MPT International 2/2016 (Apr)

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Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

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April 2016

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We transform … the world of plant automation. Booth No. 2039 May 16 – 19, 2016 David L. Lawrence Convention Center Pittsburgh, PA., USA

Plug & Work: Automation pretested by simulation. “Plug and Work” is the established product from our automation specialists. Forget time-consuming test phases at your works – our automation system is connected to a simulation model that reflects the entire process. That’s how we carefully test and optimize work routines and technological functions even before commissioning.

The result: Only proven and perfectly reliable automation systems are installed, connected and … run without a hitch. What you gain: steep run-up curves for new installations and plant revamps. Short assembly times that optimize your return on investment. What your customers gain: dependable production and guaranteed delivery dates.

SMS GROUP GMBH

Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany

Phone: +49 211 881-0 Fax: +49 211 881-4902

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

EDITORIAL

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New challenges for metallurgical operations In this issue, MPT International provides a wide range of topics covering the whole value chain of steel production. Starting at upstream operations, such as ore preparation and hot metal treatment, the gamut of articles embraces EAF steelmaking and continuous casting technology as well as downstream rolling and forming operations. Out of the broad spectrum of topics, I’d like to draw your attention to a few special highlights. The upstream production stage of hot metal making is being challenged by the limited availability of high-quality iron ore and the highly volatile prices of these selective qualities. First of all, the right mix of raw materials has to be determined – not only for the blast furnace but as early as for the sinter plant. Engineers from Germany have developed and built a facility that fully automatically produces small batches of sinter as a pre-production test. The facility not only determines the quality parameters of the sinter product made from varying ore grades but also measures the emissions generated during the sintering process for the specific materials charged. As the recipes and all operational parameters are saved as test data records, they will be available at any time in the future. Whilst the article provides a general overview, the provided QR code links to a video on YouTube showing the sinter test facility in operation.

Dipl.-Ing. Arnt Hannewald

If a blast furnace is operated with varying ore grades, the hot metal from that blast furnace may present the downstream steelmaker with major challenges. Therefore there is a growing demand for efficient hot metal pretreatments aimed at adjusting the contents of sulphur, silicon, phosphorus and even carbon. Our article featuring this special topic provides a detailed look at the concepts and results of hot metal pretreatment and examines the potentials of the different technologies and treatment routes. Last but not least we always keep a keen eye on new plants being built around the world. Shandong Iron and Steel and SMS group have recently unfolded the details of the new rolling and strip processing facilities for the Rizhao Steel greenfield project. The all-new flat steel production complex will be erected on the Chinese east coast. The new integrated iron and steel works in Rizhao is scheduled for commissioning in 2017. MPT will keep you up to date on the progress of this project.

MPT International 2 / 2016

Danieli QSP technological layouts and process know-how fully satisfy the widest market demand in terms of product mix, high productivity and flexibility, tight geometrical tolerances.

Four latest references out of total 11 ESSAR ALGOMA CANADA 1998: QSP featuring the world’s first vertical curved flexible thin slab caster, for outstanding hot strip quality production, including Peritectic grades for the automotive American market.

Flat Products Rolling Mills and Strip Processing Lines

OMK RUSSIA The flexibility of the QSP layout allows the production of API X80 grades for Artic applications as well as 1.0 mm thin gauges. The only thin slab-based plant in the world conceived for “top notch” API grades production.

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

QSP QUALITY STRIP PRODUCTION THE DANIELI WAY TO BE COST WINNER IN THIN SLAB CASTING-ROLLING > From 1.5 to 4 Mtpy capacity > From 0.8 to 25 mm strip thickness > Coil-to-coil, semi-endless, endless

MMK METALURJI TURKEY With its QSP and downstream Danieli cold mill, it represents the most modern facility for flat products in the Mediterranean area, serving both commodity and quality market segments.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

NMDC INDIA QSP plant for the widest production range including API X80, HSLA, ULC steels and thin gauges. The first plant in India featuring vertical-curved casters and separation between roughing and finishing stands.

www.danieli.com

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››› CONTENTS

Events 26

AISTech 2016 Iron & Steel Technology Conference and Exhibition

Raw materials 30 9 QTNFoU Ć‚TUV CWVQOCVGF UKPVGT VGUV HCEKNKV[ UVCTVU QRGTCVKQP KP )GTOCP[ The test facility can process small batches of raw materials before their use for mass production

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Coverphoto: Digital, camera based setting system, SMART Eye, for setting and alignment of roller guides Morgürdshammar AB – part of the Danieli group www.morgardshammar.se E-mail: mh@morgardshammar.com

The upgrade will extend the service life of the blast furnace and boost its productivity

Steelmaking 38 ' HĆ‚EKGPV JQV OGVCN RTGVTGCVOGPV VQ UCVKUH[ VJG NQY EQPVGPVU QH UWNRJWT CPF RJQURJQTWU Limited availability of high-quality ore as well as highly volatile prices have inexorably influenced the conditions of ironmaking operations for some years

52 5 JCHV CTE HWTPCEG YKVJ GHĆ‚EKGPV UETCR preheating concept provides low conversion costs A basic concept has transformed into a mature, flexible and highly efficient scrap recycling facility

Continuous casting

Hot rolling

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The revamped slab caster No. 1 of Thyssenkrupp, Germany, significantly contributes to the production of high-manganese steel

Ecoplants components guarantee high economic efficiency while improving environmental protection

Special equipment 62 4 QWIJ OCEJKPKPI CPF Ć‚PKUJKPI QH RTQĆ‚NG TQNNU HQT TQNNKPI OKNNU Czech steel producer TÄ ineckĂŠ ĹželezĂĄrny a.s. has ordered a fourth roll lathe from Georg for the roll shop

66 %TCPG CPVK EQNNKUKQP UQNWVKQP HQT VJG TQNN UJQR The precise tracking of the crane movements provides reliable protection

Company profiles 68 4 QNNKPI CPF UVTKR RTQEGUUKPI VGEJPQNQIKGU HQT 72 5KGORGNMCOR RWUJGU CJGCF YKVJ VJG 4K\JCQ ITGGPĆ‚GNF RTQLGEV KPVGTPCVKQPCNK\CVKQP

Cold rolling 74 5 VCKPNGUU UVGGN VCPFGO EQNF OKNN RTQFWEGU ƂTUV EQKN CV $GKJCK %JGPIFG %JKPC The new cold rolling mill shall produce wide strips in the 800 – 1,300 mm width range MPT International 2 / 2016

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Quality assurance

Strip processing

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Pinhole detector for strip and foil Rear view cameras detect even the smallest holes at the strip processing line

Voestalpine has invested over five million euros in the new line

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Technical innovations

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Advertisers’ index ABB AB 31 Almamet GmbH 49 Andritz AG 47 Aumund Fördertechnik GmbH 17 Automazioni Industriali Capitano srl 51 Badische Stahl-Engineering GmbH 33 BEDA-Oxygentechnik Armaturen GmbH 27 BM Group Holding 57 Boldrocchi srl 39 Braun Maschinenfabrik Gesellschaft m.b.H. 81 Bürkert Werke GmbH 53 Combilift Ltd Co 85 Danieli S.P.A. 4, 5 EMG Automation GmbH 10 Eredin Scabini Srl 35 Fabris InC. 75 Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS 77 GLAMA Maschinenbau GmbH 29 Guild International Inc. 65 Instituto Aco Brasil (IABr) 41 IMS Messsysteme GmbH 21, 22

INTECO melting and casting technologies GmbH Jasper Ges. für Energiewirtschaft & Kybernetik mbH JATO-Düsenbau AG Kiro-Nathaus GmbH Maschinenfabrik Köppern GmbH & Co. KG Kranunion GmbH KSK Kuhlmann-System Kühltechnik GmbH Küttner GmbH & Co. KG LDV Laser- und Lichtsysteme GmbH Lechler GmbH Friedrich Ley GmbH Industriebrenner-Anlagen Maschinenfabrik G. Eirich GmbH & Co. KG Messe Düsseldorf GmbH Metal-Expo, JSC NDC Technologies NoKra Optische Prüftechnik und Automation GmbH POLYTEC GMBH Primetals Technologies Austria GmbH

