MPT International 1/2016 (Feb)

Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

SSAB modernizes iron and steel works in Sweden and Finland

February 2016

Rule-based automation of a hot coil transfer system

We transform … the world of tube production.

Meet us at

Hall 7a, Booth B15

Seamless Tube Plants

Welded Tube Plants

Finishing Lines

Spiral Tube Plants

Innovative and efficient solutions for tube production.

Whatever the diameter, wall thickness or steel grade – the SMS group supplies economical and efficient plant and machinery for all tube production processes. As a reliable technology partner, we also offer innovative products for individual customers‘ needs, as well as a range of services covering the lifetime of the plant. That is why we are the first choice worldwide when it comes to tube and pipe plants.

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 in 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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Highly innovative developments in VJG ƂGNF QH TQNNKPI technologies Rolling technology has seen tangible progress during the last few years. Here and there, some of the resulting advanced solutions have already been implemented. Meanwhile the steel producers have gained experience with the new equipment and MPT has been given the opportunity to report about the results and benefits of some of these projects in this issue. For example, SMS group has successfully developed and implemented induction heating systems for thin slab plants. Within the framework of a modernization project, a small but very powerful induction furnace was added to Nucor Steel’s CSP® plant at Berkeley works. In that case, induction technology is not just another kind of reheating furnace.

The induction unit rather complements the conventional thin slab reheating furnace. Being a very flexible system, the induction unit makes it possible to very accurately adjust the slab temperature at the rolling mill entry. While the conventional furnace can be operated at a temperature level suitable for processing the major part of the steel grades and strip gauges produced, in cases where a higher temperature is required the induction unit can be switched in. That way, the induction unit provides extra heating to the slab. Combining both heating technologies provides various benefits, such as remarkable savings on energy and the ability to extend the product range to include additional steel grades.

Dipl.-Ing. Arnt Hannewald

To further enhance the efficiency in the production of specialty steel long products, Danieli has developed a highly innovative plant concept that combines the benefits of rolling and forging. The first plant of this type was commissioned at Acciaierie Bertoli Safau (ABS) in Italy, the biggest company within Danieli’s steelmaking division. At first glance, the so-called “Rotoforge” looks like an XXL blooming mill. However, rolling experts immediately realize the huge forming capabilities of the large diameter work rolls driven by colossal main motors and installed in a super-rigid, hi-tech mill stand. As a result of a high reduction ratio per pass, the products feature a fine grain structure and very good centre soundness – comparable to forged products. On the other hand, the rolling process ensures excellent surface characteristics and high productivity. Thus, the new technology may become an alternative solution to forging of specialty steel products of medium dimensions.

Now, there is the long way ahead to have products approved, pass quality audits and obtain certifications and authorizations for the supply of products made by the new plant.

The projects featured in this issue are only two examples of numerous innovations and news from the steel industry. I am sure they will catch your interest. Enjoy reading.

MPT International 1 / 2016

Pioneer in Endless Casting Rolling process since 2000 and Direct Rolling Bundling process since 2005, Danieli provides super-compact, high-yield, energy-saving environmental friendly minimills to be the most competitive in regional markets from 150,000 tpy to 1.2 Mtpy. Â Â

Seven main references of endless ESC minimills out of 9 CMC GROUP USA Two orders in 2006 and 2015 for 300,000 and 380,00 tpy Endless Casting Rolling and Direct Bundling minimills for rebars to cover regional markets in South and Midwest USA. Best quality bundle in North America at the lowest cost.

DANIELI THE RELIABLE INNOVATIVE PARTNER TO BE FRONT RUNNERS

IIC EGYPT Two 830,000 tpy Endless Casting Rolling and Direct Bundling minimills to produce rebars for a new steelmaker aiming to be the most competitive in the MENA region.

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

DANIELI ESC ENERGY SAVING COMPACT MINIMILLS A MILESTONE IN THE STEEL INDUSTRY THE ONLY ENDLESS ROLLING FOR LONG PRODUCTS > > > >

6 m/min average casting speed 90% plant utilization 99.4% endless operation 99.3% overall mill yield

MENA REGION Two new orders for 350,000 tpy Endless Casting Rolling and Direct Bundling lines to produce rebars and spooled coils.

Danieli Micromill guarantees the lowest capex and opex.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

TAYBAH GROUP PAKISTAN New 500,000 tpy Endless Casting Rolling and Direct Bundling minimill for rebar production. Greenfield project including all auxiliaries, advisory services to erection, on-site and off-site training.

www.danieli.com

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››› CONTENTS

International industry news 24 5 JCPFQPI +TQP 5VGGN VQ UVCTV C ITGGPÆ‚GNF project for the production of automotive grades in China A new, high-quality flat steel production complex will be erected in the Rizhao coastal region of Shandong province

Environmental protection 26 6 J[UUGPMTWRR VQ DWKNF PGY Æ‚NVGT CV VJG UKPVGT RNCPV KP &WKUDWTI )GTOCP[ The company will install an additional cleaning stage behind the existing electrostatic precipitator capturing the dust and preventing it from escaping into the atmosphere

Coverphoto: Electrolytic tinning lines at Chinese steelmaker Shougang Jingtang feature soluble anodes, a OQD BNMCHSHNMHMF BDKK @MC @ UDQSHB@K QD×NV TMHS SMS group, Düsseldorf, Germany "NMS@BS VVV RLR FQNTO BNL $ L@HK BNLLTMHB@SHNMR RLR FQNTO BNL

Steelmaking

Modernization

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30 5 5#$ OQFGTPK\GU KTQP CPF UVGGN YQTMU KP 5YGFGP CPF (KPNCPF

BOF plant started operation at JSW Steel 8KLC[CPCICT YQTMU KP +PFKC The first of four new LD converters was started up in September last year. High-temperature creep-resistant materials and a special cooling design ensure a long service life

Hot rolling 36 0 WEQT 5VGGN OQFGTPK\GF VJG VJKP UNCD RNCPV KP $GTMGNG[ KORNGOGPVKPI KPFWEVKQP VGEJPQNQI[

Nordic and US-based steel company SSAB has restarted its blast furnace in Luleå, Sweden. In Finland, the blast furnaces at the Raahe works have been retrofitted with PCI technology. Also the converter shops at both sites have been revamped

34 0 GYN[ FGUKIPGF TGDCT TQNNKPI OKNN RGTHQTOU YGNN CV -CNKMC 5VGGN KP +PFKC Primetals Technologies has developed a plant design that permits fast and cost-efficient execution of projects. The first operating plant of this type features an annual production capacity of 250,000 tons

The focus of the project was on higher flexibility, lower energy input and wider product range

38 # $5 UVCTVU WR 4QVQHQTIG RNCPV EQODKPKPI VJG DGPGÆ‚VU QH HQTIKPI CPF TQNNKPI An innovative rolling-forging technology designed and realized by Danieli may become a breakthrough technology for highly efficient production of special quality long products

Cold rolling 48

Tinplate manufacturer Tk Rasselstein KPXGUVU KP GHÆ‚EKGPE[ The company is carrying out extensive modernization projects to increase the efficiency of its production lines. The projects concern two cold rolling mills, a continuous annealing line and a pickling line

MPT International 1 / 2016

Automation 40 4 WNG DCUGF CWVQOCVKQP QH C JQV EQKN VTCPUHGT U[UVGO Thyssenkrupp Steel has renewed its coil transfer system as part of a modernization of its No. 2 hot strip mill. The existing material tracking and warehouse management system has been replaced by the rulebased solution TWMS/metals

44 6 WTPKPI MPQYNGFIG KPVQ CEVKQP VQ CEJKGXG EQPUKUVGPV SWCNKV[ CPF KPETGCUGF GHƂEKGPE[ The Operation, Process Expert System developed by CMI bridges the knowing-doing gap in steel strip processing – the gap between the available data and the definition of what is to be done by the operator – based on an analysis of all available process and coil data

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Columns 10 +PVGTPCVKQPCN KPFWUVT[ PGYU

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Literature service

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Technical innovations

62

In the next issue

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Cartoon

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Imprint

Advertisers’ index ABB AB 58 Andritz AG 53 Association for Iron & Steel Technology 14 BM Group Holding 17 Braun Maschinenfabrik Gesellschaft m.b.H. 51 CIEC China International Exhibition Corporation 33 CMI INDUSTRY SA Metals 13 Combilift Ltd Co 25 Danieli S.P.A. 4, 5 Fabris InC. 29 framag Industrieanlagenbau GmbH 49

hpl-Neugnadenfelder Maschinenfabrik GmbH IMS Messsysteme GmbH Friedrich Kocks GmbH & Co. KG Lechler GmbH LOI Thermprocess GmbH Messe Düsseldorf GmbH Metal-Expo, JSC Morgardshammar AB NDC Technologies Plakoma GmbH POLYTEC GMBH

50 19, 20 11 18 23 12 63 57 55 35 21

Primetals Technologies Austria GmbH Quaker Chemical Corporation Rheinbraun Brennstoff GmbH RUMP STRAHLANLAGEN GmbH & Co. KG Schmolz + Bickenbach Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG SMS group GmbH Verlag Stahleisen GmbH WOKO Magnet- und Anlagenbau GmbH Zumbach Electronic AG

8, 9, 64 27 53, 54 52 42 37 2 32 16 15

MPT International 1 / 2016

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

See it!

Feel it!

Touch it!

Get your own free ruler made from an original unpickled 0.8 mm ESP-strip: contact@primetals.com

The future of Hot Strip Production: Arvedi ESP

2008

2009

2010

2011

2012

2013

2014

• Six references worldwide within shortest time • 13 Million tons / year installed capacity • 10 Million tons already produced on ESP

2015

2015

2015

2016

2016

2017

14 Totally installed ESP capacity in mt/year 12

08 06

Ar v Ca edi r S H bon teel SL g · A rad Ita es ly Si ·0 lic 6/ on 20 gr 09 ad es 0.

8 m AP m g I au M Lin ge ul e ti Pi Ph pe as e

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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

04

Rizhao Steel 1 China · 03/2015

02 00

facilities under construction

facilities operating

Worldwide protected by patents!

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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››› INTERNATIONAL INDUSTRY NEWS

The Americas Mexico Grupo Simec to build new SBQ production facility. Grupo Simec has contracted Danieli to install a greenfield minimill in the city of Apizaco located in the state of Tlaxcala. The 600,000 t/year plant will produce large round blooms, large-diameter bars and wire rod in special bar quality (SBQ). The new facility will be installed in close proximity to an existing Grupo Simec SBQ products minimill facility which produces 400,000 t/ year of small-diameter steel bars and flats.

The new facility will include all process steps from scrap processing to steel melting, secondary refining, round billet casting, hot rolling, heat treatment, cold finishing and bar inspection facilities as well as an advanced wire rod line.

Danieli Automation will supply all electrical components and an advanced level 1 and 2 automation system for the entire plant. Start-up of the plant is anticipated to take place by the end of 2017.

Mexico Frisa Forjados orders substation and SVC system. Forgings manufacturer Frisa Forjados has awarded Primetals Technologies a contract for the supply of a substation and a static var compensation (SVC) system for their new meltshop in Villa de Garcia.

The meltshop will enable Frisa to locally process its own raw materials to produce special steel quality rings. The integrated engineering solution includes a 230 kV substation with dead tank circuit breakers, control and relay panels, metering equipment, power monitoring system, 34.5 kV medium voltage switchgear and SVC system. Start-up is scheduled for the first quarter of 2016.

with Tenova Goodfellow. The system includes hybrid optical/extractive off-gas analysis hardware, process control models, proprietary off-gas velocity and temperature optical sensors as well as a water detection system.

The iEAF® technology is designed to significantly reduce operating costs, energy consumption and to improve endpoint detection by providing robust dynamic control of both electrical and chemical energy inputs and ‘second by second’ control based on the net energy that is actually received by the charge. The technology uses full spectrum off-gas analysis provided by the analysis system together with offgas velocity and temperature and inputs received from the plant’s PLC network to close a fundamental mass and energy balance for the EAF in real time.

USA

MPT International 1 / 2016

ArcelorMittal Belval, Luxembourg, has started up the CRS® compact roller straightener supplied by SMS group. The machine has been designed for straightening large sheet piles.

SSAB Luleå, Sweden, has successfully commissioned its converter shop after a revamp by SMS group.

The project involved the supply of two converter vessels with lamella suspension, the trunnion bearings and the tilt drive systems.

NSSMC Nippon Steel & Sumitomo has concluded a contract with MMTC, India, to purchase 1.8 to 2.6 million t/year of iron ore for a span of three years. MMTC is a public corporation that sells iron ore.

United States Steel to idle Granite City Works operations. United States Steel Corporation will temporarily idle its Granite City Works steelmaking and finishing operations in Granite City, Ill. The idling is part of an on-going adjustment of steelmaking operations to continued challenging global market conditions. The company will continue to operate its steelmaking operations in Indiana, Michigan and Pennsylvania as well some finishing operations in Alabama.

Baosteel Zhanjiang, China, has started up the two two-strand continuous slab casters supplied by Primetals Technologies.

The machines are part of a new Baosteel production site in the Guangdong province.

USA

Shandong Wantong Metal Technology, China, has awarded Fata Hunter a contract for the supply of a new hSystem® automation system, which will be installed on a four-high aluminium cold rolling mill.

Hycal to install hydrogen continuous annealing line. Hycal is installing a new continuous annealing line, developed and built by Ebner. The new line, which is expected to begin running in late 2016, will utilize an optimized blend of hydrogen, rather than water, for strip cooling to produce UHSS/AHSS grades.

USA Nucor Steel Seattle purchases offgas analysis system. Nucor Steel Seattle has placed an order for the installation and commissioning of an iEAF® offgas analysis system

News in brief

USA Nucor Nebraska to upgrade coil handling system. The combination bar-in-coil and rod mill at Nucor Ne-

Tāinecký inženýring, Czech Republic, has given Primetals Technologies the final acceptance certificate for the modernized secondary dedusting system installed in the Tāinecké Železárny converter steel works.

SSAB, Finland, commenced operation of the first of three LD (BOF) converters supplied by Primetals Technologies to SSAB’s Raahe works.

With almost unchanged space requirements, the new converters have a larger reaction volume. The other two converters are scheduled to come on stream by August 2016.

