. The universal encoder system U-ONE- Safety offered by Johannes Huebner Giessen supports machine builders and system operators in their endeavours to prevent accidents. With the U-ONE-Safety system it is easy to implement motion and position-dependent safety functions such as safely-limited speed (SLS), safe direction (SDI) and safely-limited position (SLP). The system offers safe position, speed and error switches, safe absolute encoder interfaces and current or incremental outputs. The modular concept behind the system makes it possible to create the right solution for the respective application. Two different versions are available: U-ONE-Safety-Compact, which consists of the basic unit and the attached modules housed in robust casings, and U-ONE-Safety-LWL, which features a basic unit in a robust housing connected to the cor-

responding modules in the switchboard via fibre optic cable.

Contact: www.huebner-giessen.com

Encoder systems with the function modules housed in casings

VQR CPF YKVJ VJG HWPEVKQP OQFWNGU EQPPGEVGF XKC ƂDTG QRVKE cable (bottom)

© Utz Peter Greis, Düsseldorf

Cartoon

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MPT International 6 / 2015

LITERATURE SERVICE

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51

Expert system for strip processing lines 8 pages, English A brochure featuring the OPExSTM expert system offered by CMI Industry Metals. The operation and process expert system analyzes all process and coil data, ensuring consistent product quality and increased production performance in strip processing lines.

Contact: E-mail:

www.cmigroupe.com welcome@cmigroupe.com

Industrial burner technology 8 pages, English This brochure provides an overview of the range of equipment and services offered by combustion technology specialists Hans Hennig. Products include industrial burners, combustion chambers and hot gas generators, control technology and electronic components. Services such as assembly and commissioning, maintenance and spare parts complement the company’s portfolio.

Contact: E-mail:

www.hanshennig.de info@hanshennig.de

Mould level control system 6-page leaflet, English This publication provides a detailed description of a mould level control system developed by Inteco TBR Casting Technologies. The system includes a precisely actuating stopper rod mechanism with servo actuator and the Mould Level Master software package to control the steel flow in the mould.

Contact: E-mail:

www.tbr-casting.at office@tbr-casting.com

Mechanical vacuum systems for steel degassing 10 pages, English A brochure outlining the field of expertise of Oerlikon Leybold Vacuum in mechanical vacuum systems for efficient steel degassing and illustrating different types of vacuum treatment, optional systems solutions and pump arrangements to meet specific treatment requirements.

Contact: E-mail:

www.oerlikon.com/leyboldvacuum info.vacuum@oerlikon.com

Strip processing equipment 24 pages, English An illustrative brochure detailing the fields of expertise of Redex, specialist manufacturers of strip processing equipment. The brochure covers stand-alone tension levelling lines, process lines, precision rolling mills, slitters and edge trimmers, tools and the services offered by the company.

Contact: E-mail:

www.redex-group.com info@redex-group.com

MPT International 6 / 2015

52

››› IN THE NEXT ISSUE…

Environmental protection ThyssenKrupp to build new filter plant to further improve the environmental situation at the sinter plant in Duisburg, Germany ThyssenKrupp Steel Europe recently began construction of a further modern fabric filter for the Schwelgern sinter plant.

The company will install an additional cleaning stage behind the existing electrostatic precipitator capturing the dust and preventing it from escaping into the atmosphere. The new filter will remove additional dust and further improve the environmental situation in Duisburg. TKSE is investing around 46 million euros in this project.

Modernization SSAB modernized iron and steel works in Sweden and Finland SSAB has restarted its blast furnace in Luleå, Sweden, after a comprehensive revamp of the blast furnace, lasting more than three months. The blast furnaces in Raahe, Finland, have been retrofitted with pulverized coal injection technology. Also the converter shops at both sites have been revamped.

Automation Rule-based automation of a hot coil transfer system ThyssenKrupp Steel Europe has renewed its coil transfer system as part of the modernization of its No. 2 hot strip mill in Duisburg-Beeckerwerth, Germany. The existing material tracking and warehouse management system has been replaced by the rule-based system “TWMSmetals”. New functionalities have been added to the coil transfer system tailoring it to the specific requirements and conditions in the works.

Hot rolling Greenfield project for production of automotive grades in China Shandong Iron and Steel Rizhao, China, will set up a complete flat steel complex on the Chinese east coast. The complex will comprise a hot strip mill, a pickling tandem mill, a hot-dip galvanizing line and two annealing lines. The plants are scheduled to commence operation in 2017. In addition to the production of tube grades and cold strip for the construction and household appliances industries, the focus will lie on sophisticated steel grades for the automotive industry. The new facilities will feature a high-performance quality assurance system and be based on advanced operation know-how.

This preview may be subject to change.

Published by: Verlag Stahleisen GmbH P.O. Box 10 51 64, 40042 Düsseldorf, Germany e-mail mpt@stahleisen.de Publisher: Steel Institute VDEh Executive Member of the Management Board: Dr.-Ing. Peter Dahlmann Internet: www.mpt-international.com Editorial Staff: Chief Editor: Dipl.-Ing. Arnt Hannewald

+49 211 6707-568 Assistant Editor: Edith Mielke

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MPT International 6 / 2015

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MPT International

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