16 67 89 85 55 20 77 55 81 18 84 37 92 97 84 13 73 43

PRÃœFTECHNIK NDT GmbH 15 Quaker Chemical Corporation 86 REFRATECHNIK Steel GmbH 93 Saar-Metallwerke GmbH 61 Scheuch GmbH 14 SGL CARBON GmbH 98 Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG 45 SMS group GmbH 2 Stangl Technik GmbH 25 STEIN INJECTION TECHNOLOGY GmbH 53 TML Technik GmbH 88 TMT Tapping Measuring Technology 9 ThyssenKrupp Uhde Engineering Services GmbH 79, 80 VELCO GmbH Ges. f. Förder-, Spritz- und Silo-Anlagen mbH 77 Ventilatorenfabrik Oelde GmbH 71 Vereinigte Filzfabriken AG 86 WalzengieÃ&#x;erei Coswig GmbH 41 WOKO Magnet- und Anlagenbau GmbH 19 PAUL WURTH S.A. 11, 12 Zumbach Electronic AG 23 3tn Industriesoftware GmbH 89

MPT International 2 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

Africa Algeria Tosyali to install conveyor for hot DRI. At the end of August 2016, a new Aumund special conveyor for the transport of hot DRI will be delivered to the new steel mill at Tosyali. The 116-metre-long conveyor will be designed for the transport of 323 t/h of hot DRI at a material temperature of 750°C. Aumund will supply a patented pan conveyor with buckets. The improved sealing protects the material to be transported completely from any environmental influences. Thus, the inert system prevents reoxidation of the highly reactive material and any loss of metallization. The conveyor will transport hot DRI from the Midrex shaft furnace to an electric arc furnace. The new Midrex direct reduction plant will be designed for a production capacity of 2.5 million t of DRI. Probably starting at the end of 2016, hot or cold DRI will be produced alternately.

The Americas Canada Gerdau invests in NF scrap separation system. Gerdau and Danieli Centro Recycling are partnering on a project to upgrade the non-ferrous scrap separation system at Gerdau’s steel mill in Whitby, Ontario. Planning for the project is currently underway with construction slated to begin in the first half of 2016. The technology for the new system allows Gerdau to sort and extract non-ferrous scrap metal that is not used in the steelmaking process. The non-ferrous metals can be separated from the scrap steel mix and recycled or sold to be used in other manufacturing processes. The Whitby mill uses ferrous scrap steel from end-of-life vehicles and other sources to be melted and produced into merchant bar quality products and reinforcing steel used in a variety of applications. MPT International 2 / 2016

Mexico Tenaris Tamsa starts up equipment at tube mill. In December 2015, Tenaris Tamsa successfully started up a new pneumatic carbon and lime injection system on their 160 t electric arc furnace at the Tenaris Veracruz pipe operations. The injection system was supplied by More srl complete with two dispensers of 3,000 l capacity for pneumatic injection of lime from the main storage silo directly into the EAF shell, four 2,500 l dispensers for pneumatic injection of carbon to the injectors and two combined burner/flux injector units. At the same site, Tenaris Tamsa has started commissioning the new premium line for which BM Automation supplied the automation systems for the mill and installed the robotic cells produced by its sister company Polytec.

USA Feralloy to upgrade cut-tolength line. Feralloy has selected Butech Bliss to upgrade their existing cut-to-length line in Huger, South Carolina. The upgrade will include a Synergy® hydraulic roller leveller, equipped with hydraulically powered independent entry and exit roll settings, closed-loop system to compensate for machine deflection and enhanced operator friendly controls. The roller leveller will also feature a quick change roll cartridge system and scale removal conveyor system. The stretch leveller will be equipped with the Hawkeye™ flatness detection system which consists of an array of sensors mounted across the width of the strip to measure flatness deviations and deliver instantaneous feedback to the operator. Installation of the new equipment will be completed in the second quarter of 2016.

USA Weber Metals to install new forging press. Germany-based Otto Fuchs has ordered a press for large forg-

News in brief Tube City IMS, USA, provider of outsourced industrial services to steel mills, has changed its corporate name to TMS International to reflect the company’s growing global presence. Baosteel Special Steel, China, has granted Danieli the FAC for the successful installation of the Q-Panels technological package at its stainless steel EAF. The system provides process improvement and corresponding reduction of operational expenditure. Villares Metals, Brazil, signed the FAC for the new EAF supplied by Danieli two months ahead of the contractually agreed date. JSPL, India, has successfully restarted the plate/Steckel mill at its Raigarh site after a major revamp by Danieli. Gerdau Ouro Branco, Brazil, has issued the FAC for the new Steckel mill supplied by Primetals Technologies. The mill has an annual capacity of 800,000 t of hot-rolled coil. Gazpromtrubinvest, Russia, has successfully commissioned the 16” HF pipe welding line supplied by SMS group. The new line, designed for an annual capacity of up to 300,000 t, produces pipes within an outside diameter range from 127 to 426 mm. EZZ Steel, Egypt, has started up the new 2 million t/year DRI plant in Al Ain Sukhna. The plant features the Energiron III technology from Tenova HYL. MMK, Russia, has completed an overhaul of its No. 9 blast furnace in Magnitogorsk. The project included the technical overhaul of the cast houses, raking out and preparation of the chimney, reconstruction of the lining and replacement of the flue protection.

just...

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THE Tapping Technology TMT – Tapping Measuring Technology Sà rl 3 2 %R[ / /X[HPERXUJ ‡ UXH GC$OVDFH / /X[HPERXUJ 3KRQH ‡ )D[ ‡ ( 0DLO FRQWDFW#WPW FRP 0DQDJLQJ 'LUHFWRUV 'LSO ,QJ $UQR 'LHQHQWKDO ‡ 'LSO ,QJ &ODXGH %RGHYLQJ ‡ Registration No. B 91897

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A joint company of DANGO & DIENENTHAL and PAUL WURTH

10

››› INTERNATIONAL INDUSTRY NEWS

ings from SMS group for installation at its subsidiary Weber Metals located in Los Angeles. The pit-mounted hydraulic closed-die forging press will be designed for a press force of 54,000 t, a 6,000 by 3,000 mm die clamping area and a stroke of 2,000 mm. By the end of 2017, the press will start producing extra-large hot and cold forgings made of nickel and titanium-based alloys for the aerospace industry. This new press will allow Otto Fuchs to expand its portfolio of extra-large premium-grade forgings.

ing machine to produce oil-tempered wire at its plant in Jiangyin, Jiangsu province. Plans call for mass production to commence in October 2016. JYSF was established in 2005 to produce and sell oil-tempered wire for cold-coiled suspension springs. Fullscale operation began in 2007. As the need for lighter automobiles increases, demand for advanced oil-tempered wire for cold-coiled suspension springs is anticipated to expand in the future. The installation of induction tempering equipment will make possible rapid quenching and tempering to produce high-strength wire.

USA

Wee g W gu uiide de yo ou ur p pro rod du ucction tion aand nd prrod oducctt q qu uaali littyy

Market leader for strip guiding systems Determine material characteristics such as yield and tensile strength — online Prepare your forming process with oil layer measurement — online Observe surface roughness — online

ade ing tr h, m o c p g eu bur s at th n Pitts Visit u: AISTech i 16; show 16-19, 20 May # 3444 booth

EMG USA Inc. 1603 N. River Rd. NE Warren, Ohio 44483, USA Phone: +1 330 372 4418 Telefax: +1 330 372 4431 patric.jobst@emg-automation.com www.emg-automation.com Group

Nucor Yamato Steel to upgrade universal finishing mill. TMEIC will replace the large motor and variable frequency drive powering the No. 2 universal finishing mill at Nucor Yamato Steel in Blytheville, Arkansas. The custom-designed motor for Nucor Yamato Steel weighs 93 t, with a power of 44.5 MW, and runs at a variable speed of 60 to 120 rpm. The large induction motor is a 16-pole motor, fitted with a speed sensor for superior control. Due to its integrated overhead water heat exchanger, the enclosure is designated as totally enclosed water-air cooled. The pulse width modulated drive consists of a large AC to DC converter, feeding a DC bus which supplies two DC to AC inverters working in parallel. Both inverters supply the motor through a combining reactor. The mill start-up is scheduled for 2016.