®

KOCKS RSB

OUR CUSTOMERS ARE OUR BEST ADVERTISEMENT

YONGXING SPECIAL STAINLESS STEEL CO., LTD RSB SCS® 370++/4 Order placed on 29th of October, 2015

SHIJIAZHUANG IRON & STEEL CO., LTD. RSB SCS® 370++/4 Order placed on 24th of November, 2015

5 IN A ROW SHIJIAZHUANG IRON & STEEL CO., LTD. RSB® 500++/4 Order placed on 24th of November, 2015

www.kocks.de ®

®

®

RSB , SCS and KOCKS rolled are German trademarks registered by KOCKS.

SEAH CSS RSB SCS® 370++/6 with AUL and 4D EAGLE Order placed on th 15 of December, 2015

FENG HSIN STEEL CO., LTD RSB SCS® 370++/5 and Water Cooling Equipment Order placed on th 11 of December, 2015

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››› INTERNATIONAL INDUSTRY NEWS

The Bright World of Metals TECHNOLOGIES PROCESSES APPLICATIONS PRODUCTS

braska will have upgraded coil handling equipment designed and installed by Primetals Technologies in September 2016. The plant, located in Norfolk, Nebraska, produces 900,000 t/year of long products. The contract scope includes the supply of a continuously rotating shear, coil receiving equipment with a coil plate, pallet system conveyor, transfer and cooling equipment. Also automation for all new equipment and an updated automation system for Nucor’s existing pallet system and compactor will be provided as well as installation and commissioning supervision.

USA

International Trade Fair for Metallurgy, Machinery, Plant Technology and Products

6 – 9 June 2016 EXPOCENTRE Krasnaya Presnya Moscow, Russia www.metallurgy-tube-russia.com

Voestalpine orders residuals briquetting plant.

Primetals Technologies received an order to supply a residuals briquetting plant for Voestalpine Stahl’s HBI plant near Corpus Christi, TX. Primetals Technologies and Midrex Technologies are currently building a direct reduction plant there, which will produce 2 million t/year of hot briquetted iron. The recently ordered briquetting plant will briquette around 160,000 t/year of dusts, sludges and pellet fines. Primetals Technologies will provide the process know-how and engineering for the plant, supply some of the equipment, including the electrical installation and automation systems, and commission the fines recycling plant. The briquettes will be used as a substitute for pellets to produce HBI. Commissioning is scheduled for July 2016.

International Exhibition & Conference on Metallurgical Technology, Processes, Material Handling and Services

5 – 7 October 2016 Bombay Convention & Exhibition Centre Goregaon (East), Mumbai, India www.metallurgy-india.com

International Metal & Steel Trade Fair for Southeast Asia

25 – 27 October 2016 Jakarta International Expo Kemayoran, Indonesia www.indometal.net

SUPPORTED BY

USA Feralloy orders new leveller. Feralloy recently purchased a Butech Bliss Synergy® hydraulic roller leveller for their Decatur, Alabama facility. The enhanced menu-driven operator interface allows simple graphical controls and a recipe system for quickly saving and recalling the best shape correction settings for a particular product. It is both intuitive and operator friendly. The cut-to-length line is equipped with a Butech Bliss stretch leveller capable of 1,850 t of stretching force and a Butech Bliss direct drive shear. The new leveller will enhance the line’s ability to process hot rolled, pickled and oiled material and produce memory-free panel flat product for OEM’s that laser-cut parts and components. Installation of the new leveller will be completed in the first quarter of 2016.

Asia China

www.tbwom.com

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Phone +49 (0) 2 11/45 60-01 _ Fax +49 (0) 2 11/45 60-6 68

www.messe-duesseldorf.de

MPT International 1 / 2016

Kobe Steel to expand wire rod processing capacity. Kobe Steel will expand the production capacity of its Chinese joint venture Kobe Special Steel Wire Products (KSP). The joint venture was established in 2007 to process steel wire rod into cold heading steel wire used

to make automotive bolts, nuts and bearing products. To meet the growing need for cold heading wire, KSP will install additional pickling equipment, increasing the production capacity of special steel wire from the current 3,500 t/month to about 4,900 t/month. The new equipment is scheduled to start up in December 2016.

China Nippon Steel & Sumikin Cold Heading Wire begins operations. Nippon Steel & Sumikin Cold Heading Wire (Suzhou) has begun operations. The company has been established by Nippon Steel & Sumitomo Metal Corporation (NSSMC) for the purpose of expanding the capacity and processing system of Nippon Steel Bar & CH Wire (Suzhou), a production/sales company for cold heading wire in China. The integrated plant is equipped with pickling, wire drawing and heat treatment facilities for a production capacity of 42,000 t/year.

India Field Gun Factory orders ESR furnace. Field Gun Factory Special Steel has awarded Inteco the order to engineer and supply a 10 t static mould ESR furnace. The fully coaxial furnace will be designed for protective gas operation and have a control system of the latest state of the art. The project is estimated to be completed within one year.

High-performance long products pickling solutions IRU Hσ HFWLYH UHPRYDO RI PLOO scale and other surface impurities

Japan Tokyo Steel orders billet and bloom caster. Tokyo Steel has placed an order with Danieli Engineering Japan covering the supply of a new continuous casting machine to be installed in their Okayama plant. The new machine will be added to the DC electric arc furnace shop to produce billets and blooms on structural steel grades with cross sections from 170 mm x 170 mm to 250 mm x 310 mm and product lengths from 2.8 m up to 7.5 m. The five-strand caster will be engineered and manufactured by Danieli CentroMet. It will feature the Danieli-patented Eco Power Mould, a 10 m main radius, Hy-Power mould oscillators, secondary air-mist cooling with five independent zones, a rigid dummy bar for fast restranding, and modular withdrawal and straightening units. Danieli Automation will supply all the electrical and automation systems.

Batch pickling plants for ferrous and non-ferrous metals: Wire Coil Pickling Lines Tube Pickling Lines Bar Pickling Lines Plate Pickling Lines Universal Pickling Lines

www.cmigroupe.com South Korea Posco orders annealing furnace for new galvanizing line. Posco has awarded Fives the contract to

DESIGN | FEASIBILITY STUDIES | ENGINEERING | COMMISSIONING | INSPECTION | TRAINING | SPARE PARTS

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››› INTERNATIONAL INDUSTRY NEWS

News in brief NLMK, Russia, has completed the replacement of its screening equipment at the sintering plant in Novolipetsk. New high-efficiency screeners have replaced the existing obsolete ones, reducing consumption of expensive pellets and furnace coke.

New Steel, Brazil, successfully commissioned the pilot plant of its newly developed dry iron ore concentration process. The new plant, installed in Ouro Preto, utilizes Loesche grinding technology.

ArcelorMittal Bremen, Germany, has brought into operation the second strand of the continuous slab caster modernized

by Primetals Technologies.

design and supply a high-performance vertical annealing furnace for the new hot-dip galvanizing line at Posco’s Gwangyang plant. The new No. 7 continuous galvanizing line will be designed for an annual production capacity of 500,000 t of high-end GI/GA exposed and advanced high strength steels (AHSS). The line is expected to be completed in 2017. Fives will design and supply its latest generation Stein Digiflex® vertical annealing furnace, including the patented Flash Cooling® technology operating at up to 65% H2 and the latest radiant tube combustion system operating with coke-oven gas.

Europe Austria Böhler to build ESR plant.

Böhler Edelstahl, which belongs to the special steel division of Voestalpine, awarded Inteco the contract to engi-

neer and supply a 12 t protective gas ESR plant. The furnace, to be installed at the Böhler specialty steel shop in Kapfenberg, will be designed for ingots of up to 900 mm diameter. Hot commissioning is scheduled to take place early in 2016.

France Union des Forgerons to build ring-rolling line. Union des Forgerons has ordered an open-die forging press and a ring-rolling mill from Siempelkamp for the new ring-rolling line being built in Méréville. Siempelkamp will design the 33/30 MN forging press as a combination open-die and ring blanking press. In addition to producing blanks for the manufacturing of rings, conventional open-die forgings with weights of up to 10 t will be produced. The ring-rolling mill will process the ring blanks from the forging press. It will be capable of producing rings with a maximum diameter of

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The Iron & Steel Technology Conference and Exposition

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MPT International 1 / 2016

AISTech.org

INTERNATIONAL INDUSTRY NEWS 2,500 mm, a height of up to 700 mm and weights of up to 5 t. The entire project will be carried out by a consortium made up of three companies. Siempelkamp will supply the mechanical equipment for the open-die forging press, Oilgear Towler will contribute the hydraulic and electrical systems.

The ring-rolling mill will be completely supplied by Siempelkamp including electrics, hydraulics, and the control system. Glama will supply the charging manipulator, the forging manipulator as well as a rail-bound forging robot. Full production of the new plants is scheduled to begin in the summer of 2017.

France Safran Group signs supply agreement for titanium alloy billets. Nippon Steel & Sumitomo Metal Corporation (NSSMC) has entered into a long-term agreement covering the supply of titanium alloy billets.

NSSMC has recently been approved

by SNECMA, jet engine manufacturer and member of Safran, as a supplier of standard grade (SQ) titanium alloy.

Germany Salzgitter to expand secondary metallurgy facilities. Salzgitter Flachstahl has awarded Tenova Metals Germany the contract to supply a new duplex RH unit for the Salzgitter plant.

Tenova’s scope of supply will include the complete engineering, the entire mechanical and electrical equipment, hardware and software, as well as installation and commissioning of the equipment. The nominal heat size of the new plant will be 220 t. The duplex RH plant will consist of two independent treatment stations, operated with a hybrid steam jet pump system.

The LD steelmaking shop of Salzgitter Flachstahl produces about 4.7 million t/year of slabs. With the installation of the new duplex RH plant, the annual

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15

News in brief NLMK, Russia, has launched a new strip straightening machine at its Novolipetsk site to improve the surface quality of uncoated cold-rolled steel.

Uddeholm, Sweden, has successfully started up the second new ESR plant supplied by Inteco.

The plant is an identical copy of the first Inteco ESR plant supplied to Uddeholm, which was commissioned in April 2015.

ArcelorMittal Kryviy Rih, Ukraine, has granted Danieli the FAC for the newly supplied teeming crane. The steelmaker also commissioned equipment for non-contact mould tube wear measurement and for the setting of the support roller.

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16

››› INTERNATIONAL INDUSTRY NEWS

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production volume of vacuum treated steel will increase by another 2 million t. The new plant will be mainly used for the production of automotive steel grades (ultra-low carbon IF steel) as well as heavy plate grades. The new plant is scheduled to start operation in spring 2017.

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Germany HKM to modernize converter.

Primetals will revamp LD (BOF) converter No. 2 in the Duisburg plant of HĂźttenwerke Krupp Mannesmann (HKM). The project will involve fitting the converter with a new trunnion ring as well as modernizing the tilting drive. These measures will help to extend the lifetime of the converter and increase its availability. Primetals will handle the project in a consortium partnership with Buchinger Anlagen-Stahl-Rohrbau. The project is scheduled for start-up in October 2016.

Germany ESF modernizes roughing stand drives. AIC has supplied new drives for the roughing stands 5, 6, 7 and 8 of the hot rolling mill of ESF ElbeStahlwerke Feralpi in Riesa. The project involved the replacement the old ACV700 drives with new ABB ACS880 inverter series. The entire new system has been equipped with standard devices to avoid a black-box solution.

Russia NLMK to revamp hot-dip galvanizing line. NLMK has begun upgrading its No. 1 continuous hot-dip galvanizing line at the Lipetsk production site. The project will boost the lineâ&#x20AC;&#x2122;s productivity by 30% to 500,000 t/year. The use of modern burners and furnace control systems will reduce natural gas and electric energy consumption and air emissions.

Russia Mechel to modernize another BOF converter. Primetals Technologies has won an order from the Mechel Group to modernize an LD (BOF) converter in the steel works of the Chelyabinsk Metallurgical Plant (ChMK). The project aims are replacement of the worn-out equipment, a capacity increase by raising the tapping weight, and optimized tap-to-tap times by cutting the melting time. Primetals Technologies is responsible for the basic and detail engineering, and will supply core components, including the converter, trunnion ring and maintenance-free suspension. It will also replace the tilt drive, together with its AC motors, and implement the associated basic automation. At the same time, a new cooling stack and the associated offgas cleaning plant will be installed to reduce converter emissions. The latter equipment will be supplied by Rosenergostal, Belgorod.

Russia The Netherlands

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MPT International 1 / 2016

Tata Steel plans major solar energy project. Working with sustainable energy developer Pure Energie, Tata Steel will mount 80,000 solar panels on its factory roofs at its IJmuiden steelworks. Tata Power Solar is in discussions to supply the solar panels in what would be its biggest international project. Pure Energie will fund the development. The solar project will have a 22 MW capacity. The energy generated will be used in steel manufacturing processes. The two-year installation of the panels will start in the spring of 2016 and cover a total of 25 hectares.

NLMK to cut dust emissions from BF operations. NLMK is reconstructing the dedusting systems at blast furnace No. 6, which has a capacity of 3.2 million t/year of hot metal. As part of the project, NLMK has signed a contract for engineering works and supply of equipment. The plan is to replace dedusting systems at the casting yard, the trestle, the receiver and the breeze bins and to install bag filters in place of the electric filters currently in use. The project, which is scheduled to be completed by 2018, is expected to bring down overall dust emissions from Novolipetsk blast furnace operations by more than 20%.

Companies Pittini purchases Verona works.

The Pittini group, through its holding company FIN.FER, has completed the purchase of the Verona plant previously owned by Riva Acciaio. The facilities of the newly founded and wholly controlled subsidiary company Acciaierie di Verona mainly consist of a steel plant, a wire rod mill, a rebar mill and a section mill producing coils and arc-welded meshes. The purchase will enable the Pittini group to expand its operations and reinforce its position in the rebar and building fields.

ATM becomes part of Verger group. With the acquisition of ATM, the Dutch technology group Verder has extended the portfolio of its Scientific division in the business segment of sample preparation of solids. ATM is specialized in the manufacture of instruments for metallographic applications. The instruments are used both in industrial processes and research to prepare solid bodies of metal or compound materials, usually followed by microscopic analysis. As part of the Verder laboratory division, ATM will benefit from the international sales and marketing strength of the group with activities in more than 80 countries. ATM will continue to operate out of its headquarters in Germany as an independent company.