Asia China Kobe Steel’s wire rod JV to increase production capacity. Kobe Steel, its partners Sugita Wire and China’s Fasten Group have agreed to increase the production capacity of their Chinese joint venture that processes special steel wire rod into wire. The joint venture Jiangyin Sugita Fasten Spring Wire (JYSF) will install high-frequency induction tempering equipment and another wire drawMPT International 2 / 2016

China Shandong orders cokemaking and ironmaking technology for new site. At the end of 2015, Shandong Rizhao Iron & Steel and Paul Wurth signed a contract for the delivery of two Bell Less Top® charging systems for the two blast furnaces of Shandong Rizhao’s new ironmaking plant. Each blast furnace will have an inner volume of 5,100 m3, designed for a daily production of more than 11,500 t of hot metal. These furnaces will be among the largest ever equipped with a Central Feed BLT®. The order comprises all mechanical equipment for the BLTs, including material hoppers of 100 m3 volume, the cooling systems, parts of the hydraulic system, field-mounted electrical and lubrication equipment and site supervision services during erection and commissioning. The tops will feature some of Paul Wurth’s latest developments, such as the pressurized cooling concept for the main gearbox and spherical maintenance valves. Equipment supply and services will be provided from Luxembourg and China. The two blast furnaces of Shandong Rizhao’s new plant are scheduled to be commissioned in 2017 and 2018 respectively. Paul Wurth will also provide engineering and supervision services for the construction of four Paul Wurth jumbo oven batteries of the top charging type to be built at the coke making plant of the new Rizhao iron and steel complex. Each battery will consist of 58 ovens of 7.3 m height.

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China Fushun Special Steel orders furnaces for ESR plant. In November 2015, Fushun awarded Inteco the order to supply a 20 t ESR plant. The plant concept is based on two furnace heads with three melting stations producing ingots with a max. diameter of 1,200 mm and a max. weight of 30 t. In January 2016, Fushun signed a follow-up contract for a smaller version of the same furnace concept, producing ingots with a max. diameter of 750 mm and a max. weight of 7 t. Start-up of the plants is scheduled to take place in autumn 2016.

China Mintal to build new ferrochrome plant. Outotec will design and supply a ferrochrome plant to Mintal in Baotou. Outotec’s scope of delivery will include engineering and supply of proprietary and other key equipment for a steel belt sintering plant with an annual capacity of 700,000 t of sintered pellets and two 75 MVA smelting furnaces with preheating technology. The new plant will produce 300,000 t/year of ferrochrome and is estimated to become operational by the end of 2016. This is Outotec’s second ferrochrome plant for Mintal.

China Xinxing Ductile Pipe to upgrade wire rod line. Xinxing Ductile Pipe will equip the outlet of the extisting 600,000 t/year wire rod line with a Danieli TMB twin module block. The new equipment will be designed for the production of 5.0 to 20 mm dia. smooth wire rod in 2 t coils at rolling speeds of up to 112 m/s. The product mix will include building steel, quality high-carbon grades, hard wire, welding wire, cold heading, spring steel and bearing steels. The supply will include a double-pipe oil film bearing loop laying head, associated auxiliaries and a controlled cooling line also suitable for low temperature rolling. The project is being carried out directly by Danieli

China, with plant start-up scheduled for mid-2016.

China VAMA issues FAC for processing lines. Valin ArcelorMittal Automotive Steel (VAMA), a joint venture between ArcelorMittal and Hunan Valin, has awarded the final acceptance certificate to CMI for the supplied continuous hot-dip galvanizing line and the combined continuous annealing and galvanizing line (Combi CAL-CGL). Both lines were installed at VAMA’s new steel plant in Loudi, Hunan province. The Combi CAL-CGL line attains a maximum speed of 700 m/min and will produce close to 900,000 t/year. The CGL line has been designed to produce 500,000 t/year of steel strip at a process speed of 200 m/min. The current line layout already provides for future upgrades, such as the additional post-treatment section recently supplied by CMI.

South Korea SeAH Changwon to install melting and remelting plant. In November 2015, Inteco received an order from SeAH Changwon Speciality Steel for the engineering and supply of a complete special melting and remelting plant. The scope of supply consists of one vacuum induction melting furnace, two electroslag remelting furnaces and one vacuum arc remelting furnace. The contract foresees the supply of all plants within nine months. Startup is planned for autumn 2016.

... a passion for precision.

Thickness measurement of heavy plates, plates, coils and roll clad products Flatness measurement on cold or hot rolled sheets and strips Profile and Shape measurement of rails, tubes, bars, pipes or slabs

visit us at our booth #1321

South Korea Posco orders new blast furnace charging system. Posco is planning the third reline of its No. 3 blast furnace at Pohang. Since 1989, the blast furnace has been operating with a Central Feed®-type Bell Less Top® supplied by Paul Wurth’s licensee IHI of Japan. Now, the furnace will be enlarged and hot metal production increased to 14,000 t/day. Posco decided to in-

nokra Inc., USA Phone +1 630 377 2477 info@nokra.us nokra GmbH, Germany Phone +49 2401 60770 info@nokra.de www.nokra.de

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››› INTERNATIONAL INDUSTRY NEWS stall a classical parallel-hopper top with a hopper volume of 108 m3 each. The charging system to be supplied by Paul Wurth will include a reinforced chute transmission gearbox with pressurized water cooling and a spherical maintenance valve. Pressure equalizing will be performed with full gas recovery. Paul Wurth will provide the engineering, supply all mechanical key equipment and part of the auxiliary hardware, and will perform site supervision during erection and commissioning of the complete system.

WWW.SCHEUCH.COM

Vietnam Ton Dong A orders cold rolling mill and galvanizing line. Danieli will supply a new hot-dip galvanizing line and a two-stand four-high cold rolling mill for the production of GL coated strip and thin low-carbon strip to Ton Dong A for the new facility in Binh Dong. The new hot-dip galvanizing line will be designed for a total capacity of 150,000 t/year of finished coils for thin strip with thicknesses from 0.16 to 1.0 mm and widths up to 1,250 mm, producing thin GL coatings down to 40 g/m2 on each side at 150 m/min. The annealing furnace in the process section will be supplied by Danieli Centro Combustion, the air wiping system by Danieli Kohler. The new two-stand four-high cold reversing mill will be designed to achieve a total annual production of 400,000 t/year of low-carbon cold-rolled strip, with a minimum thickness of 0.11 mm and a maximum width of 1,250 mm. Three thickness gauges and laser meters will be provided for mass flow control.

Europe

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

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

MPT International 2 / 2016

Austria AMAG orders aluminium sheet and strip production plant. AMAG has placed an order with SMS group for the supply of a cold rolling mill, a heat treatment line with a connected passivation section, a high-bay warehouse and a packaging line. Thus, numerous key assets of the AMAG 2020 investment project, dedicated to the set-up of production facilities for cold rolled premium aluminium strips and sheets, will all be supplied by SMS group. Commissioning of the new facilities is scheduled for 2017. The six-high cold rolling mill with CVC® plus technology supplied by SMS group will provide the high degree of flexibility required to handle the extensive range of products, including strip in widths of more than 2 m. An Airwash™ system will provide most efficient purification of the exhaust air from the rolling process. The technological highlights of the heat treatment line and the connected passivation section are the water-cooled floater furnace, the resource-saving process technology and the compact layout. An integral element of the new

rolling complex will be the central coil handling system which consists of a fully automatic high-bay warehouse with links to the rolling and processing lines. All material flows will be controlled by a warehouse management system which will be connected to the higher-level production control system. SMS group’s scope of supply also includes a semi-automatic packaging line. The warehouse and the packaging line will be provided by SMS Logistiksysteme.

Belgium Aperam extends mill services contract. Harsco Corporation signed a five-year contract extension of its steel mill services at the Châtelet site of Aperam. Harsco will continue to provide a broad array of core services in support of the mill’s EAF stainless steel production, ranging from onsite scrap yard management and slag transport to the handling and grinding of production slabs from the mill’s continuous caster.

Germany Rheinzink to integrate new surface treatment section. Rheinzink has awarded SMS group the order to expand the No. 2 pre-weathering line at its Datteln facilities. The main element of the contract is the integration of an alternative surface treatment section into the existing cleaning and pickling section, which was also supplied by SMS. With the new coating unit, Rheinzink will expand its portfolio of pre-weathered zinc sheets for the building industry. The installation activities will take place in August 2016 during a line stoppage of only five days, immediately followed by the commissioning. In order to be able to complete the installation in such a short time, the existing plant will first be scanned by a 3D laser scanner. SMS will integrate the new equipment into the virtual 3D image of the facilities, which will show all existing machines, cabling and piping. SMS will supply the coating unit complete with pre-tested electrical and automation systems, providing for a speedy commissioning process. The construction-grade zinc sheets treated in the new process section will be between 500 and 1,250 mm wide and between 0.4 and 1.5 mm thick.

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Germany Outokumpu’s investment programme taking shape. At Krefeld, Outokumpu’s investment programme aimed at enhancing the production capabilities of ferritic materials by new facilities for hood annealing, pickling, cold rolling, bright annealing and temper rolling processes is advancing well. The investment was initiated two years ago in order to strengthen the company’s long-term competitiveness in one of its most important markets.

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THE

Edition 1/1

TECHNOLOGIST CONTINUOUS CASTING

The company expects to have transferred current production from the Benrath plant to Krefeld by the end of 2016. With the state-of-the-art process and equipment technology, Outokumpu will be able to significantly increase efficiency and synergy effects in the production of stainless steel products, while at the same time reducing energy consumption and emissions. The over 26-metre-high new hood-annealing building is the most visible alteration to the Krefeld site. Installation of the batch-annealing equipment is going on, with production ramp-up planned for mid-2016.

Italy

The INTECO Group offers continuous casting machines for long products as well as special solutions for the production of special steels. The SRUWIROLR FRYHUV FRPSOHWH JUHHQ ¿HOG SURMHFWV DQG UHYDPSV RI H[LVWLQJ casters. INTECO‘s competence center for casting, INTECO TBR, offers EDVHG RQ LWV ORQJ WHUP H[SHULHQFH LQ HQJLQHHULQJ DQG GHVLJQ RI LQGLYLGXal bloom casters, tailor-made solutions for all kinds of steel producers. Bloom and Billet Casters The continuous casting of blooms has become a well-established technology for the production of semis for high-quality applications. Similarly, continuous casting of billets is the basis for highly productive steelmaking. INTECO TBR supplies robust continuous casting machines with higKHVW TXDOLW\ RI WKH ¿QDO SURGXFW ORZ PDLQWHQDQFH UHTXLUHPHQWV DQG KLJK operator friendliness. Design Criteria ‡ %RZ W\SH RU YHUWLFDO EHQGLQJ PDFKLQHV ‡ 0RGXODU GHVLJQ ZLWK WKH SURYLVLRQV IRU XSJUDGLQJ IHDWXUHV RI WKH caster at a later stage ‡ 2SHUDWRU IULHQGO\ FDVWLQJ ÀRRU ‡ $GYDQFHG PRXOG OHYHO FRQWURO VROXWLRQ ‡ 4XLFN FKDQJH RI PRXOG DQG VHJPHQWV ‡ +LJK SUHFLVLRQ UREXVW PRXOG RVFLOODWRU ‡ 0RXOG DQG ¿QDO VWLUUHU ‡ '\QDPLF VHFRQGDU\ FRROLQJ ZDWHU DQG DLU PLVW

‡ &XVWRPL]HG UXQ RXW DUHD FRQ¿JXUDWLRQ ‡ 5LJLG FRROLQJ EHG ‡ 3HUIRUPDQFH DVVXUDQFH E\ LQWHJUDWHG DXWRPDWLRQ V\VWHP ‡ +LJKHVW ¿QDO SURGXFW TXDOLW\ E\ TXDOLW\ PRGXOHV RI WKH /HYHO automation Special Casting Applications &RQWLQXRXV FDVWLQJ PDFKLQHV IRU VSHFLDO WHFKQLTXHV VXFK DV KRUL]RQWDO RU YHUWLFDO FDVWLQJ URXQG XS WKH SURGXFW SRUWIROLR LQ WKH ¿HOG RI WKH SURGXFWLRQ RI VSHFLDO VWHHOV $ ÀH[LEOH DQG LQWHOOLJHQW GHVLJQ DQG WKH LPSOHPHQWDWLRQ RI FXVWRPHU GHPDQGV HPSKDVL]H RXU FRPSHWHQFH LQ WKLV product segment.

Forgia Rapida to upgrade ring rolling facilities. SMS group will supply the first unit of its newly developed ring rolling machine to Forgia Rapida in Bologna. The RAW ecompact® ring rolling machine type features electro-hydraulic direct drives that are mounted on the roll shafts – an innovative drive solution for this type of application. The new machine will replace a smaller ring rolling machine in operation at the Bologna works and will roll rings with diameters up to 3,000 mm and a maximum height of 480 mm. SMS group will deliver and install the machine in summer 2016. Start of production is scheduled for September 2016. In the RAW ecompact® ring rolling machine, the otherwise common central hydraulic system has been eliminated. Consequently, no associated machine and foundation pipework needs to be installed. This not only provides economic benefits, but also eliminates the risk of environmental pollution by oil leakage. The new machine type is mounted on a simpler foundation than conventional ring rolling machines, and additional installation space for a separate hydraulic power pack is not required. The RAW ecompact® for Forgia Rapida will produce, among others, rings for radial compressors, reciprocating piston compressors and gas turbines.

Poland ArcelorMittal Poland to install robotic cell. ArcelorMittal Poland has signed the factory acceptance test for the robotic solution supplied by Polytec, member of the BM Group. The cell, installed at the Swietochlowice steel plant, includes an automatic ingot charger integrated into a robotic cell able to automatically remove the slag produced during the galvanizing process.

Romania

INTECO Group Wiener Strasse 25 8600 Bruck an der Mur Austria Phone: +43 (0) 3862 53110-0 Fax: +43 (0) 3862 53844 inteco.austria@inteco.at www.inteco.at

TMK-Artrom orders heat treatment line for tubes. TMK-Artrom, located in Slatina, has placed an order with SMS group for the supply of a heat treatment line for tubes. The plant will serve for the production of

W E seamless tubes, OCTG pipes (oil country tubular goods) as well as high-strength tubes for mechanical applications. The annual capacity will be 160,000 t. The heat treatment line ordered by TMK-Artrom will consist of an austenitizing furnace with walking beam transport system, a quenching head, a quenching tank, a walking beam tempering furnace and a cooling bed. The plant is scheduled to commence operation in the second quarter of 2017.

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Russia MMK produces new high-strength steels. MMK Magnitogorsk Iron and Steel is actively implementing a programme to launch production of high-tensile and wear-resistant steel grades for a wide range of uses under the “Magstrong� brand. The first shipment of the new steel to Russian consumers was completed in January 2016. The high-tensile wear-resistant steel produced by MMK meets the standards of international peers. This steel is characterized by high resistance against abrasive wear, impact hardness, good welding properties and workability. MMK carried out large-scale market research, scientific research and development of production technologies. In November 2015, manufacturing of the new steel started: H350 (hardness of 350 HBW), H400 (400 HBW) and H450 (450 HBW). Prototypes were shipped to key MMK customers for comparison tests versus international peers. The tests confirmed that MMK managed to achieve mechanical working properties at least equal to the level of leading global companies.

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Russia Severstal orders ladle furnace. Primetals Technologies has received an order from Severstal to supply a new twin-ladle furnace for the Cherepovets converter steel works. The ladle furnace will be designed to treat 375 t charges of liquid steel in a treatment time of not more than 45 min. The annual capacity will be 4.8 million t. It will increase converter steel production from

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››› INTERNATIONAL INDUSTRY NEWS

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9.5 million to almost 10.3 million t/ year. The additional ladle furnace will also allow all the steel treatment to be performed in a single section of the plant, reducing annual operating costs by approximately 10 million euros. The project is scheduled to be completed by the beginning of 2017. Primetals Technologies will be responsible for engineering the twin ladle furnace, the alloying system and the dedusting system, and will supply key components as well as the associated electrical and automation equipment. Primetals Technologies will also supervise installation and commissioning, and provide staff training.