Major upgrade of IMI Z&J facility. IMI Critical Engineering, provider of critical flow control solutions, has announced a further major investment to support its global growth ambitions. The company is committing 7.4 million euros to a major upgrade of its IMI Z&J facility in Duren, Germany, as part of an overall 17 million euros programme which is optimizing the quality and efficiency of its manufacturing base across the world. The upgrade at IMI Z&J involves refurbishment of five manufacturing buildings, the construction of new offices, and the enhancement of both the site and equipment in line with ever more stringent local and international health

and safety standards. The anticipated completion date is mid-2016. IMI Z&J, which was acquired by IMI in 2011, manufactures high-specification large valves, primarily for the petrochemical, iron and steel and glass industries.

Oerlikon sells vacuum segment to Atlas Copco. Oerlikon has signed an agreement to sell its Leybold Vacuum business to Atlas Copco. By this move, Oerlikon advances its strategic agenda and continues to focus on streamlining its portfolio. The divestment marks the thirteenth strategic transaction for the group since 2010.

It will allow the group to further allocate resources and management attention to its strategic growth areas in the fields of energy, mobility and urbanization. Atlas Copco has a strong position and wide expertise in the vacuum and compressor sector.

Outotec initiates additional cost savings programme. In anticipation of a continuing weak market, Outotec has initiated an additional cost savings programme. The new programme aims at 70 million euros annualized savings in fixed costs compared to the situation in the third quarter of 2015. Approximately two thirds of the savings are expected to be coming from personnel costs. The planned measures may lead to the reduction of maximum 650 permanent employees globally through redundancies and other arrangements. In Finland, Outotec will reduce 150 jobs, 105 permanent jobs through redundancies and the rest through other arrangements, such as non-renewal of fixed-term contracts, retirement arrangements and voluntary leavers. Outotec will also adjust the production capacity during 2016 through temporary lay-offs depending on the development of the market environment and Outotecâ&#x20AC;&#x2122;s order intake. Significant savings will also be achieved through reducing the use of external contractors.

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totec has changed its operating model, corporate structure and composition of the executive board to adapt its operations to the further weakened market situation. In the new operating model, Outotec’s business operations will consist of two business units (Minerals Processing and Metals, Energy & Water) and a Markets unit. The business units continue as reporting segments and the Markets unit will be responsible for managing customer relationships, geographical market areas as well as the spare and wear part and maintenance service business.

Outotec acquires business of Sinter Plant Services. Outotec has agreed to acquire the business of Sinter Plant Services in South Africa to complement its service offering to South African ferrochrome plants. Sinter Plant Services provides spare parts from its service centre and manufacturing facility close to Johannesburg.

As Outotec has delivered steel belt sintering and preheating kiln technologies to major ferrochrome producers in South Africa, the acquisition will strengthen Outotec’s position as a provider of life-cycle solutions in that area.

Air Liquide to acquire Airgas.

Air Liquide and Airgas have entered into an agreement under which Air Liquide will acquire Airgas. Airgas will become a wholly-owned subsidiary of Air Liquide. This acquisition will increase Air Liquide’s geographic reach in the North American market, as Airgas is a leading US-based supplier of packaged gases.

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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 1 / 2016

Bosio to further expand business in Western Europe. Slovenian industrial furnace manufacturer Bosio is stepping up its business in Western Europe. The company, with extensive experience in heat treatment projects in Southeast Europe, has been attracting business from steelmaking and forging shops in Western Europe, supplying shaft, chamber and bogie hearth furnaces. The company close-

ly collaborates with its Austrian parent company and principal shareholder Aichelin, benefitting from Aichelin’s extensive distribution and after-sales services network.

Harsco pursues separation of its Metals & Minerals business.

Harsco will pursue strategic options for the separation of the company’s Metals & Minerals segment from the Industrial and Rail businesses and brand joint venture. The process to evaluate options for implementing a separation of Metals & Minerals, including but not limited to a potential sale or tax-free spinoff, is ongoing.

Joint statement by Eurofer and European trade union. The European Steel Association (Eurofer) and the European Trade Union “industriAll Europe” have issued a joint call for action by policy makers to ward off further job losses in the sector. According to Axel Eggert, director general of Eurofer, the EU needs to adapt trade, climate and energy policies, in particular the review of the EU Emission Trading Scheme, to keep the steel sector competitive. In the face of Chinese exports, which have exploded to 110 million t during 2015 and doubled over the past two years, the EU needs to do more to speed up the deployment of its trade defence instruments and to safeguard steel industry jobs.

Eurofer comments on global climate agreement. The European Steel Association (Eurofer) welcomes the global agreement concluded at the 21st Conference of the Parties climate conference, but criticizes that there is no comprehensive strategy as to how to achieve the intended objectives. According to Eurofer, the agreement does not create a level playing field for European industry. Third country competitors will continue to face far lower environmental burdens. “It is clear that so long as no equal measures exist for industrial competitors globally, the EU’s most significant climate policy, the Emissions Trading System (EU

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Mills & more and Nokra sign cooperation agreement. Mills & more, a joint venture of three German companies active in the field of mechanical, electrical and technological equipment for rolling mills, and Nokra, Germany-based specialist manufacturers of high-precision laser measurement systems, have entered into a cooperation agreement.

Nokra’s portfolio includes contactless profile, flatness and thickness gauges.

The joint venture companies of Mills & more have many years of experience in rolling mill design, revamping and automation projects for rolling mills for all metals.

Voith establishes new Digital Solutions division. As part of its digital agenda, the Voith group has established a new group division, Voith Digital Solutions. The new unit will consolidate all of the group’s knowhow in the field of the digital transformation known as Industry 4.0. Its focus will be on the development of new digital business models for sectors that already exist today as well as for completely new sectors which are not yet being served. Expertise related to automation, software, IT, digitization and sensor technology that is currently covered by the group divisions Voith Hydro, Paper and Turbo, will now be consolidated and refined in the new division.

Steel associations present unified position on China. Nine regional steel associations (the American Iron and Steel Institute, the Steel Manufacturers Association, the Canadian Steel Producers Association, Canacero, Alacero, Eurofer, Instituto AcoBrasil, the Turkish Steel Producers Association and the Committee on Pipe and Tube Imports) presented

a unified position on the negative impact of granting China market economy status (MES). Representatives from the various regional associations detailed the negative consequences that would result from granting China MES before Chinese market-distorting policies were fully reformed. The regional steel associations continue to urge governments around the world to undertake comprehensive assessments of the continuing role of the state in the Chinese economy and the steel industry, and the impact on industries around the world.

Steel division of Thyssenkrupp launches strategic programme.

Following a strong focus on cost reduction measures in recent years and successful financial stabilization, the steel business of Thyssenkrupp now aims to maintain and continuously improve its performance with the ‘one steel’ strategic programme. Under the programme, strategic initiatives will be bundled together, managed centrally and implemented systematically in the coming years. With the optimization programme “Best-in-class reloaded” launched in 2013, Steel Europe has already achieved significant efficiency gains totalling over 600 million euros.

Thyssenkrupp with new brand identity. In the future Thyssenkrupp will use one common brand the world over. The redevelopment of the brand reflects the transformation of the technology company to a diversified industrial group. The new brand communicates the company’s positioning as a diversified industrial group and its aspiration to work in an integrated way, leveraging internal synergies and creating added value for customers, employees and shareholders. Over 180 different brand identities currently exist side-by-side within the group.

That results in complexity and an inefficient use of resources. In the new logo, the Thyssen and Krupp signets, previously separate, now form a single element. Thyssenkrupp will be introducing the new brand gradually and in accordance with the company’s financial situation.

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››› INTERNATIONAL INDUSTRY NEWS

Precoat Metals acquires coil coating and processing assets.

Precoat Metals, a unit of independent metal coil coater Sequa Corporation, has acquired the metal coil coating and processing assets of Consolidated Metal Products, a business unit of Consolidated Systems Inc. The assets located in Columbia, South Carolina, USA, will be operated as a toll processing facility in the Precoat Metals southern region, offering the application of paints and other coatings and films to metal coils, in addition to slitting, blanking, levelling, embossing, and packaging services. Precoat Metals now operates 16 coil coating lines in 14 locations, with over 1,000 employees.

Personalities Management and structural changes at Severstal. Severstal has implemented various management and structural changes. Alexander Kolobov, previously deputy business system development director of Severstal Russian Steel, has been appointed business system development director of Severstal. Severstal has also announced to separate the sales and marketing departments of Severstal Russian Steel.

New CEO at Ovako. Marcus Hedblom has been appointed as new president and CEO of Ovako with immediate effect. He will succeed Tom Erixon, who is leaving Ovako to be the new president and CEO of Alfa Laval.

Marcus Hedblom

New Eurometal president. During the Eurometal general assembly, which took place in December 2015, Alain Le Grix De La Salle, vice president of ArcelorMittal, stepped down as Eurometal president. Jens Lauber, CEO of Tata Steel Distribution Mainland Europe, was unanimously elected as the new president. First vice president is Robert Kay of Ferona, Czech Republic.

Outokumpu appoints president and head of business area. Outokumpu has appointed Liam Bates as the president and head of business area Quarto Plate and member of the Outokumpu leadership team. Liam had been leading the Quarto Plate operations in Europe and the production unit in Degerfors, Sweden, since September 2014.

Prior to that, he had held several senior management positions in the company.

Liam Bates

Executive promotion at AK Steel. AK Steel has named Jaime Vasquez vice president, finance and chief financial officer. Jaime Vasquez is currently director, finance.

News in brief Gerdau Jackson, USA, has issued the FAC to AIC for the upgrade of all main rolling mill drives at the Jackson, TN plant.

AMAG, Austria, has granted Danieli the FAC for the twin-coiler aluminium rolling mill. Danieli has meanwhile received another order from AMAG, cov-

MPT International 1 / 2016

officer of both Dillinger Hütte and Saarstahl and as managing director of SHS – Stahl-Holding-Saar to join the management board of Volkswagen AG as their new board member for human resources.

Personnel change on management board of Dillinger Hütte and Saarstahl. Karlheinz Blessing has resigned from his post as chief executive

ering the supply of a slitting and coil preparation line.

Ezz Rolling Mills (ERM), Egypt, started up and successfully completed the performance test of the new Energiron direct reduction plant installed by Danieli.

Angang, China, has granted Danieli the FAC for the revamp of its tandem cold mill. The project involved the in-

Jens Lauber

New president of Eurofer. The board of Eurofer has elected Geert Van Poelvoorde, an executive vice president of ArcelorMittal and CEO of Flat Carbon Europe, as its new president for a twoyear term. Geert Van Poelvoorde takes over from Robrecht Himpe, who was Eurofer president from 2014 onwards.

Changes to organizational structure of ArcelorMittal Americas. Lou Schorsch, senior executive vice president, member of the group manage-

stallation of a new six-high stand as a replacement of the existing four-high stand.

OneSteel, Australia, has issued the FAC to Primetals Technologies for the installed upgrades at its Laverton wire rod mill. Improvements to the water cooling line and laying head have resulted in higher finishing speeds on small diameter products.

INTERNATIONAL INDUSTRY NEWS ment board and CEO of ArcelorMittal Americas will retire from the company, effective end of February 2016. Jim Baske will be chief executive of ArcelorMittal Nafta Flat Rolled, with responsibility for all other operations in Nafta, excluding USA but including AM/ NS Calvert. John Brett, currently executive vice president finance, planning and procurement for ArcelorMittal USA, has been appointed chief executive of ArcelorMittal USA. Andy Harshaw, the current CEO of ArcelorMittal USA, is retiring. Separately Robrecht Himpe, currently executive vice president and CTO of ArcelorMittal, has been appointed chief executive of AM/NS Calvert.

Metal & Steel and Fabex Saudi Arabia. These exhibitions will bring together exhibitors and visitors from all areas of metals and steel production and processing. The first international steel conference in Saudi Arabia, “Steel in the Gulf”, will be staged concurrently with the exhibitions.

›

26 – 30 June 2018 Düsseldorf, Germany

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Organizers: Messe Düsseldorf www.metec-tradefair.com METEC, GIFA, THERMPROCESS, NEWCAST. The four “Bright World of Metals“ trade fairs are switching to a three-year cycle. The next time the leading trade fairs for foundry technology, metallurgy, thermo process equipment and castings will be taking place is June 2018. The organizers are responding to the changes in the innovation cycles within the industries.

Events ›

4 – 8 April 2016 Messe Düsseldorf, Germany; www.wire.de; www.tube.de

Tube 2016 and wire 2016. Tube 2016 will cover the full range of pipe and tube manufacturing and trade. Wire 2016 will feature machinery for the production and finishing of wire and cables.

›

21 April 2016 Brussels, Belgium Organizers: Eurofer www.eurofer.be

European Steel Day. Hosted by the European Steel Association, this year the event will be held under the motto “Building a future as strong as steel”.

›

1 – 4 May 2016 Riyadh, Saudi Arabia Organizers: Arabian German Exhibitions & Publishing www.metalsteelsa.com

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş INTERNATIONAL INDUSTRY NEWS

Shandong Iron & Steel to start C ITGGPĆ&#x201A;GNF RTQLGEV HQT VJG RTQFWEVKQP QH CWVQOQVKXG ITCFGU KP %JKPC $ QHZ KLJK TXDOLW\ Ć&#x192;DW VWHHO SURGXFWLRQ FRPSOH[ ZLOO EH HUHFWHG LQ WKH 5L]KDR FRDVWDO UHJLRQ RI 6KDQGRQJ SURYLQFH :LWK WKH QHZ SURGXFWLRQ IDFLOLWLHV 6KDQGRQJ ,URQ 6WHHO ZLOO EH DEOH WR SURGXFH DOPRVW Ć&#x201A;YH PLOOLRQ WRQV RI KRW VWULS DQG WZR PLOOLRQ WRQV RI VXUIDFH Ć&#x201A;QLVKHG FROG VWULS SHU \HDU PDLQO\ VXSSO\LQJ HQG FXVWRPHUV LQ WKH DXWRPRWLYH LQGXVWU\

Signing the contract with SMS group (from left): Dieter Rosenthal (Managing Director of SMS group), Wang Jichao (Vice President of Shandong Iron and Steel Rizhao) and Olaf Stalfort (Head of Commercial Sales at SMS group)

Shandong Iron and Steel Rizhao, China, has ordered equipment for a complete flat steel complex to be erected in the Shandong province on the Chinese east coast. The equipment is scheduled to commence operation in 2017. With the new equipment, Shan-

SMS group, DĂźsseldorf, Germany Contact: www.sms-group.com Primetals Technologies, London, UK Contact: www.primetals.com

MPT International 1 / 2016

dong Iron and Steel Rizhao will be able to produce almost five million tons of hot strip and two million tons of surface-finished cold strip per year.

Slab casters with an annual capacity of 4.6 million t of steel Two twin-strand continuous slab casters will be supplied by Primetals Technologies. The casting plants are scheduled to go on stream in June 2017. The casters are designed to pro-

duce 4.6 million metric tons of slabs per annum. The steel for the two continuous casting machines will be produced in basic oxygen steel converters with a total annual capacity of five million metric tons.

A number of technology packages will ensure high surface and interior quality, even under fluctuating production conditions, and facilitate flexible casting operations. The equipment and technology packages will be installed according to the Primetals Technologies â&#x20AC;&#x153;Connect & Castâ&#x20AC;? principle. This means that all plant functions and systems are completely ready for use from the very first batch.

The two continuous casters will have a machine radius of 9.5 metres and metallurgical length of around 32 metres.

They will produce slabs with a thickness of 230 mm in widths ranging from 1,000 to 1,950 mm. The casting speed will reach up to 1.7 metres per minute.

The casters will process a wide range of carbon steels, peritectic grades, structural steel, HSLA (high strength low alloy) steels, deep-drawn grades, and various alloys for pipes.

Primetals Technologies will be responsible for the detail engineering of the casting platform and strand-guide system, the basic engineering of the exit zone, and the basic and detailed engineering for the maintenance area, as well as for configuring the automation system and associated software.

Primetals Technologies will also supply core components, hydraulic cylinders, drives, spray nozzles, and electrical and automation equipment. The scope of services will also include su-

INTERNATIONAL INDUSTRY NEWS pervision of installation and commissioning work as well as customer training.

Hot strip mill and various strip processing lines including quality assurance system Shandong Iron & Steel has contracted the SMS group to supply the complete flat steel rolling mill and strip processing lines – including a newly developed quality assurance system and operation know-how. This project will comprise a hot strip mill, a pickling tandem mill, a hot-dip galvanizing line and two annealing lines. A special feature of this project will be the supply of cross-process know-how while simultaneously monitoring, documenting and securing the product characteristics. The SMS group will supply the electrical and automation systems for the entire equipment. The

scope of supply for the electrical and automation systems comprises a plug & work test before commissioning to ensure the functionality of all systems and provide for intensive training and familiarization of the customer staff on the equipment.

The hot wide strip mill is designed for an annual capacity of 4.8 million tons and produces strips in widths of up to 1,900 mm. The slab sizing press allows width reductions of up to 350 mm and therefore ensures great flexibility as regards casting and strip widths.

A major part of the hot strip produced will be processed in a pickling line linked to a tandem cold rolling mill with an annual capacity of two million tons. Two annealing lines and one hot-dip galvanizing line provide a finish to the cold rolled strip to obtain a high-quality product. The two annealing lines have an annual production capacity of 950,000 and 650,000 tons,

‹‹‹

25

while the hot-dip galvanizing line has a production capacity of 400,000 tons.

The total of two million tons of surface-finished cold strip comes in widths between 900 and 1,850 mm and final gauges of 0.3 to 2.5 mm. Production comprises the material grades CQ, DQ, DDQ, EDDQ, SEDDQ, BH, HSLA, HSS, DP, TRIP, achieving tensile strength values of up to 1,000 MPa.

Conclusion Thanks to the investment in high-quality equipment technology combined with extensive know-how and innovative quality assurance, Shandong Iron & Steel will have one of the most up-to-date plants worldwide.

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.

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››› ENVIRONMENTAL PROTECTION

6J[UUGPMTWRR VQ DWKNF PGY ƂNVGT at the sinter plant in Duisburg, Germany 7K\VVHQNUXSS 6WHHO KDV UHFHQWO\ EHJXQ FRQVWUXFWLRQ RI D IXUWKHU IDEULF ƂOWHU IRU WKH Schwelgern sinter plant. The company will install an additional cleaning stage behind the existing electrostatic precipitator capturing the dust and preventing it from escaping LQWR WKH DWPRVSKHUH 7KH QHZ ƂOWHU VKDOO UHPRYH DGGLWLRQDO GXVW DQG IXUWKHU LPSURYH WKH environmental situation in Duisburg. Thyssenkrupp is investing around 46 million euros in this project.

Thyssenkrupp Steel Europe has begun construction of a second fabric filter at the Schwelgern sinter plant in Duisburg, Germany. The official starting signal was given by North Rhine-West-

hannes Remmel during his visit to the construction site in Duisburg. According to Thyssenkrupp, the filter will remove additional dust and further improve the environmental situation in

world and will capture large additional amounts of dust, states Thyssenkrupp.

The third fabric filter is planned to go into operation by 2020. Thyssenkrupp Steel Europe is investing around 46 million euros in this project. The steel producer declares already having emitted around 20% less dust in 2014 compared to 2010.

Electrostatic precipitators prevent dust from escaping into atmosphere

NRW environment minister Johannes Remmel (centre) installs a plaque on the works UKVG EQOOGOQTCVKPI VJG UVCTV QH EQPUVTWEVKQP HQT VJG UKPVGT RNCPVoU PGY HCDTKE ƂNVGT

phalia environment minister Johannes Remmel in mid-November 2015. “The new filter units are a clear commitment to steel production in Duisburg and an ecological and economic opportunity to prepare for the future,” said Jo-

Thyssenkrupp Steel Europe AG, Duisburg, Germany Contact: www.thyssenkrupp-steel-europe.com E-mail: erik.walner@thyssenkrupp.com

MPT International 1 / 2016

Duisburg. “We expect this measure to have a big impact on air quality,” comments Andreas Theuer, head of Environmental and Climate Protection at Thyssenkrupp Steel Europe.

The smallest of the three belts in the Schwelgern plant already has a downstream fabric filter since 2011. The filters for the two other sinter belts will be using the same technology. Construction work on the filter for the biggest sinter belt is set to be completed in early 2017. The filter unit will go into operation in March 2017 at the latest.

It will be the biggest of its kind in the

Thyssenkrupp Steel Europe contracted Essen-based Küttner GmbH & Co. KG to install the fabric filter plant.

The main features of the contract include design, plant engineering, manufacturing and commissioning. The dust of the sintering process is captured by several conventional electrostatic precipitators and prevented from escaping into the atmosphere by these filter units. “Our electrostatic precipitators are already very efficient but we can still improve,” says environmental expert Andreas Theuer. In the already existing downstream fabric filter the air that has passed through the electrostatic precipitator flows through around 15,000 three-meter-long extremely fine fabric bags that capture even very fine dust particulates. It cleans up to 450,000 m3/h of waste air.

Sinter plant in Duisburg In the sinter plant in Duisburg, fine iron ores are mixed with coke and other materials such as lime, heated and baked together. The mixture is placed on a sinter belt, ignited under a furnace

ENVIRONMENTAL PROTECTION

)TCRJKEU QH VJG PGY HCDTKE ƂNVGT CV 6J[UUGPMTWRR 5VGGN 'WTQRG 6JG WPKV KU UEJGFWNGF VQ IQ KPVQ QRGTCVKQP KP GCTN[ %QWTVGU[ -ØVVPGT )OD* %Q -)

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at temperatures of around 1,200°C, and sintered. The combustion air required for the process is sucked through the mixture by large fans to burn the coke.

At the end of the sinter belt the “cake” is removed, cooled and crushed to an average particle size of around 20 mm. From the Schwelgern sinter plant with its three sinter belts the material is supplied to the four blast furnaces of Thyssenkrupp Steel Europe in the north of Duisburg.

28

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

BOF plant started operation at JSW Steel Vijayanagar works in India 7KH Ć&#x201A;UVW RI IRXU QHZ /' FRQYHUWHUV ZDV VWDUWHG XS LQ 6HSWHPEHU ODVW \HDU $IWHU WKH VWDUW XS ZHQW VPRRWKO\ DQG WKH FRQYHUWHU LV LQ IXOO SURGXFWLRQ PRGH QRZ WKH UHPDLQLQJ FRQYHUWHUV ZLOO EH FRQVHFXWLYHO\ UHSODFHG XQWLO VSULQJ +LJK WHPSHUDWXUH FUHHS UHVLVWDQW PDWHULDOV DQG D VSHFLDO FRROLQJ GHVLJQ HQVXUH D ORQJ VHUYLFH OLIH In mid-September 2015 a new LD (BOF) converter supplied by Primetals Technologies was started up in the converter steel plant No. 2 in Vijayanagar, Toranagallu of Indian steelmaker Jindal South West Steel Ltd. (JSW Steel).

Since then, the converter is in full production mode. It is part of an order received in September 2014 under which Primetals Technologies will exchange a total of four LD converters (basic oxygen furnaces).

The converters are made of high-temperature creep-resistant steel. In conjunction with a combined air and water cooling system, this will achieve a long service life. The new converters will have a larger interior volume than the previously used models. This will reduce slopping. The remaining converters will be consecutively replaced until spring 2016.

JSW Steel is the leading steel producer in India with an installed capacity of 14.3 million metric tons of steel per annum. Of this total, ten million metric tons are produced alone by the Vijayanagar steel works in Toranagallu, in the state of Karnataka. On account of the high maintenance requirement of the existing LD converters in steel works No. 2, JSW Steel decided to replace them with new converters from Primetals Technologies.

Each converter will have a tapping weight of 180 metric tons. Primetals Technologies will supply the converter vessels, including the trunnion

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 1 / 2016

LD (BOF) converter from Primetals Technologies in the steel plant No. 2 in Vijayanagar, Toranagallu, India of JSW Steel

rings and suspension systems. All the converters will be equipped with bottom-stirring systems. The converters will be constructed of high-temperature creep-resistant materials in order to limit heat-related deformations. In conjunction with a specially designed, combined air and water cooling system, this will achieve not only a long service life but also reduce maintenance requirements. Each converter will have

a water-cooled cone cooling system and air cooled trunnion ring. The scope of delivery will also include two new tilting drives, two sets new quick-change couplings for top blowing lances, and the complete basic automation (Level 1) for the converters. Primetals Technologies will also be responsible for supervising the installation and commissioning, and will engineer the modifications required to the converter housings.

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››› MODERNIZATION

SSAB modernizes iron and steel works in Sweden and Finland Nordic and US-based steel company SSAB has restarted its blast furnace in Luleå, Sweden, after a comprehensive revamp lasting for more than three months. In Finland, WKH EODVW IXUQDFHV DW WKH 5DDKH ZRUNV KDYH EHHQ UHWURƂWWHG ZLWK SXOYHUL]HG FRDO injection technology. Also the converter shops at both sites have been revamped.

“It makes me very proud to say that we now have world-class crude iron production facilities,” says Olavi Huhtala, head of SSAB Europe. “Even before the recent revamp, our blast furnaces ranked among the world’s most carbon-dioxide efficient ones.

The recent installations in both Luleå and Raahe will further improve both our cost efficiency and environmental footprint. The investments will enable our facilities to continue producing high-class steel for many years to come. This means that we can now continue to develop world-leading steel applications in close collaboration with customers.”

Extensive modernization at the Luleå ironmaking site and steel plant After 15 years of continuous operation, the blast furnace at the Luleå ironmaking site underwent a complete modernization. According to statements by the operator, the blast furnace is now set to continue production for another 15 to 20 years.

The blast furnace hearth was relined with new carbon refractories. Also, the cooling staves was replaced. A new dedusting filter plant was fitted to the cast house. This benefits the environment through less dust emissions, less noise and better workplace conditions. At the

SSAB, Sweden Contact: www.ssab.com; SMS group, Germany Contact: www.sms-group.com; Primetals Technologies, Austria Contact: www.primetals.com

MPT International 1 / 2016

New converter from SMS group at SSAB Luleå works, Sweden (Courtesy: SMS group)

coke plant, the quenching tower was replaced, which again means less dust emissions released to the environment.

At the steel plant, the two converters were renewed. German-based SMS group supplied the converter vessels with lamella suspension and the tilt drive systems. The scope of supply further included the converter trunnion bearings, the height increase of the ex-

isting trunnion pedestals and the installation of the vessels and trunnion rings.

Thanks to the design concept developed by SMS group, the new converter vessels have become significantly larger: With an unchanged quantity of charge material of up to 130 t, the internal volume of the converter has been increased by 10%. The additional capacity allows for more environ-

MODERNIZATION ment-friendly process control and efficient energy recovery.

The increase in capacity was achieved by improved utilization of the existing installation space. This was possible thanks to the lamella converter suspension system developed and patented

by SMS group. It is a maintenance-free converter suspension system designed for arranging the converter vessel in the trunnion ring without restraint.

efficiently under suppressed combustion. In addition, diffuse dust emissions are substantially reduced. Gas recovery is used in the best possible way by generating CO gas under suppressed combustion.

The SMS group scope of supplies and services included the revamp of the primary gas cooling system as well as the engineering and supply of the major cooling stack components. The steam

New converter from Primetals Technologies at SSAB Ruukki Raahe works, Finland (Courtesy: Primetals Technologies)

SMS group’s Ecoplants solution comprised the revamp of the primary gas cooling system of the BOF steelmaking plant. For this, the cooling stacks of both converters were modified and provided with easy-to-maintain adjustable skirts. These are lowered hydraulically onto the converter mouth during the blowing phase and they enable the primary gases to be extracted

produced in the cooling stacks is used as process steam in the entire integrated iron and steel plant. The complete energy recovery from the two cooling stacks is thus performed with extremely high energy efficiency.

“We are highly satisfied with the Ecoplants technology and we can produce with a clean environmental conscience,” comments Kurt Lindqvist,

‹‹‹

31

project manager of the converter shop at SSAB Luleå.

First of three new converters started up at Raahe works Across the Gulf of Bothnia in Raahe, Finland, SSAB operates the Ruukki integrated iron and steel works. It is the largest production facility of its kind in the Nordic countries. With two blast furnaces, three BOF converters, secondary metallurgy facilities and three continuous casting systems, up to 2.6 million t of steel can be produced and cast here every year.

The blast furnaces in Raahe were modernized in 2011. Now a pulverized coal injection system has been installed, replacing a heavy fuel oil injection system. This investment will result in more cost-efficient steel production and lower raw material costs.

Work is under way on replacing the 125 t converters at the steel plant in Raahe. In October 2015, the first of three LD (BOF) converters supplied by Primetals Technologies commenced operation. With almost unchanged space requirements, the new converters have a larger reaction volume. The maintenance-free Vaicon Link 2.0, which will be used as the converter suspension, minimizes stress caused by heat-induced deformation and has a longer useful life. Also, a new refractory concept will ensure a long converter lining campaign.