Spain New single fluid full cone nozzle Series 490

Acerinox to build cold strip annealing and pickling line. Andritz has received an order from stainless steel producer Acerinox Europa to supply a turnkey cold strip annealing and pickling line for its Campo de Gibraltar plant in Los Barrios. The line

will produce flat products in stainless steel, e.g. 2D and 2B surface quality strip, and will have a total annual production capacity of 300,000 t. The first coil is scheduled to be produced in the third quarter of 2017. The Andritz Metals scope of supply also includes the skin pass mill and leveller, the automation and electrical equipment, as well as the instrumentation systems.

United Kingdom Tata Steel announces job cuts. Tata Steel UK has announced cost-saving proposals to improve the competitiveness of its UK business. The plans would lead to the loss of 1,050 jobs – 750 jobs at its Port Talbot-based Strip Products UK business, 200 jobs in support functions and a further 100 jobs at steel mills in Trostre, Corby and Hartlepool. The proposed changes follow continued falls in the European steel price caused by a flood of cheap imports, particularly from China. A

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www.lechler.de MPT International 2 / 2016

News in brief Wuppermann, Netherlands, has granted SMS group the FAC for equipment added to the hot-strip galvanizing line in Moerdijk. A seven-roller flattener and a side trimmer were installed at the line entry.

Ugitech, France, has awarded the FAC to Primetals Technologies for its custom engineering solution to upgrade and automate the compacting and coil handling process in the rod mill. The upgrade included a new vertical compactor and a newly designed unloading station.

Salzgitter Mannesmann Röhrenwerke, Germany, has received orders for 70,000 t of spirally welded large-diameter pipes from Open Grid Europe GmbH. The pipes will be used to extend the natural gas grid in southern and western Germany. Salzgitter Flachstahl is to supply the input material.

NLMK, Russia, has completed hot testing of its continuous hot-dip galvanizing line No. 1 at its Lipetsk site following upgrades. The project is expected to boost the line’s production capacity by 30% to 500,000 t/year.

Aperam Inox, Brazil, has successfully commissioned the revamped converter at Timoteo. The revamp, carried out by Danieli Linz Technology, included engineering and supply of the converter vessel, suspension system, trunnion ring and slag shields.

Salzgitter Flachstahl, Germany, has issued the FAC to Paul Wurth for the successful modernization of the Bell Less Top® charging system of its “B” blast furnace. The modernization took place within the framework of a general reline of the blast furnace.

INTERNATIONAL INDUSTRY NEWS full consultation process with employee representatives has been initiated.

United Kingdom Goodwin Steel Castings orders engineering of VOD unit. In December 2015, Goodwin Steel Castings awarded Inteco the order to engineer a 30 t VOD converter. The plant will allow Goodwin to carry out normal AOD as well as vacuum treatments in the same plant and enhance the quality of the alloys produced. Engineering of the plant will be completed by June 2016. The order for the delivery of the equipment is to be expected soon as Goodwin plans to start producing with the new plant in December 2016.

line shop for small users and end customers has now gone live on schedule as part of a European rollout. After the United Kingdom, Spain is the next European market where customers can order products in quantities as low as they require online. Spanish customers can now choose from 2,500 items in the “Materials4Me� online shop, including products in standard dimensions, standard short lengths and custom short lengths. With the option of purchasing low quantities, the shop addresses the needs of repair and maintenance contractors, researchers, small trades as well as home improvement enthusiasts. Materials Services’ digital strategy has its roots in the USA, where Materials Services has been successfully operating an online shop for end customers since 2007. “Materials4Me� will also be available to customers in Germany from April.

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19

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Companies SGL Carbon reacts to weak graphite electrode business. In accordance with international accounting standards (IAS 36), SGL Carbon SE is obliged to perform both regular and event-driven impairment tests. In preparation for the 2015 financial statements, SGL Carbon SE has identified a need to recognize impairment losses on fixed and other intangible assets in the group consolidated statements in the reporting segment Performance Products. The impairment losses relate exclusively to the graphite electrode business. The reason for these non-cash impairment charges is the reduced expectation for graphite electrode pricing in the planning period compared to the prior year. Reacting to the persistently difficult market conditions for graphite electrode, it is planned to gradually shut down the production site in Griesheim, Germany.

Thyssenkrupp Materials Services continues European rollout of online shop. With the launch of “Materials4Me� in Spain, Thyssenkrupp Materials Services is continuing the digital transformation of its materials distribution network. As announced at the end of 2015, the on-

ArcelorMittal launches award to honour sustainability champion. ArcelorMittal has established a new sustainability award to honour its former head of R&D for sustainability, Jean-SÊbastien Thomas, who passed away in December 2014. The prize will reward the best research paper on sustainable development presented at the annual Society and Materials (SAM) conference, which brings together material producers, scientists and other parties investigating the connection between society and materials. Jean-SÊbastien Thomas was known for leading a group of sustainable development experts at the World Steel Association. The prize will be awarded for the first time at the conference’s 10th edition in Rome this May.

PSI Metals announces new strategy for Asian markets. PSI Metals has announced its new strategy for growth across Asia, twelve months after the successful integration of its Broner Metals acquisition. Across Asia, the merged business of PSI and Broner is already working with many customers such as Tata Steel India, Nippon in Japan, and Tangsteel in China. The new Asia strategy incorporates existing PSI Metals solutions for produc-

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MPT International 2 / 2016

20

››› INTERNATIONAL INDUSTRY NEWS

tion planning, scheduling and MES, and builds on successful industrial internet (Industry 4.0) and SAP integration with over 200 of the world’s greatest steel, aluminium, and other metals companies. It also brings together the existing PSI teams in India, China, and Japan under one management team.

Strategic partnership between SMS group and Houghton International. In December 2015, SMS group and Houghton International Inc., with its head office in Pennsylvania, USA, agreed their partnership for the development and marketing of oil-based cooling lubricants and emulsions for cold rolling mills. Both suppliers have joined forces in this partnership with a view to providing their joint customers with the added value obtained from a harmonized symbiosis of plant and fluid technology. Houghton is a leading supplier in the

field of fluids and special chemicals for metal processing. The partnership between the two companies covers the common development and marketing of oil-based cooling lubricants and emulsions for steelmaking. Under this partnership, SMS and Houghton will be pooling their research and development resources with a view to offering innovative cooling lubricant technologies to steelmakers.

Worldsteel launches 3rd Steel Safety Day. Aligned with the World Day for Safety and Health at Work held by the International Labour Organisation on 28 April, Steel Safety Day launched by the World Steel Association is to create a safer working environment across the entire steel industry worldwide. The five most common causes of incidents are moving machinery, falling from height, falling objects, gas and asphyxiation, and overhead cranes. Each year one of the

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Schenck and Sandvik enter into partnership. Schenck Process business unit Minerals & Metals, supplier of solutions for screening applications in mining, and Sandvik, supplier of crushers and crushing technologies, have signed a global partnership agreement. The partnership provides increased crushing circuit productivity for Schenck Process’ double and single deck banana screens and Sandvik cone crushers. It also enables a single service provider approach to support customers throughout the entire plant life cycle.

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INTERNATIONAL INDUSTRY NEWS

Personalities Changes to Ovako board. Joakim Olsson has been elected new chairman of Ovako‘s board of directors, replacing Finn Johnsson. Johan Pernvi has been elected board member and will replace Björn Nilsson.

and commercial capabilities from the company’s U.S. base. MCC’s centrifugal casting process provides a cost-effective method for manufacturing ferrous and non-ferrous rolling mill sleeves, bearing parts, bi-metallic gear blanks, bushings, nuts, valve bodies etc. used in a wide range of applications, including steel mills, power transmission lines and elevators.

New president of Pro-Tec Coating Company. Richard E. Veitch has been named president of Pro-Tec Coating Company, a 50/50 joint venture be-

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23

tween United States Steel Corporation and Kobe Steel, Ltd., of Japan. He succeeds Brent Rosebrook, vice president of finance and administration, who had been serving as acting president since Bryan Vaughn’s retirement in June 2015. Veitch most recently served as general manager of U. S. Steel Granite City works in Granite City, Ill.

Chief financial officer to leave Outokumpu. Outokumpu’s chief financial officer Reinhard Florey has decided to leave Outokumpu to take a role as CFO at OMV, an international oil and gas company based in Austria.