The three new converters feature a detachable bottom and a bottom stirring system as well as the Vaicon Stopper to minimize slag transfer during tapping. The tip of the blowing lance has been adapted to the new converter geometry, improving the blowing process and as a result the metallurgical properties of the steel produced. The work in connection with the replacement of the converters at the steel mill in Raahe will be completed in 2016.

The converters are scheduled to come on stream in stages by August 2016.

Reduced costs from this year onwards SSAB’s five blast furnaces in the Nordic region have a total capacity of around 6.4 million t. One blast furnace is located in Luleå, and two are located in Oxelösund and RaaMPT International 1 / 2016

MPT International

the leading technical journal for the global iron and steel industry

Metallurgical Plant and Technology

Đ&#x153;ĐľŃ&#x201A;аННŃ&#x192;Ń&#x20AC;гиŃ&#x2021;ĐľŃ ĐşĐžĐľ ĐżŃ&#x20AC;ĐžĐ¸ĐˇĐ˛ĐžĐ´Ń Ń&#x201A;вО и Ń&#x201A;ĐľŃ&#x2026;нОНОгиŃ? ПоŃ&#x201A;аННŃ&#x192;Ń&#x20AC;гиŃ&#x2021;ĐľŃ ĐşĐ¸Ń&#x2026; ĐżŃ&#x20AC;ĐžŃ&#x2020;ĐľŃ Ń ĐžĐ˛

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ТоŃ&#x2026;нОНОгиŃ? кОнŃ&#x201A;Ń&#x20AC;ОНŃ? и Ń&#x20AC;огŃ&#x192;НиŃ&#x20AC;ОваниŃ? наŃ&#x201A;Ń?МониŃ? ĐżĐžĐťĐžŃ Ń&#x2039; в НиниŃ?Ń&#x2026; нопŃ&#x20AC;ĐľŃ&#x20AC;Ń&#x2039;внОгО ĐžŃ&#x201A;Мига (c. 34)

MetalĂźrji Prosesleri ve Tesisleri

PuriĆ&#x201A;caç¿o de gases com eĆ&#x201A;ciĂ&#x2020;ncia energĂŠtica, atravĂŠs de controle inteligente

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33

Panoramic view of SSAB Ruukki Raahe works, Finland (photo from the archives, 2006)

he respectively. The maintenance and installation work in Luleå involved over 600 people from companies across Europe working together with SSAB’s employees.

During the modernization process at Luleå, the blast furnaces in Raa-

016 17-20, 2 r

Mayternational Exhibition Cente China In e) • Beijing enu (New V

he and Oxelösund continued to supply the company’s rolling mills.

Afterwards, in mid-October 2015, when the blast furnace in Luleå was up and running again, the smaller one of the two blast furnaces in Oxelösund was idled.

According to the company, the modernizations in Luleå and Raahe will reduce SSAB’s annual costs by around SEK 200 million (about EUR 21.5 million) from 2016 onwards and result in more cost-efficient steel production and lower raw material costs.

M e tta al + Metallurgy Chi na 01 Metal Me eta et Me M eta et e tta allu a lllu urg gy C hin a 20 2016 20 016 16 1 6 g gyyy China The 16th China International Metallurgical Industry Expo The 14th China International Foundry Expo The 14th China International Industrial Furnaces Exhibition The 12 12th China International Refractories and Industrial Ceramics Exhibition

Review w 2014

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34

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

Rebar rolling mill supplied by Primetals Technologies at Kalika Steel Alloys Pvt. Ltd. (Kalika Steel) in Jalna, Maharashtra, India

Newly designed rebar rolling mill performs well at Kalika Steel in India 3ULPHWDOV 7HFKQRORJLHV KDV GHYHORSHG D SODQW GHVLJQ WKDW SHUPLWV IDVW DQG FRVW HIĆ&#x201A;FLHQW H[HFXWLRQ RI SURMHFWV 7KH Ć&#x201A;UVW RSHUDWLQJ SODQW RI WKLV W\SH ZDV LPSOHPHQWHG DW .DOLND 6WHHO ,W IHDWXUHV DQ DQQXDO SURGXFWLRQ FDSDFLW\ RI WRQV At the Indian steel producer Kalika Steel Alloys Pvt. Ltd. (Kalika Steel), a new rebar rolling mill supplied by Primetals Technologies and started up in 2015 recently achieved all agreed performance parameters. The mill was erected in the Jalna plant in the state of Maharashtra and can produce about 250,000 metric tons of rebar per year of low-carbon steels. Primetals Technologies specifically developed this plant design for small to medium-size production capacities. It allows projects to be implemented comparative-

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 1 / 2016

ly quickly and economically. The order had been placed with Primetals Technologies in mid-2013.

Kalika Steel is a leading private-sector producer of structural steels. The company produces the billets required as semi-finished material for this purpose from sponge iron in induction furnaces. Kalika Steel aims to expand its production with the new rolling mill in order to serve the growing Indian construction sector. With the new rebar mill, Kalika Steel now hosts the billet production and the rebar rolling at the same location.

Primetals Technologies supplied the complete mechanical and electrical equipment as well as the automation systems for the rebar rolling mill which produces reinforcing bars with diameters of between eight and 40 millimetres and lengths of between nine

and 15 metres. The rolling mill consists of 18 Red Ring stands, followed by a 54 metre long cooling bed and machines for bundling the rolled bars. The mill processes billets with a cross-section of 130 x 130 millimetres and a length of 9 metres. Rolling speed is up to 13 metres per second. An induction furnace raises the billets to the necessary starting temperature of 950°C. The scope of supply also included loopers, guides, rotary shears, a PQS cooling system, pinch rolls, a divide shear, the roller tables, a cold shear, a gauge beam and machines for bar handling, counting and bundling. In addition, Primetals Technologies provided the fluid systems, roll change robots and the complete electrics and automation. Primetals Technologies was also responsible handling the construction and commissioning of the rolling mill.

From concept to design – we manufacture steel and rolling mill technology: Superb design consists not only of a bold plan but also of simple and reliable solutions.

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36

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş HOT ROLLING â&#x20AC;&#x201C; MODERNIZATION

Nucor Steel modernized the thin slab plant in Berkeley implementing induction technology SMS group has successfully completed the modernization of the thin slab plant at Nucor 6WHHO LQ %HUNHOH\ 6RXWK &DUROLQD 86$ 7KH IRFXV RI WKH SURMHFW ZDV RQ KLJKHU Ć&#x192;H[LELOLW\ lower energy input and wider product range.

Nucor Steel has successfully complet- der oscillation system, wider segments, slabs right before they run into the ed the modernization of the CSPÂŽ plant and a new bending and straightening rolling mill. This enables Nucor Steel (compact strip production) at the steel unit. Thanks to the implementation of to achieve greater reductions per pass works in Berkeley, South Carolina, USA. the liquid core reduction (LCR 3) mod- and expand its mix of products in the The new modernization concept with ule in the containment zone, the thick- thin gage range.

An additional benefit of the inducinductive heating systems between the ness of the thin slabs can be infinitely thin slab reheating furnace and hot roll- adjusted between 48 and 63 millimetres. tive heating systems is the fact that ing mill was implemented for the first time.

The objective of the modernization was to upgrade the double-strand CSPÂŽ plant, supplied by SMS group in 1996, to the grown requirements of the market. With an increased final strip width of 1,880 millimeters (formerly 1,680 millimetres), Nucor Steel now operates one of the widest CSPÂŽ plants in the world. At Nucor, SMS group for the first time implemented a new modernization concept designed to expand the product range and Graphics of the entry section of the thin slab rolling mill showing the induction heating units reduce energy consumpSMS group added a seventh finish- the energy consumption of the whole tion at the same time.

The implemented measures com- ing stand to the hot strip mill. The new plant can be even further reduced. By prised the revamp of one of the two stand features CVCÂŽ plus technology, flexibly adjusting the thin slab temthin slab casters, the extension of the like the stands F1 through F6. The CSPÂŽ perature prior to rolling, the furnace hot rolling mill, renewal of the elec- rolling mill also received a new X-PactÂŽ temperature can now be lowered to trical and automation systems and, as level-2 automation system including a level suitable for rolling the major a premiere, the installation of an in- profile, contour and flatness control part of the steel grades and strip gagduction heating system from SMS Elo- systems as well as a cooling model. es without compromising process staWith the installation of an induc- bility or the product quality. For all therm upstream of the hot strip mill.

The continuous thin slab caster was tion heating system between the re- strips requiring a higher entry temfitted with new molds, a new four-cylin- heating furnace and the hot rolling perature, the inductive heating sysmill, SMS group implemented a fu- tems will be there to provide the exture-oriented modernization concept tra heating. By means of this concept, at Nucor Steel. By means of the induc- it is possible to achieve both the exSMS group, DĂźsseldorf, Germany tion heating units supplied by SMS Elo- tensive product range typical of the Contact: www.sms-group.com therm, it is now possible to increase as CSPÂŽ technology and marked savings E-mail: communications@sms-group.com required the temperature of the thin on energy.

MPT International 1 / 2016

www.vip-kommunikation.de

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38

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

ABS starts up Rotoforge plant EQODKPKPI VJG DGPGĆ&#x201A;VU QH HQTIKPI and rolling ABS â&#x20AC;&#x201C; Acciaierie Bertoli Safau presents the new Rotoforge plant, an innovative rolling-forging technology designed and realized

by Danieli. Rotoforge technology is an alternative to forging while SUHVHUYLQJ WKH EHQHĆ&#x201A;WV RI UROOLQJ It may become a breakthrough WHFKQRORJ\ IRU KLJKO\ HIĆ&#x201A;FLHQW production of special quality long products.

Supplying superior quality products in the shortest possible time with a greater degree of flexibility and efficiency to better fulfil market requirements â&#x20AC;&#x201C; it is with this intention that ABS â&#x20AC;&#x201C; Acciaierie Bertoli Safau has introduced the Rotoforge plant, a unique, innovative technology that will provide the Italian steelmaker with a wider range of products. The new plant was inaugurated on Saturday, 17 October 2015 in the presence of the Italian Prime Minister, Matteo Renzi, the President of the Region of Friuli, Debora Serracchiani, and the top management of ABS and Danieli. â&#x20AC;&#x153;This is a highly innovative plant based on a new concept, developed and designed at Danieli and manufactured at ABS,â&#x20AC;? explains Alessandro Trivillin, Chief Executive Officer of ABS. â&#x20AC;&#x153;It is the first of its kind in the world. Since 1988, ABS has been Danieliâ&#x20AC;&#x2122;s steelmaking division, a synergy that guarantees cutting-edge technologies and production systems.â&#x20AC;?

&CPKGNK % 1HĆ&#x201A;EKPG /GEECPKEJG S.p.A., Buttrio, Italy %QPVCEV YYY FCPKGNK EQO #$5 s #EEKCKGTKG $GTVQNK 5CHCW 2Q\\WQNQ FGN (TKWNK +VCN[ %QPVCEV YYY CDUCEEKCK KV

MPT International 1 / 2016

Rotoforge plant during commissioning

HOT ROLLING

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39

Inauguration of the new Rotoforge plant in the presence of Carla de Colle (ABS Chairwoman), Debora Serracchiani (Governor of Friuli region), Matteo Renzi (Prime Minister of Italy), Nicola Turello (Major of Pozzuolo del Friuli), Gianpietro Benedetti (Danieli Chairman and CEO), Alessandro Trivillin (ABS CEO) (from left)

The products manufactured using the new Rotoforge plant will represent the evolution and combination of the two traditional hot forming techniques for special quality long products, namely rolling and forging, while expanding the range of products offered by ABS. The target markets for the Rotoforge products are large mechanical components, earthmoving machinery, trucks and the energy sector.

“The quality of our service and the fulfilment of our customers’ requirements are our primary objectives,” continues Trivillin. “In this respect innovation is fundamental. In the past six years we have invested 408 million euros in revamping existing plants and in starting up the Rotoforge plant, in order to broaden our product range with respect to size and type, streamline our plants, diversify and become more competitive and increase ABS’ production efficiency.”

# DTGCMVJTQWIJ KPPQXCVKQP KP JGCX[ 5$3 RTQFWEVKQP NGCFKPI VQ UWRGTKQT RTQFWEV EJCTCEVGTKUVKEU Danieli Rotoforge is an alternative solution to the production of high quality material via forging, with the efficiency and profitability of a rolling mill. The plant provides the same internal quality achievable by forging, thanks to the features of the new design Rotoforge heavy-duty stand which is capable of impressing the same strain towards the centre of the material.

Rotoforge offers remarkable advantages, such as: ▪ high internal quality, comparable to that of a forged product, ▪ improved size quality and tolerances, ▪ high reduction ratio (>1:3) for rounds up to dia. 500 mm or equivalent squares, ▪ high productivity,

▪ short lead time and fast response to the market demand.

As a result of the high drafting per pass, Rotoforged material features small grain sizes and very low soundness (FBH < 2 mm), while the rolling process ensures excellent surface characteristics, high productivity and hence dramatic reduction of transformation costs (no additional turning is required).

In addition, ABS benefits from feeding the Rotoforge with high quality large dia. (850 mm) blooms produced by the nearby continuous casting machine No. 3. The largest of its kind and a benchmark, that caster is highly competitive in terms of quality, offers an enhanced production range including ternary grades, while assuring high productivity and metallic yield. Hence, the Rotoforge is considered a real breakthrough innovation bringing ABS one step ahead of competitors.

MPT International 1 / 2016

The HMI displays each individual coil and the statuses of all plant components

Rule-based automation of a hot coil transfer system Thyssenkrupp Steel has renewed its coil transfer system as part of a 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 solution TWMS/metals of 3tn. New functionalities have been added to the coil transfer system WDLORULQJ LW WR WKH VSHFLĆ&#x201A;F UHTXLUHPHQWV DQG FRQGLWLRQV LQ WKH ZRUNV The hot strip mill in Duisburg-Beeckerwerth is the biggest one of German number one steel producer Thyssenkrupp Steel Europe (TKSE). The plant has an annual capacity of around 6 million tons. In recent years, the hot strip mill has been modernized with focus on better capabilities to produce high strength

Sebastian Weber, Thyssenkrupp Steel, Duisburg, Germany; Thomas Niepmann, 3tn Industriesoftware GmbH, Holzwickede, Germany Contact: www.3tn.de E-Mail: niepmann@3tn.de

MPT International 1 / 2016

steels. Within the scope of such modernization TKSE has revamped its coil handling management system.

The previous coil handling management system consisted of a material tracking and warehouse management system, whilst the input for the handling processes used to be supplied by a second system operating in parallel. TKSE was looking for a more modern solution that could combine both functions within one system. In February 2014, TKSE awarded 3tn the order for the supply of the new system.

3tn is a leading provider of warehouse management solutions for the metals industry. The company had already

gathered experience with its rulebased TWMS/metals warehouse management system for slab and coil storage operations.

Harmonize, simplify and automate the process The request was that the new coil handling management system should cover the entire handling operations from the recoiler down to the hot coil store. TKSE wanted to avoid reprogramming in case any operating procedures or coil handling steps changed. Furthermore, the objective was to implement a solution that would allow the

AUTOMATION production staff to adapt the system to current customer requirements without any involvement of IT staff. The aim was to harmonize, simplify and automate as much as possible the process of entering the coil handling instructions for the packing, marking, sampling and inspecting devices.

Because good experience with rulebased systems had been made in other works areas, the idea was born to also have a rule-based system installed for the management of the processes downstream of the hot strip mill. The advantage of such a system would be the possibility to customize the system via what is called the “technological editor” without having to change the source code of the software. It would be possible to freely define many of the rules and parameters by using a simple syntax, i.e. a simplified programming language.

Rules automatically generate the handling data for each individual coil The new automation system manages all coil handling processes downstream of the hot strip mill, starting as soon as a coil is being removed from the recoiler and continuing all the way down to when the coil is being deposited in the hot coil store. 3tn has implemented specific rule books for sampling, coil tying and coil weighing.

Based on these rules and the characteristics of each coil, the process automation system decides which coil handling route has to be taken – for example, how it will be tied and marked.

The system also determines whether a coil has to undergo an additional inspection, and if so which measures that inspection will have to include. In this way, the process automation system generates the input data for the subordinated systems, namely the tying and marking machines and the inspection line. The standard procedure is that the process automation system generates the input for the inspection and tying machines based on material data which the production control system extracts from its database. The programme thus relieves the operator from routine tasks. However, the operator may at any time intervene in the process via the 3D HMI and overwrite the data, for example, in the event of extraordinary operating conditions.

Helpful visualizations The process automation system visualizes the handling operations between the recoiler and the hot coil store in 3D views. Additionally, all statuses of the subordinated systems, for example, the inspection equipment, are displayed on the control pulpit. The coil handling activities can be viewed from preset or freely selectable perspectives.

The visualization is extremely helpful for the operators as the modernized plant places the operators in the situation that some of the equipment has become somewhat concealed. In addition to fixed preset views optimized for specific workplaces, at other workplaces the views are freely configurable. While one view may show the inspection plant, another may focus on a coil-specific activity, for example, at the tying machine. 3tn has also incorporated status charts for the machines, indicating fault messages or the necessity to refill a tying machine. Also video images may be integrated. This feature allows the operator to compare the visualized processes on the monitor with video images taken from the vid-

‹‹‹

41

coil will have to be tied, whether it will have to be sent directly to the coil conveyor or whether it will first have to be transferred to the inspection plant by the cross transfer car.

The inspection plant receives all the information needed for the inspection of a specific coil. The samples for the visual surface inspection and for checking the strip shape will be automatically cut according to the information received. When all inspection activities have been completed, the cross transfer car will take the coil back to the coil conveyor and feed it into the material flow. The inspection results will be sent to the process automation system and displayed on the control monitor. In addition to the automatically transmitted results, the operator can enter further quality-relevant information outside the scope of the system such as complementary inspection data or photos.

Based on the received information, the process automation system also determines which activities have to be performed while the coil is on the conveyor. Then the process automation system

Free view of the overall plant without status information

eo streams recorded by physical cameras installed in the plant.

Clear view of activities Whenever a strip is being recoiled, the material tracking and presetting system (MTP) sends the coil data to the process automation system. The latter sends the coil handling information to the individual machines via the MTP. The information may detail how the

sends the data to the marking robot. As the last step, the coils are transferred through a tunnel and taken to the hot coil store by a second conveyor.

As part of the modernization, TKSE also implemented a high-availability cluster together with a new operating system. 3tn installed the software in virtual machines which had been provided by TKSE in a pre-installed state.

The client systems interacting with the operators consist of ThinClients MPT International 1 / 2016

42

››› AUTOMATION

which, if necessary, can be exchanged in virtually no time.

3tn also implemented a mobile solution for tablet PCs which may be used to enter inspection results or view storage and coil data.

The process automation system for the coil handling was installed and commissioned during a one-week stoppage of the hot strip mill. On the first day after the rolling mill had been restarted, the new system actively managed the marking and coil discharge operations. Nine days later, all functions of the process automation system were up and running. So far,

there have not been any system failures or other unplanned downtimes.

High operator acceptance The rule books have made the entry of coil data a largely automated process.

This relieves operators from the need to handle each coil individually. In case of rules being modified, the production staff is able to do so without having the IT department involved.

From the beginning, acceptance amongst the operators has been very high. They appreciate that all coil handling operations are very realistically

View of the handling area managed by the system

Düsseldorf | 4 – 8 April | Hall 17 | Booth A22

MEET US AT WIRE 2016

and clearly visualized, even those that cannot directly be seen due to the layout of the plant. Certain visualization elements of PFSBAT can also be controlled via PLT keys on the operator pulpit. This allows for simple commands, such as the switching between different views performed without a mouse or keyboard.

About TWMS/metals The process automation system of the coil handling at the TKSE hot strip mill is a project-specific functional enhancement of the standard version of the technical warehouse management system – TWMS/metals – offered by 3tn. The standard programme manages and visualizes handling and storage activities in the metals industry from the continuous caster through to the dispatch of the finished products and optimizes the use of storage capacities across various warehouses.

TWMS/metals supports plant operators in optimizing the storage of slabs, billets, sheets or coils, while maximizing the utilization of the handling equipment, such as cranes or cross-transfer cars.

It was developed specifically for the metals industry. In one direction, the system communicates with enterprise resource planning system (ERP) and manufacturing execution system (MES) and, in the other direction, with the basic automation system and the sensor equipment.

Highest quality for precision strip Four column 20-high rolling mill

The

technological

devel-

nowadays up to 1,550 mm strip

Highest quality

opment in the industry places

width, because of systematic re-

Highest flexibility

ever

on

search and continiously devel-

Easy to operate

cold rolled strip and thus on

opment, beginning in 1958 with

Investment for the future

the

equipment.

the ďŹ rst mill stand in four column

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ANDRITZ Sundwig is able to

design of the world wide well

produce

known 20-high technology.

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demands mill

precision

ANDRITZ Sundwig GmbH Stephanopeler Strasse 22 58675 Hemer, Germany Phone: +49 (2372) 540 sundwig_welcome@andritz.com

strips

www.andritz.com

44

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş AUTOMATION

Turning knowledge into action to achieve consistent strip quality and increased production GHĆ&#x201A;EKGPE[ The Operation, Process Expert System developed by CMI bridges the knowing-doing JDS LQ VWHHO VWULS SURFHVVLQJ Ĺ? WKH JDS EHWZHHQ WKH DYDLODEOH GDWD DQG WKH GHĆ&#x201A;QLWLRQ RI ZKDW LV WR EH GRQH E\ WKH RSHUDWRU Ĺ? EDVHG RQ DQ DQDO\VLV RI DOO DYDLODEOH SURFHVV DQG coil data. This is to determine the process and quality conditions and provide operational DGYLFH DQG JXLGDQFH ERWK LQ WHUPV RI WKH VHOHFWLRQ RI VXLWDEOH RSHUDWLRQDO SDUDPHWHUV and production processes.

Example of a model screen display

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AUTOMATION When being faced with multiple challenges, it may be complicated for the operator to choose the right equipment or process. For a successful conclusion of a project, steel producers need to find the optimum balance between the technical performance of their products and the production and operating costs. To make the right decision, they need to be able to rely on sound and versatile technical and process skills.

Michel Dubois, José Callegari, CMI Industry Metals, Seraing, Belgium Contact: www.cmigroupe.com E-mail: anja.roxin@cmigroupe.com

Consistent product quality and increased production performance in strip processing Quality control systems in steelmaking plants are often set up to simply monitor key variables that affect the production process in real time. Any deviation from the acceptable limits will be indicative of quality issues, but the solution to solve them is not always at hand. This is precisely where CMI’s OPExSTM (Operation, Process Expert System) comes into play, as it closes the gap between the available data and the definition of what is to be done by the operator, based on an analysis of all process and coil data. This is to determine the process and quality con-

‹‹‹

45

ditions and provide operational advice and guidance, both in terms of the selection of suitable operational parameters and production processes.

As such OPExSTM provides customized assistance needed to make quality decisions. The line model functions as a control chart that monitors process stability and gives signals when the charted parameter shows an unpredicted drift. It condenses all process data on a single wide-screen. This procedure increases the speed of problem identification and intervention.

This helps the steelmaker to determine whether a produced coil that may not be compliant with the criteria set for a specific production run or customer would still meet the criteria for another

Recorded process parameters by plant sections

%QKN XCNKFCVKQP EJCTV MPT International 1 / 2016

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş AUTOMATION

customer. This coil grading process automatically performed by the OPExSTM software drastically reduces the number of rejected coils, and thus the associated costs.

For example, a yield increase from 90% to 93% for a hot-dip galvanizing line with an annual capacity of 450,000 t represents a gain of approximately 1.35 million euros, based on a downgrade of 100 euros per tonne of non-prime product, or approx. 15% in comparison to the prime product pricing. This impressively shows the potential provided by the OPExSTM expert system.

The core of the CMI OPExSTM software is the expert know-how that is linked online to the process control system. As such, quality data from the line are recorded, stored and analyzed by the OPExSTM system, allowing for easy and visual best practice sharing, improved utilization of equipment, and eventually reduced scrap and increased yield. Also procedures like the certification or implementation of new steel grades are speeded up.

The display on the left hand side of the screen provides an overall view of the grading status of all produced coils, using specific markers indicating whether or not the current line status has met the required quality.

A traffic light report helps the operator to visually identify anomalies by coils produced and process sections (green = in line/ orange = partially out of line/ red = out of line). Additionally, the data displayed under the line model details the different process parameters in each process section of the line.

It thus helps to identify at which point the data is outside the defined criteria settings and where exactly the anomaly occurred. The criteria setting can be made up of either fixed criteria or tolerance ranges.

The expert system While the condition-based operational advice is provided via the software, an expert system defines what action to take as well as where and when to take it. Such advice is transmitted via a pop-up window that opens when the operator clicks on the process parameter that is out of range.

All data and instructive guidance are displayed as corrective action to be takMPT International 1 / 2016

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en, additional checks to be conducted, a library of reference documents or similar events for comparison. The individual pop-up windows are divided into three tabs: expert advice, data and actions. The expert advice indicates what the operator is supposed to do and helps him understand the underlying process behaviour. It prioritizes and selects which actions are to be performed in order to restore the nominal quality of the line. The expert advice can be provided as a list of actions by equipment and/or a flow chart indicating the methodology to follow for trouble shooting and problem solving.

It may also include supporting documents, such as 3D drawings making it easier for the operator to visualize the specific equipment where the problem has been detected. Also photos, e.g. related to quality defects, or other instructive documents such as standard operating procedures may be included.

Under the data tab, detailed recorded data related to the out-of-line parameter are provided and, under the action tab, the operator acknowledges which actions have been taken. The system also provides a weekly analysis of suggested actions versus actions taken. The operator may enter required or

AUTOMATION

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

47

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voluntary input in the form of observations or recommendations.

As the pop-up window and the related advice is available within minutes after the coil has been produced, the operators are guided and supported most effectively in their day-to-day activities. Additionally, the OPExSTM software provides a direct link to the processing data coming from the line and access via the web for fast and customized intervention by external experts if needed.

Another important advantage provided by the OPExSTM system is its capability of correlating recurrent incidents that impact quality. Such a correlation is vital to anticipate problems. Orange traffic lights highlighting sections that are not fully consistent with the line parameters over a certain period of time indicate where to take corrective actions in order to prevent anomalies.

As such, OPExSTM also functions as an online statistical process control (SPC) method. Via its continuous monitoring and process analysis it provides just-intime maintenance planning. Also, the recorded process parameters can be displayed by process section and synchronized per running meter of coil.

This helps to define when exactly a non-conformity occurred and reduces the amount of unusable strip, leading to decreased scrap and increased yield.

ple, it is possible to define the exact percentage up to which an unintended slow-down of the line, e.g. due to problems at the entry or exit section, does not affect the final strip quality as defined by the specific set of criteria. This functional feature increases the yield.

OPExSTM not only allows to run the line under the criteria set by the CMI experts or the steelmaker. The software can also be easily and quickly updated to reflect any other specifications, as for example those related to the final customersâ&#x20AC;&#x2122; (e.g. car makers) quality needs.

It thus allows to adjust the lineâ&#x20AC;&#x2122;s quality specifications as well as the coil validation and adjustment based on various final customersâ&#x20AC;&#x2122; quality needs and the related grading rules. As such, the same processing line can make products in accordance with the specifications and needs of various final customers.

CMIâ&#x20AC;&#x2122;s OPExSTM solution also allows to translate characteristics of a final product into process and product parameters, process steps and tolerances.

It also allows to include trial runs in case of a deviation from the process and production path defined by the CMI experts. This may be applicable in cases where a steelmaker is looking for advice of how to produce a required steel grade that he has not produced so far.

Conclusions Coil validation Based on defined criteria the system also helps to set the mechanical and chemical limits by product. For exam-

OPExSTM allows to optimize the line settings based on the analysis of data coming from processed coils, upstream data analysis and event reporting. It also provides line operators with con-

text information as to the customerâ&#x20AC;&#x2122;s processing specifications and to specifications set by final customers. The corrective or preventive action to be taken is identified based on this analysis and available within minutes after the coil has been processed. Markers indicate the origin of the problem to be solved and specify any required manual intervention. Additionally, the system displays similar events for comparison. It also has the capacity to learn, i.e. it continuously complements its database with knowledge acquired during daily strip processing operations.

In addition to providing the necessary context information for operators, the benefits of such a comprehensive know-how package include features such as the display of similar cases for comparison and on-site know-how assistance. OPExSTM also provides the necessary expertise and support to secure audits and certifications, including automotive related certification.