Joakim Olsson

New president & CEO of MCC International. MCC International, a subsidiary of Austria-based ESW, has appointed Trevor Dunthorne to continue growing MCC’s technical

Richard E. Veitch

Leadership changes at Tata Steel Europe. Karl Koehler has decided to step down as a director of Tata Steel Limited and as chief executive officer and managing director of Tata Steel Europe in order to take up a

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24

››› INTERNATIONAL INDUSTRY NEWS

senior leadership position with a large privately-owned industrial company in Germany. Hans Fischer, currently chief technical officer of Tata Steel Europe, has been appointed chief executive officer and will join the board of Tata Steel Europe. Koushik Chatterjee, group executive director and member of the boards of Tata Steel and Tata Steel Europe, will be Tata Steel’s executive director for Europe in addition to his current responsibilities.

Hans Fischer

Changes to board of Quaker Chemicals. Patricia C. Barron and Joseph B. Anderson, Jr. will retire as directors on the board of directors of Quaker Chemical Corporation. Fay West and William H. Osborne have been appointed as new board members.

Danieli Centro Recycling introduces new organization. Daniel Damart, managing director at Danieli Henschel (France), and Jake Allen, managing director at Danieli Lynxs (UK) and Danieli Riverside Products (USA), have been appointed as vice presidents for Danieli Centro Recycling. To strengthen the team and coordinate the activities among the different Danieli workshops worldwide, Daniele Scaranto has been appointed as executive manager projects for Danieli Centro Recycling.

Top management changes at Vallourec Deutschland. Norbert Keusen will pass on the chair of the management board of Vallourec Deutschland to Ulrich Menne, director production and investments. Norbert Keusen, who has been chairman since March 2008, will retire in August 2017. Until then he will remain a member of MPT International 2 / 2016

the board and continue to be in charge of finance, legal matters, and communications. With this step, the company is ensuring a smooth handover of CEO responsibility. Ulrich Menne will take over the chair in addition to his function as director production and investments.

Changes on executive board of Outotec. Kaisa Aalto-Luoto has been appointed senior vice president, human resources and communications, and member of Outotec’s executive board. She is currently in charge of human resources of Outotec’s minerals processing business unit. Kaisa Aalto-Luoto will succeed Kirsi Nuotto, who has decided to leave the company. Olli Nastamo has been appointed senior vice president, strategy, marketing and operational excellence, and member of the executive board.

New president of Sanyo Special Steel. Shinya Higuchi has been nominated for the position of the representative director and president of Sanyo Special Steel Co., Ltd. as of June 2016. Prior to assuming the new positions, Shinya Higuchi will retire as director and member of the board of Nippon Steel & Sumitomo Metal Corporation.

Events ›

1 – 4 May 2016 Riyad, Saudi Arabia Organizers: Arabian German Exhibitions & Publishing www.metalsteelsaudi.com www.fabxsaudi.com

Metal & Steel Saudi Arabia and Fabex. The two exhibitions will cover the full value chain of steel: steelmaking, steel fabrication, metal works, steel structures, tube and pipe, metal forming, etc. The accompanying conference “Steel in the Gulf”, held on 2 and 3 May, will feature topics related to the future of the steel industry in the GCC market.

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

Metall + Metallurgy China 2016. This key event for the metals industries will again combine four complementing international Chinese exhibitions under one roof: the metallurgical industry exposition, the foundry exposition, the industrial furnaces exhibition and the refractories and industrial ceramics exhibition.

›

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

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

›

30 May – 2 June 2016 Hanoi, Vietnam Organizers: South East Asia Iron and Steel Institute (SEAISI) www.seaisi.org

2016 SEAISI Conference & Exhibition. This year’s SEAISI Conference will focus on the theme “Innovating and sustaining competitiveness in the ASEAN steel industry”. Papers presented will cover topics related to steel market developments, steel price trends, the problem of overcapacity, new product developments, development of steel applications, etc.

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6 – 9 June 2016 Graz, Austria Organizers: ASMET www.rolling 2016.org

Rolling 2016. Jointly organized, the 10th International Rolling Conference and the 7th European Roll-

ing Conference target the whole metals rolling community by covering flat and long product rolling, and related topics such as automation and control, new products and new processes, oxidation and descaling, roll technology, thin slab rolling, thermomechanical treatment, and mathematical modelling and simulation.

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6 – 9 June 2016 Moscow, Russia Organizers: Messe Düsseldorf www.metallurgy-tubealuminium.ru

Metallurgy Litmash, Tube Russia, Aluminium/Non-Ferrous. This trade fair trio will provide a comprehensive view of latest steelmaking technology, plant and equipment for tube and pipe making and the stateof-the-art in aluminium and other NF-metals production and processing.

›

27 – 29 September 2016 Darmstadt, Germany Organizers: DGM – Deutsche Gesellschaft für Materialkunde www.mse-congress.de

MSE 2016. The Materials Science and Engineering Congress (MSE) is the central platform for material science and engineering experts to present their research field to a large international community and to network across borders. A special highlight will be this year´s guest country, the USA, one of the most important research and economic regions in the world.

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25 – 29 June 2019 Düsseldorf, Germany Organizers: Messe Düsseldorf www.messe-duesseldorf.de

METEC 2019. The four international trade fairs METEC, GIFA, THERMPROCESS and NEWCAST will continue to be staged at a four-year interval. Responding to the request of many exhibitors, the organizers decided to reverse the previously announced decision to switch to a three-year cycle.

Downtown Pittsburgh and the Three Rivers City skyline

AISTech 2016 will be the steel’s premier event in North America this year AISTech 2016 – the Iron & Steel Technology Conference and Exposition – will take place in Pittsburgh, PA/USA on 16 – 19 May 2016. The town hall forum and the president’s award breakfast are the two most exciting events planned for AISTech 2016. AISTech 2016 – the Iron & Steel Technology Conference and Exposition – will incorporate North America’s biggest steel event of the year. More than 8,000 attendees are expected to attend this global event, which will feature technologies from the world over, allowing steel producers to compete in today’s global market. At the conferences more than 550 technical presentations will provide a very comprehensive technical program for the steel industry. In the exhibition hall about 500 exhibitors will display their products and services. As the annual kick-off event, AIST foundation golf classic 2016 has been arranged for Sunday, 15 May, in two sessions, in the morning and in the afternoon respectively, to be held at Chartiers Country Club what is known as a “shot maker’s course”.

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

MPT International 2 / 2016

Unlike 2010 and 2013, AISTech 2016 will not start just the day after the Pittsburgh marathon, that takes place two weeks earlier. In 2016 Pittsburgh is celebrating the 200th anniversary. The bicentennial celebration marks the 200th anniversary of Pittsburgh’s incorporation as a city, which gave Pittsburghers the right to vote and govern themselves. There are exciting events and activities happening throughout the city all year long.

Iron and steel technology exposition The 2016 exposition is slated to be the largest yet, with 310,000 square feet (29,000 m²) of exhibit space and more than 500 exhibitors. The AISTech 2016 exposition is an opportunity to meet face-to-face with the individuals who specify, design, deliver and commission plants and facilities associated with the production and processing of iron and steel. The exhibition will feature more than 500 U.S. and international companies for

an unrivaled display of steel technology. Due to increased demand, organizers of AISTech 2016 have expanded the exposition floor to accommodate the growing number of exhibitors for the 2016 show. The exposition will be available for all attendees to explore.

Conference schedule The technology conference will showcase more than 550 presentations on aspects of iron and steel manufacturing technology. Highlights include the latest environmental technologies throughout the iron- and steelmaking process; safe work practices and procedures for projects, production, and maintenance; cutting-edge research and advancements in the processing, product development, and application of steel; and discussions on efficient material movement both within the facility and to the customer. The three day technical program will kick off on Monday with the J. Keith Brimacombe memorial lecture. The 2016 Brimacombe memorial lec-

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28

››› EVENTS

turer is Prof. Peter Hodgson, ARC Laureate fellow, Alfred Deakin professor, pro vice chancellor (Strategic Partnerships), Deakin University. His lecture is titled “Engineering steels at the nanoscale for improved performance.”