By speeding up procedures, such as automotive certification, the system makes it possible to reduce the time until a prime-quality can be produced. In case of a hot-dip galvanizing line producing 450,000 t/year and a selling price of 700 euros/t, shortening the certification process by only one month allows an additional 4,000 t to be produced, meaning an additional turnover of approx. 400,000 euros for the steelmaker.

OPExSTM is not only useful for and easy to implement in single-process lines, but also in lines combining several processes like pickling and galvanizing or annealing and galvanizing.

While the complexity of single-process lines is already very high, the complexity of combi-processing lines is an even bigger issue. The latter include many different items of equipment and various processes all of which must be precisely controlled to ensure that the final products meet the required quality. OPExSTM helps to effectively manage this complexity and increases the plantsâ&#x20AC;&#x2122; flexibility in making products according to market requirements at the lowest possible capital expenditure.

MPT International 1 / 2016

48

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

Tinplate manufacturer Thyssenkrupp Rasselstein invests KP GHĆ&#x201A;EKGPE[ Thyssenkrupp Rasselstein is carrying out extensive modernization projects to increase WKH HIĆ&#x201A;FLHQF\ RI LWV SURGXFWLRQ OLQHV 7KH SURMHFWV FRQFHUQ WZR FROG UROOLQJ PLOOV D FRQWLQXRXV DQQHDOLQJ OLQH DQG D SLFNOLQJ OLQH Thyssenkrupp Rasselstein GmbH has a history stretching back more than 250 years. The Germany-based company is today a subsidiary of Thyssenkrupp Steel Europe. It produces tin-coated and chromium-coated blackplate (cold-rolled steel in thicknesses of 0.100 to 0.499 mm) at the worldâ&#x20AC;&#x2122;s biggest packaging steel production site. Provided with or without organic coating (paint, film), the material is suitable for diverse packaging solutions.

Thyssenkrupp Rasselstein is carrying out extensive modernization projects to increase the efficiency of its production lines and improve its competitive position. The projects concern three central units operated by the tinplate manufacturer: one of its two cold rolling mills, a continuous annealing line and a pickling line. To allow the work to be carried out the units concerned were temporarily shut down in the fourth quarter 2015. At times, several hundred specialists from external contractors together with Rasselstein employees were busy around the clock carrying out the work. The modernization efforts further strengthen Thyssenkrupp Rasselstein and secure the sustainability of the Andernach plant. In making this investment, parent company Thyssenkrupp Steel Europe has underlined its commitment to highly attractive specialized areas of application like the packaging steel sector.

Thyssenkrupp Rasselstein, Andernach, Germany Contact: www.thyssenkrupp-rasselstein.com E-mail: volker.lauterjung@thyssenkrupp.com

MPT International 1 / 2016

After over 50 years of operation, the first of the two cold rolling mills was fitted with a completely new cooling water circuit. This involved the construction of two new buildings and a cooling system as well as the installation of a new technical infrastructure.

Together with investments in previous years it means that tandem mill 1 was practically fully refurbished.

In operation for around 30 years, continuous annealing furnace 4, a further core unit, was equipped with a new power supply system. A large part of the work including the installation of a new distribution station and the preparation of the connections was already carried out in advance while production continued.

In addition to the electrical revamp, a number of mechanical modifications have increased the lineâ&#x20AC;&#x2122;s capacity by 60,000 to around 430,000 t/year. At the same time, the switch from DC to three-phase power has contributed to lowering the lineâ&#x20AC;&#x2122;s energy consumption.

The third major project, increasing the capacity of the pickling line, was a consequence of the transfer of production from the close by Neuwied production site. As well as supplying the sheet mill, the pickling line in Neuwied provided around 200,000 t of pickled hot-rolled strip for the production of packaging steel in Andernach.

The rebuild of the Andernach pickling line will enable it to meet all the plantâ&#x20AC;&#x2122;s needs on its own. While Neuwied employees gradually began preparing from 2013 for new roles in the Andernach plant, initial measures were carried out to increase the performance of the pickling line. After the rebuild will be completed and the line will be restarted thereafter, the Neuwied pickling line will be closed.

â&#x20AC;&#x153;These projects executed simultaneously have involved a total investment of around 40 million euros,â&#x20AC;? says Oliver Hoffmann, COO of Thyssenkrupp Rasselstein. â&#x20AC;&#x153;Thyssenkrupp is strengthening its packaging steel business and securing the sustainability of the Andernach plant, the worldâ&#x20AC;&#x2122;s biggest site manufacturing this quality product,â&#x20AC;? he adds. The concentration of tinplate business at the Andernach plant was part of the Thyssenkrupp Steel Europe optimization programme â&#x20AC;&#x153;Best-in-Class Reloadedâ&#x20AC;? and involved the closure of the sheet mill in Neuwied with the transfer of the pickling operation. The majority of the around 400 Neuwied employees found jobs in Andernach, while socially acceptable solutions were found for the others. â&#x20AC;&#x153;We are proud that thanks to the joint efforts of all employees we have succeeded in securing an attractive future in the company for our colleagues in Neuwied,â&#x20AC;? says Hoffmann.

Raw material for Thyssenkrupp Rasselstein comes from Duisburg The starting material for tinplate production is hot-rolled steel strip.

Thyssenkrupp Rasselstein obtains it in coils weighing between six and 28 t from Thyssenkrupp Steel Europe in Duisburg. The hot-rolled strip is 1.5 to 3.8 mm thick. Processing at Thyssenkrupp Rasselstein begins in the continuous pickling line, where the scale produced during hot rolling is removed.

Annealing takes place by passing the strip at high speed through a system of annealing furnaces. Thyssenkrupp Rasselstein has three continuous annealing lines. The entire process including annealing and cooling takes only a few minutes. The furnaces are

Continuous quality control â&#x20AC;&#x201C; here during

Control pulpit of a strip processing line at TK Rasselstein

cutting to size

specially designed to process packaging steel. Precise temperature control gives the steel exactly the mechanical properties required by the productâ&#x20AC;&#x2122;s end use.

Thyssenkrupp Rasselstein is one of Europeâ&#x20AC;&#x2122;s three biggest packaging steel producers. It currently employs around 2,400 people and produces

roughly 1.5 million t/year of packaging steel, serving 400 customers in 80 countries. More than 90% of the material produced by Thyssenkrupp Rasselstein is used in the packaging sector, e.g. for the packaging of food, drinks and chemical/technical products such as aerosol cans or paint tins. The material is ideal for these uses. Tinplate is a

highly efficient, strong and safe packaging material. It provides 100-percent product protection against light and oxygen. It is also particularly eco-friendly and the most recycled material in Europe. Tinplate can be recycled endlessly with no loss of quality, making it a thoroughly modern packaging material.

framag Industrieanlagenbau GmbH /FVLJSDIOFS 4USBÂ&#x2022;F " 'SBOLFOCVSH 5FM

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50

››› TECHNICAL INNOVATIONS

Extended pyrometer range MEASURING TECHNOLOGY Two new products have recently been added to the SPOT pyrometer family offered by Ametek Land. These pyrometers provide continuous online temperature measurements within the range 50°C to 1,800°C. The latest additions incorporate advanced technologies and features that are combined in one easy-to-use temperature sensor.

SPOT R210 is an innovative multimode pyrometer operating within the range 1,250°C to 11,000°C. It features five selectable measurement modes, making it completely configurable to a wide range of different process applications: Mono 1 (2.1 μm short wavelength), Mono 2 (2.4 μm short wavelength), Ratio/2 Colour (both detectors used in a ratio mode), Duo (uses Mono 2 at low temperatures and Mono 1 at higher temperatures) and Multi (uses Mono 2 at low temperatures and seamlessly transfers to Ratio mode at higher temperatures).

The second addition to the product family is the SPOT M210, a single wavelength pyrometer utilizing short wavelength 2.3 μm spectral response and providing high accuracy readings within the range of 500°C to 11,000°C. It is ideal for low and uncertain emissivity metals measurements.

All the pyrometers are designed for simple installation, configuration and flexible design. The processing functions are integrated into a single sensor. As standard, each SPOT pyrometer has multiple interfaces. In addition, precision mirror optics eliminate chromatic aberrations. A popular

Multimode pyrometer

feature is the built-in web server, enabling the sensor to be viewed and configured from any standard web browser over an Ethernet connection. SPOT pyrometers feature an integrated keypad and screen, a live video view of the scene and motorized focusing between 600 mm and infinity.

Contact: www.ametek-land.com

Radio-based solutions for optimized logistics and automation processes SPECIAL EQUIPMENT An expert in sensor systems for distance measurement, position detection and data transmission, Symeo offers solutions for reliable collision avoidance for cranes, vehicles and other moving objects. The industry proven systems are based on the patented wireless

Visit us at hall 7A booth C14 Ideas do not care where they come from. Because only when intelligence and precision, craftsmanship and design work together, an optimum concept can be developed with our know-how DQG SHUIHFWO\ LQ OLQH ZLWK \RXU VSHFL¿F requirements.

LPR® local positioning radar. They are robust and wearfree, and ideally suited for use in dirty, dusty and hot environments. By using an own wireless channel, LPR® measures distances of up to 1,000 m independent of adjacent WiFi networks and tracks crane and vehicle movements in-

We supply: • Strip processing lines • Rolling mill technology • Slitting lines • Un-/Recoilers • Strip edge trimming lines • Coil handling systems • Coiler drums and heads • Packaging lines • Cut-to-length lines

...IF PRECISION IS REQUESTED hpl-Neugnadenfelder Maschinenfabrik GmbH Ň Spangenbergstraße 20 ŇD-49824 Ringe / Neugnadenfeld Fon + 0 (49) 5944 9301 - 0Ň info@hpl-group.de Ň www.hpl-group.de MPT International 1 / 2016

TECHNICAL INNOVATIONS doors and outdoors down to a few centimetres. In the outdoor area, the radio-based position detection can be optionally combined with satellite-based positioning. The solutions are suited for all types of cranes and vehicles.

The new wireless system LPR®-1D24 not only measures long distances of up to 1,000 metres, but also transmits the positional data and, optionally, additional information such as the payload or loading status over the LPR®’s own wireless

‹‹‹

51

channel. Connecting cranes and vehicles by a separate WiFi network can thus be avoided. The system operates in the international, license-free 24 GHz ISM band, which eliminates potential interference with WiFi networks. Multiple antennas incorporated in the device provide redundant measurement signals for a high level of measurement accuracy.

Contact: www.symeo.com

Software solution for plant engineering and plant management INFORMATION TECHNOLOGY Thyssenkrupp Industrial Solutions has opted to use the Siemens Comos plant engineering and plant management software solution throughout the company as part of the further integration of its global plant construction business. The Process Technologies unit (formerly Uhde) has already been using Comos since 1997.

Comos plant engineering and plant management software encompasses the process engineering of components and plants all the way through to complete automation including operations relevant to electrical engineering, measurement and control. It enables the user to achieve higher plant efficiency through all phases of the lifecycle. The uniform

Process optimization towards Industry 4.0 AUTOMATION The topic of Industry 4.0 presents the steel sector with new opportunities and new challenges. Process optimization has been an issue in the steel industry for a long time. It started with plant automation and has been increasingly complemented with information and telecommunication technologies. Today also aspects like cost-effective production, greater flexibility, constant quality improvements and new product development play a more and more important role, with new digital monitoring solutions being required to collect, analyze and link large amounts of different data. BM Group is a pool of brands with one common objective, namely optimizing production processes and product quality in the steel industry, while improving safety at work and environmental sustainability. Since 2007, BM has invested heavily in research and development. Combined with a profound production know-how, these investments have allowed BM to develop complete customer-oriented packages including system integration, intelligent machines and energy conservation for newly built and existing steel plants, including those with limited investment potential. BM has worked out a specific low-cost “Plug & Play”-based range of solutions to make innovation accessible to all plant operators.

data platform of the Comos software solution gives plant designers, operators and installers a seamless flow of project-relevant data across all company levels and project phases. Workflows become more efficient, productivity and quality in engineering are raised. Plant data is always kept up to date and consistent throughout the entire lifecycle. Integrated engineering reduces sources of error as there are fewer interfaces between the various technical subsystems. Jobs such as process engineering or design of the electrical engineering can be carried out in parallel with automation engineering.

Contact: www.siemens.com

Technology at the cutting edge

BRAUN high-performance abrasive cut-off machine

Bar end quality after cutting

Ground billet surfaces

BRAUN high-pressure grinding machines

• High-performance abrasive cut-off machines (up to 2000 mm cutting wheel diameter and above) • High-pressure grinding machines • Flexible and innovative solutions for fully-automated turn-key-facilities • Consulting engineering and life cycle service support

MASCHINENFABRIK

Contact: www.bmgroup.com

BRAUN Innovations vations for Steel

www.braun.at

A-4840 Vöcklabruck, Austria, Tel. +43(0)7672-72463, E-mail: office@braun.at

MPT International 1 / 2016

52

››› TECHNICAL INNOVATIONS

Micromill technology for aluminium sheet production ALUMINIUM As part of a collaboration recently set out in a letter of intent, Alcoa will grant Danieli exclusive rights to sell Alcoa’s Micromill equipment. In addition, the companies will work together to license the Micromill alloys and process technology to potential customers around the world, initially targeting Europe, South America, and Southeast Asia. The Alcoa Micromill turns molten metal into coil in just 20 minutes. The partnership with Danieli is intended to move this technology from pilot plant to full-scale production. The Micromill process dramatically changes the microstructure of the metal, producing an aluminium alloy that has 40% greater formability and 30% greater strength than today’s automotive aluminium. Micromill material is expected to be twice as formable and at least 30% lighter than parts made from high-strength steel. The Micromill alloy has formability characteristics comparable to mild steels.

Contact: www.danieli.com

Thermal imaging camera for hot metals MEASURING EQUIPMENT Compact, short-wave and highly dynamic are the three key attributes that describe the latest thermal imaging camera launched by Micro-Epsilon. The

Thermal image camera of compact design

thermoIMAGER TIM M1 camera comes with a USB interface and the license-free TIMConnect software as standard. The camera is designed for a continuous temperature measuring range from 450°C to 1,800°C, image frequency of up to 1 kHz and different resolution/image frequency modes. The entire temperature measuring range can be used without any subranges. Therefore, in many applications there is no need for any measuring range switchovers, giving the camera a great deal of flexibility. The new thermoIMAGER TIM M1 camera is specifically designed for measurements on hot metals, graphite or ceramics. This is why it is primarily used in the metals processing industry, e.g. for temperature monitoring of hardening and forming processes. The highly dynamic CMOS detector allows a maximum resolution of 764 x 480 pixels at an image frequency of 32 Hz. For high-speed processes the camera can be switched to 72 x 56 pixels at 1,000 Hz .