President’s award breakfast and town hall forum

▪ John Brett, president and chief executive officer, ArcelorMittal USA; ▪ Piotr Galitzine, chairman and chief executive officer, TMK IPSCO; ▪ Lourenco Goncalves, chairman, president and chief executive officer, Cliffs Natural Resources Inc.; ▪ Doug Matthews, senior vice president Industrial, Service Center and Mining Solutions, United States Steel Corp.; ▪ Glenn Pushis, senior vice president,

al conference and exposition. Attending AISTech will procure an introduction to the steel industry and show the advanced technology in modern steelmaking. Attendance will provide opportunities for networking with steel industry leaders and a look at what is needed for a future career in steel. The student schedule includes a plant tour (sold out already) to Steel Dynamics Inc., an undergraduate student project presentation contest, and a graduate student poster contest. At the “Steel to students reception” students from various universities meet for a brief orientation and reception with representatives from a number of steel companies.

The AIST president, George J. Koenig, Hatch Associates Inc., will host the president’s award breakfast on Tuesday, 17 May, in the Spirit Sunday, 15 May of Pittsburgh Ballroom in the Golf classic 7 a.m. – 7 p.m. Convention Center. The breakStudent plant tour Noon – 4 p.m. fast program will consist of the Young professionals’ plant tour 12:30 – 4 p.m. presentation of several prestigious association-level awards, Ore-based metallics short course 1 – 5 p.m. including AIST’s steelmaker of Young professionals’ reception 5 – 6 p.m. the year. Mario Longhi, president and CEO of United States Ore-based metallics – Monday, 16 May Steel Corporation (U.S. Steel) short course J. K. Brimacombe 8 – 9 a.m. will address a keynote entitled Ore-based metallics – pig memorial lecture “The future of steel”. iron, cold direct reduced iron Exhibit hall open 9:00 a.m. – 6 p.m. Once again, a major high(DRI) and hot briquetted iron Technical sessions 9:30 a.m. – 5 p.m. (HBI) – are continuing to gain light of the event will be the popularity in steelmaking optown hall forum, which will University-industry Noon – 1:45 p.m. erations throughout the world. be held on Wednesday mornrelations roundtable ing, 18 May, at the Convention AIST, in partnership with the AIST welcome reception 5 – 6 p.m. Center. The town hall forum International Iron Metallics Steel to students reception 6 – 8 p.m. provides an inside view into toAssociation (IIMA), is bringday’s business climate from the ing together industry experts Tuesday, 17 May people who know: a panel of refrom around the world for one President’s award breakfast 8 – 9:45 a.m. spected leaders from some of day to lead a short course on Technical sessions 10 a.m. – 5 p.m. the steel industry’s best regardthe basics of ore-based metalExhibit hall open 9:30 a.m. – 6 p.m. ed companies. The town hall lics. The afternoon course will forum’s moderated discussion cover topics including: producExhibit hall reception 5 – 6 p.m. format gives attendees a deeption, sourcing, usage of prodWednesday, 18 May er understanding of the factors ucts in the electric arc furnace, that help determine the direcintegrated and foundry indusTechnical sessions 8 – 10 a.m. tion of not just an individual tries, value-in-use, shipping, Town hall forum 10 a.m. – noon company, but also the greater handling, and proper storage Exhibit hall open Noon – 4 p.m. steel industry. Those in attendof materials. The event will also include a panel discussion ance will have the opportunity Thursday, 19 May and question-and-answer sesto submit questions to the panPlant tours 7:30 a.m. – noon sion featuring industry proelists. The global steel industry was AISTech 2016 events at a glance (This schedule may be ducers and experts. challenged by excess capacity, subject to change.) excess production and excess long products steel group, Steel Plant tours imports in 2015. Despite a recovering construction market and a record year Dynamics Inc. Four plant tours will be held in confor auto sales, the headwinds buffeted The town hall forum will take place at junction with AISTech 2016. Ellwood steel producers. The AISTech 2016 town a new time for 2016: 10 a.m. – 12 p.m. Group Inc., Steel Dynamics Inc. – The hall forum will explore the challenges – Techs Division, and U.S. Steel Corp. Mon Valley Works will host the respecand discuss the opportunities – that lie Student activities tive industry tours. For the first time a ahead for the steel industry. 2016 town hall forum panelists are the following Students in all disciplines of engi- fourth tour will lead to a place of indusVIPs: neering with a technical interest in trial history: the Carrie blast furnaces ▪ John R. Bass, general manager public the iron and steel industry can benefit being part of Pittsburgh’s steel heritaffairs, Nucor Corporation; from attending this major internation- age. MPT International 2 / 2016

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30

››› RAW MATERIALS

Within a few hours an optimum mix of charge materials can be experimentally determined (Picture: Thyssenkrupp Steel Europe)

9QTNFoU Ć‚TUV CWVQOCVGF UKPVGT VGUV HCEKNKV[ UVCTVU QRGTCVKQP KP )GTOCP[ *HWWLQJ WKH ULJKW PL[ LV NH\ Ć‚QGLQJ WKH HIĆ‚FLHQW EOHQG RI YDU\LQJ UDZ PDWHULDOV DQG DFKLHYLQJ DQ RSWLPL]HG HFR IULHQGO\ FRPSRVLWLRQ IRU LURQPDNLQJ Ĺ? GRLQJ WKDW LV HDV\ QRZ IRU 7K\VVHQNUXSS LQ 'XLVEXUJ *HUPDQ\ 7KH WHVW IDFLOLW\ FDQ SURFHVV VPDOO EDWFKHV RI UDZ PDWHULDOV EHIRUH WKHLU XVH IRU PDVV SURGXFWLRQ After several years of research and development Thyssenkrupp Steel Europe has started operation of the world’s first automated sinter test facility. The aim of the steel producer is to Thyssenkrupp Steel Europe AG, Duisburg, Germany Contact: www.thyssenkrupp-steeleurope.com Heat and Power Engineering GmbH, Stuttgart, Germany Contact: www.heat-and-power.de

MPT International 2 / 2016

be able to adapt to the problem of varying raw material quality through test sinter production: “Using the new test facility we will be able to react quickly to changes in ore grades from different sources and offset differences flexibly. Thanks to full digitization of the test process we will be able to keep an eye not only on precise quality indicators but also the emissions related to the charge materials,� says Dr. Urban Janhsen, head of the “Technology Ore and Iron� team at Thyssenkrupp Steel Europe AG. The test facility will be able

to test in small batches how raw materials will behave in mass production. During sintering, fine grains of iron ore are mixed with other materials, heated intensely and baked together into lumps through fusing of the grain edges. The lump shape of the so-called sinter cake is necessary for the production of hot metal in the blast furnace. For the daily mass production of sinter the test facility will make it possible within a few hours to determine exactly the optimum mix of charge materials. From the weighing of samples to

The QR code links to a video on YouTube showing the sinter test facility in operation (https://youtu.be/mC_N4DMBc_M)

examining the finished sinter, a robot operates all handling and transport steps. The recipe and all operational data are recorded for further evaluation. The facility produces and analyzes 190 kg of sinter in about 90 minutes, supervised by only one operator.

The fully automated plant comprises weigh station, batch mixer, burner, crusher, gas analyzers and manipulator (Picture by courtesy of Heat and Power Engineering)

Emission monitoring to identify low-dust charge materials In the future the sinter test facility will also help reduce emissions from the production sinter plant. A key innovation is precise dust analysis during the entire test process, designed to facilitate reductions in emissions. Dust emissions are measured by laser and can be assessed as representative samples. Thanks to the fully automated workflow, low-dust charge materials can be identified and the optimum charge mix determined. Thus, the sinter test facility represents a further active contribution to improving the environmental situation in Duisburg, Germany. Only recently Thyssenkrupp began building a further modern fabric filter for the sinter plant here. Equipped with Siemens automation, the facility was designed, built and supplied as a turn-key plant by Heat and Power Engineering GmbH. The facility also meets high standards in terms of ergonomics and occupational safety thanks to automation of handling processes.

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32

›››    IRONMAKING

NLMK Group to reconstruct one of its biggest blast furnaces in Lipetsk, Russia NLMK Group, an international steel company with assets in Russia, the USA and the EU, will modernize blast furnace No.6 at its production site in Lipetsk, Russia. The blast furnace has a capacity of 3.2 million t/year of hot metal. The upgrade, planned to begin in Q1 2018, will extend the service life of the blast furnace by at least 20 years and boost its productivity by 8% to 3.4 million t/year of hot metal.