Contact: www.micro-epsilon.com

Heavy-duty sawing machines for large workpieces CUTTING MACHINERY The heavy-duty bandsaws of the new series offered by Behringer are based on the modular design principle, allowing users from a wide range of sectors to machine cumbersome material quickly and precisely. Tolerances of just 0.1 mm per 100 mm MPT International 1 / 2016

If you talk about environment and industries, say HOK . ®

And it‘s okay.

Rheinbraun Brennstoff GmbH D-50416 Köln Tel.: +49 221-480-25386

www.hok.de

tuoba klat uoy fI tnemnorivne ,seirtsudni dna . KOH yas ®

And it‘s okay.

HOK® . Activated lignite. Flue gas adsorbent and catalyst.

First choice for gas cleaning in metallurgical processes.

Substantial reduction of dioxins and furans e.g. in electric steel mills and sintering plants.

Sometimes, a single, well-considered decision is all it takes: for the beneğt of your company, for the good of the environment.

The choice is HOK®. HOK® is OK.

Rheinbraun Brennstoff GmbH D-50416 Köln Tel.: +49 221-480-25386

www.hok.de

TECHNICAL INNOVATIONS cutting height are easily possible. The bandsaws come with precise saw feed provided by two ball screws with servo drive. The axes are electrically coupled and constant chip removal is guaranteed even at low feed rates.

Their gantry-type design of the Behringer bandsaws guarantees optimum stability during sawing, ensures quiet, smoothly running saw blades, prevents torsion and minimizes vibration. All band guiding components are made of vibration-damping grey cast iron. The open design improves access for saw blade changes or maintenance work.

A gantry machine, whose entire saw frame is moved on linear guides over the workpiece, requires the least space. It is predominantly suited for users who need to divide freeform forgings or large solid forged parts. The fixed support table is able to cope with extreme loads of over 100 t. The variants with table support are the ideal all-rounders in forges, rolling mills and gravity die casting foundries, and also for steel finishing applications as well as tool and mould making. Large bandsaws with roller conveyors are highly suitable for dividing large pipes or round and rectangular material. To enhance safety for the operating staff and ensure better alignment prior to cutting, the table version with T-slots has proven highly successful in practical application for many years. For large-diameter round material prism supports are used.

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55

Gantry bandsaw

Behringer’s LPS ring saw for large pipes opens up enormous savings potential for customers wishing to divide rings from pipe sections. The sawn rings are automatically deposited on a mandrel, so allowing unmanned operation over a period of several hours. This collecting fixture is designed to be fed forward to engage the cut rings in such a way that the offcuts cannot collide with the bandsaw blade.

After re-tooling, which takes only 15 minutes, the next pipe can be fed into the machine and the LPS can continue to operate automatically for several hours.

Contact: www.behringer.net

Revamped control DPTHOLDMS ENQ OQNÖKD stacker MODERNIZATION In collaboration with Acciaierie Venete, AIC has modernized the control and automation equipment of the profile stacker at the Mura facilities of Acciaierie Venete. AIC had already replaced the original Orsi PLC with a General Electric PLC in 2001. Within the framework of the most recent project, AIC replaced the GE 90-30 PLC with a new Rockwell Automation GuardLogix and supplied three new cabinets with Rockwell Automation PowerFlex755 drives, Nidec-ASI SPDM drives and direct motor starters to operate the roller table, hydraulic units, chains transfers, stackers, magnets and bundle discharge units. A key challenge of the project was to re-engineer the software in such a way that performance would be improved while maintaining all adjustments implemented over the years. The user interface was upgraded and complemented with a supervision function for the entire rolling mill. Special care was taken to maintain a structure familiar to the operators.

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MPT International 1 / 2016

56

››› TECHNICAL INNOVATIONS

Stainless steel slabs improve yield and cost DEÖBHDMBX HM GD@UX ENQFHMF FORGING Using stainless steel slabs instead of ingots in heavy forging provides significant cost and material savings. Forging an ingot requires more heating, work, energy and time than forming a slab. Due to the ingot’s narrow, tapering shape, the heads and tails must be discarded, resulting in wasted material. Outokumpu produces up to 300 mm thick stainless steel slabs. They are widely used in demanding applications such as flanges, power plant components, shipbuilding, marine parts and petrochemical pipes and parts.

Contact: www.outokumpu.com

Continuously cast stainless steel slabs of different thicknesses

Backlash-free shaft coupling with integrated clamping system SPECIAL EQUIPMENT KTR, in cooperation with the Swedish company ETP Transmission, developed a backlash-free servo coupling with an integrated ETP clamping system. The coupling can be mounted with just one screw in a matter of seconds. Traded under the name Rotex® GS P, the servo coupling is fully made of steel and particularly suitable for application in high-speed drives.

The clamping system consists of a double-walled, hardened steel sleeve filled with a pressurizing medium. The flange comprises a screw and a piston with a gasket for pressure generation.

As the screw is tightened radially, no axial space for assembly tools is required. The sleeve expands while generating a uniform surface pressure against the shaft and hub. This single-screw principle makes for continuously variable positioning of the coupling. The uniform stress distribution in the basic body of the hub results in an accurate concentricity of the ETP system while ensuring very smooth running.

KTR and ETP are currently working on a two-part type which is to allow for the use of other coupling types and materials.

Contact: www.ktr.com MPT International 1 / 2016

Coupling with clamping system

...precise

afe rolli s n nd

g!

a

160 years ...

We are strong in know-how, engineering and service of long product rolling mills and guide systems.

Branch Office:

Phone: +46 240 668500 Fax: +46 240 668501 E-mail: mh@morgardshammar.se www.morgardshammar.se

P.O. Box 101552 D-47715 KREFELD, Germany Phone: +49 2151 81290 Fax: +49 2151 611795 E-mail: office@mh-guides.de

www.mh-guides.com

www.gk-mas.de

Morgårdshammar AB SE-777 82 SMEDJEBACKEN, Sweden

Morgårdshammar AB Sales office Krefeld

58

››› TECHNICAL INNOVATIONS

Material handling L@BGHMDR ENQ FQDDMÖDKC project in Vietnam BULK MATERIAL HANDLING Schade Lagertechnik is supplying material handling machinery for the new steel mill built by Formosa Heavy Industries at Ha Tinh in Vietnam.

The supply includes a total of 21 machines: two trippers for the coal-burning power plant, four trippers for the steel mill, each with a capacity of 5,400 t/h, six semi-portal scrapers with a track distance of 40.7 m. At the steel mill, a portal scraper with a track distance of 48.5 m as well as two boom

Set-up of a stacker

stackers, with a capacity of 360 t/h and 3,200 t/h respectively, will be deployed. The project will be rounded off by six rail-bound conveyor wagons for mobile discharge machines.

At the first stage, 5 million t/year of steel will be produced at the new steel complex. It is planned to expand the capacity in two phases to 10 and 22 million t/year.

Contact: www.schade-lagertechnik.com

Millmate Strip Scanner. The leading edge technology.

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

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

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

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

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

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

Electromagnetic stirrer ELECTRIC STEELMAKING Being the result of over five years of research and development, ArcSave, ABB’s next generation electric arc furnace electromagnetic stirrer (EAF-EMS), reduces carry-over slag and shortens tap-to-tap time while strengthening slag-melt homogenization and increasing yield. It also contributes to safer operations. The ArcSave’s powerful electromagnetic stirring enhances the melting of large scrap items and makes stratification less significant due to forced convection. The melt velocity achieved is roughly ten times faster as compared to just having natural convection in the bath and results in less power-on time.

The temperature homogenization further helps manufacturers not only to obtain an exact tapping temperature for different grades of steel, but also allows smooth tapping without delays. The uniform melt gives producers a safer, more reliable EAF operation with a reduction in the number of scrap cave-ins, fewer instances of over tap temperature and carbon boiling out, as well as less un-molten big scrap. Increased steel yields, as well as savings in scrap cost and conversion are achieved, given that manufacturers can more readily attain a low carbon and oxygen mix, with a reduction in the slag’s iron oxide (FeO) content. Damage at the slag-line level is reduced due the stirrer’s ability to lessen superheating during power on, lower tapping temperatures, the decreased FeO content in the slag and the diminished oxygen in the steel.

EMS unit for electric arc furnaces

Contact: www.abb.com

© Utz Peter Greis, Düsseldorf

Cartoon

After discussing extensively the steel company´s current order situation against the background of global overcapacities, members of the supervisory board are paying a visit to the company´s recently commissioned plants.

MPT International 1 / 2016

60

››› LITERATURE SERVICE Cokemaking technology 6 pages, English

Coke Making Technology Next generation technologies

A brochure outlining the services provided by cokemaking specialists DMT. These include refurbishments of coke plants, planning and supply of coke oven gas cleaning equipment, development of products and process engineering solutions. The brochure also includes references of recent projects.

Contact: E-mail:

www.dmt.de kt@dmt.de

Water-cooled high-current cables 12 pages, English, German A product brochure presenting the range of water-cooled power transmission elements offered

by Druseidt Elektrotechnik. Detailed descriptions, technical drawings and technical data are provided of all the presented products, including single- and multi-conductor cables, hollowcore cables and water-cooled pipes for mains and medium frequency up to 10 kHz. Contact: E-mail:

www.druseidt.de info@druseidt.de

Products for ingot casting 4 pages, English A brochure outlining DWL-Wolf’s line of tools and products for ingot foundries. These include ramming forms for the relining of induction furnaces, casting and skimming ladles, slag binders, insert feeders, cover plates and lining chains.

Contact: E-mail:

www.dwl-wolf.de info@dwl-wolf.de

Universal encoder system 8 pages, English, German This product brochure features the U-One®-Safety universal encoder system offered by Hübner for monitoring the movements and positions of machine parts. The modular system provides a high degree of safety, a robust design, special cable glands for safe cable entry, secure wiring and highly reliable protection against the ingress of water and dust.

Contact: E-mail:

www.huebner-giessen.com info@huebner-giessen.com

Industrial furnaces 12 pages, English, German A brochure illustrating the wide range of furnace equipment supplied by Löcher. Specifically featured are different types of forging furnaces, annealing and hardening furnaces and heat treatment furnaces as well as the associated control, heating and burner systems.

Contact: E-mail:

MPT International 1 / 2016

www.loecher.de info@loecher.de

LITERATURE SERVICE

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61

Online monitoring of vacuum pumps 4 pages, English A brochure outlining the technical features and benefits of the SmartCheck vibration sensor developed by Oerlikon Leybold Vacuum for the monitoring of vacuum pumps in real time.

The system is capable of detecting damages and influences such as the formation of deposits, intake of particles, damage to rolling bearings, etc.

Contact: E-mail:

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

Coding and marking INDUSTRIAL CODING AND MARKING SOLUTIONS – MADE IN GERMANY

The World of Coding and Marking Product Overview

24 pages, English This comprehensive brochure describes in great detail the REA Jet industrial coding and marking systems offered by REA Elektronik, namely large-character and high-resolution ink jet printers, laser systems, spray mark systems, barcode verifiers as well as labelling technology.

Contact: E-mail:

www.rea-jet.com info@rea-jet.de

Measuring technology for melting and holding equipment 28 pages, English, German A brochure illustrating the systems and services offered by Saveway for furnace safety and lining diagnostics. The systems measure the remaining lining thickness and hot spots, monitor wear, leakage and coil-shunt insulation and provide temperature measurements.

Contact: E-mail:

www.saveway-germany.de saveway@saveway-germany.de

Pneumatic conveying, dosing and injection systems 36 pages, English Comprehensive information on pneumatic solutions for steel mills offered and implemented by Stein Injection Technology, for example, for EAF, EOF, converter, blast furnace and ladle processes. The brochure includes detailed descriptions of the systems and references of application.

Contact: E-mail:

www.sit-gmbh.net stein@sit-gmbh.net

Refractory systems 16 pages, English This brochure outlines the portfolio of shaped and unshaped refractory products and refractory services offered by Steuler-KCH. It covers all stages from refractory engineering and development, refractory production and installation through to refractory management.

Contact: E-mail:

www.steuler-kch.com info@steuler-kch.com

MPT International 1 / 2016

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››› IN THE NEXT ISSUE…

Ironmaking Efficient technologies to satisfy the limited sulphur and phosphorus content during hot metal pretreatment Limited availability of high quality ore as well as highly volatile prices of these selective qualities have inexorably influenced the conditions of ironmaking operations for some years, which has lead to a growing demand to pretreat the hot metal prior to further processing or ingot casting. Contents of sulphur, silicon, phosphorus, and carbon are typically adjusted at hot metal pretreatment or refining facilities. In this context, the prevailing technologies for hot metal pretreatment and refining, their constraints and their typical applications shall be discussed.

Steelmaking Modernized shaft arc furnace concept enables low conversion costs due to efficient preheating of scrap Is productivity the main goal driving the meltshop operator or is a cost oriented strategy the better one? The combination of both may be the most competitive and powerful tool. The 100-t electric arc furnace at Hellenic Halyvourgia in Greece is a practical example of the way from which a basic concept and idea was transformed to a mature, extremely flexible and highly efficient low-cost scrap recycling facility.

Quality assurance Pinhole detector for strip and foil: rear view cameras detect even the smallest holes at the strip processing line The tightness of material plays a critical role in the production of foil for the packaging industry. Even the smallest of pinholes can cause foodstuffs to spoil quickly and containers or spray cans to leak. The new pinhole detector localizes and classifies even the smallest of perforations reliably during the production of strip and foil. The basis of the system is formed by the patented camera cluster technology.

This preview may be subject to change.

Metallurgical Plant and Technology

Publishing Director: Frank Toscha Advertising Manager: Sigrid Klinge

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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

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MPT International 1 / 2016

Production Manager: Burkhard Starkulla e-mail burkhard.starkulla@stahleisen.de Production/Layout: Mike Reschke e-mail mike.reschke@stahleisen.de Advertising rate card No. 39 of 01.01.2016 Publication: Every 2 months Annual subscription rate (incl. postage): Germany: € 209.00 incl. 7% VAT Member states of the EU: subscribers with VAT ID number € 195.33; subscribers without VAT ID number € 209.00 Other countries: € 209.00 Single copy: € 42.00 Minimum subscription period 12 months.

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AS ONE We are stronger

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Creating the future of metals as one. primetals.com