In 2018, blast furnace No. 6 will be dismantled right down to its foundations and then completely rebuilt

In preparation of a complete reline of blast furnace No. 6 at Lipetsk, Russia, NLMK recently signed a contract

NLMK Group, Lipetsk, Russia Contact: www.nlmk.com Paul Wurth S.A., Luxembourg Contact: www.paulwurth.com E-mail: paulwurth@paulwurth.com

MPT International 2 / 2016

awarding to Paul Wurth engineering, supply of equipment and technology as well as site supervision related to the rebuild of the BF’s central unit, i.e. the blast furnace proper and directly attached systems and equipment. Konstantin Lagutin, NLMK Group vice president for investment projects, said: “This project is part of the programme we announced previously aimed at upgrading and enhancing the reliability

of our equipment. At the same time, it will have a substantial economic effect. The upgrade will result in a blast furnace that is greener, more productive, and more efficient in terms of its consumption rates. Reconstruction of the blast furnace dedusting systems will provide a six-fold increase in the efficiency of off-gas treatment, and achieve a level of performance that is among the best in the global steel industry.”

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collision risks stops the robot and retracts it back into parking position automatically. O Cartridge exchange either

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manually by operator in safe distance or automatically, based on a classical cartridge rack enabling the concurrent storage/usage of different cartridge types. O Tool exchange by mecha-

O Increase of flexibility – tool exchange provides for multiple functions with solely one robot. O No interruption of power-on cycle and foaming slag practice during temperature and sample taking.

nical clamping of two plates equipped with pins and holes. O Detailed furnace inspection with camera tool for detection of skulls, hazardous water leakages, bath level and refractory status.

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34

››› IRONMAKING

At the beginning of 2018, as part of the large-scale reconstruction, blast furnace No. 6 will be dismantled right down to its foundations and then completely rebuilt within a period of 135 days. Auxiliary facilities will also be upgraded, including the stoves, the dedusting systems at the cast house and stock house, and the blast furnace cooling system. Advanced technical solutions will be implemented to boost the productivity of the equipment: â–Ş Use of thin copper plate coolers will increase the blast furnace’s usable volume by 10%. â–Ş A new off-gas treatment system will enable the use of excess gas pressure for energy generation at the top-pressure recovery turbine (TRT), a new green energy generating facility. â–Ş A new, highly-efficient steam blower will supply a sufficient amount of cold blast to BF-6 using the energy of utilized steam. â–Ş Dedusting systems at the cast house and stock house will be upgraded, providing reduction in emissions and bringing this indicator down for all of Novolipetsk blast furnace operations by over 20%. Once the reconstruction is completed in mid2018, dedusting performance will deliver a new low of 5 mg/mÂł. The capex of the BF-6 upgrade project, which is part of NLMK’s “Strategy 2017â€?, is estimated at RUB 7.5 billion (approx. 106 million US$).

NLMK relies on blast furnace technology from Paul Wurth Paul Wurth, Luxembourg has been awarded the order for engineering, supply of equipment and technology as well as site supervision related to the rebuild of the BF’s central unit, i.e. the blast furnace proper and directly attached systems and equipment. Paul Wurth will adapt the basic engineering (delivered at an earlier stage) to the final technical solutions chosen together with NLMK, and will be further in charge of the overall engineering which will be executed in close collaboration with the local design institute Lipetsk Gipromez. Paul Wurth’s scope of supply comprises the BF shell, hearth lining with super-microporous carbon and ceMPT International 2 / 2016

ramic cup, all cooling elements (copper and cast iron staves, copper cooling boxes, tuyeres and tuyere coolers), low-energy tuyere stocks and a completely new bustle pipe. The original Bell Less TopŽ, Paul Wurth’s first ever reference in the former Soviet Union and in operation since 1978, will be replaced completely by a new, parallel hopper-type charging system (60 m3 hopper volume) including the pressure equalizing and bleeder valves. Furthermore, Paul Wurth will supply the cooling water pump house, the complete instrumentation, general electrical and control equipment.

ly awarded to Paul Wurth: the implementation of measures related to the improvement of the top gas cleaning system, the top-pressure energy recovery turbine (TRT) and the pulverized coal injection (PCI) plant for BFs No. 6 and 7 is currently under way.

Powerful ironmaking site in Lipetsk Besides sintering operations and coke-chemical operations, Novolipetsk currently operates five blast furnaces: â–Ş BF-3 with a production capacity of 1.6 million t/year,

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On the process side, blast furnace control will be supported by TMT’s stockline recorders, the SOMA acoustic temperature measurement system and the 3D TopScan profilemeter. For the casthouse, four sets of TMT’s fully hydraulic clay guns and taphole drills as well as radar level probes for torpedo ladles will be supplied. All hardware and equipment supply are scheduled to be completed by the second half of 2017. It is planned to erect and commission the furnace within a 135-day shutdown starting in February 2018. Some important auxiliary plants related to this furnace are already subject of orders previous-

â–Ş BF-4 with a production capacity of 2 million t/year, â–Ş BF-5 with a production capacity of 2.8 million t/year and â–Ş BF-7 with a production capacity of 4.2 million t/year. Blast furnace No. 7 is the first and only blast furnace built in a post-Soviet country. Blast furnace No. 7 was built using the most advanced, innovative technical solutions developed by leading Russian and international engineering companies. The entire production process is based on the best available environmental and resource efficient technologies, including highly efficient dust collection and closed-loop water systems.

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The dedusting system at the casthouse will be upgraded to further reduce emissions

The new blast furnace No. 6, with a hearth diameter of 12.0 m, an inner volume of 3,818 m3, 32 tuyeres and 4 tapholes, will be designed for a nominal production of 3.38 million t/year of hot metal.

Novolipetsk reached all-time high output in 2015 In 2015, Novolipetsk, NLMK Group’s main production site in Lipetsk, produced 12.85 million t of steel (+2.4% year-on-year), an all-time high in the history of the integrated iron and steel works. This record performance was supported by productivity improvements throughout the value chain of the site. Sergey Filatov, Novolipetsk managing director, said: “Over the last 15 years, Novolipetsk has seen a technological break-through: we have significantly modernized our facilities and expanded our production capacity by over 50%. We are now using the potential this has unleashed to improve the efficiency of technological processes and productivity. Our record output and the significant reduction of costs is evidence of the progress we have achieved.” In 2015, all production stages at Novolipetsk posted record performance. Sinter output totalled 15.2 million t MPT International 2 / 2016

(+2.7% year-on-year), including 14 million t of skip sinter (+3.9% year-onyear). The quality of sinter is improved: the amount of screenings has been reduced to an all-time low of 7.3%. At the coke-chemical operations, record performance in optimizing raw material consumption was achieved, with dry coal charge consumption per t of dry bulk coke reaching a record low of 1,309 kg/t. The output of hot metal at the blast furnace operations increased to 12 million t (+5.5% year-on-year) as a result of improved ironmaking technology, mastering pulverized coal injection, and increased operational efficiency. Consequently, commercial pig iron production almost doubled to 631,000 t. As a result of projects aimed at improving resource use efficiency, coke consumption continued to reduce year-on-year by 3%. At the steelmaking operations, the highest productivity over the entire history of BOF operations at the Lipetsk site was achieved. 12.85 million t of crude steel (+2.4% year-on-year) was produced in 2015. Output of slabs with special dimensions featuring superior chemical composition, the bulk of which is supplied to the domestic market, increased by 21% to 1.03 million t. These products are used for com-

plex infrastructure solutions and in machine building. Also, finished product output spiked in 2015. Over 6 million t of hot rolled coil was produced, an all-time high considering the complexity of the product mix produced on the wide hot rolling mill 2000 in 2015. Deliveries of commercial galvanized steel strip increased by 8.6% reaching 0.64 million t. Deliveries of electrical (dynamo) steel increased by 5% to 250,000 t. Production of 1st choice transformer steel increased by 1% to 93,000 t. Output of top steel grades grew by 0.4% to 100,000 t. Total transformer steel production in 2015 increased by 12% to 102,000 t. Novolipetsk is the main production site of the NLMK Group. More than that, Novolipetsk is the nucleus of NLMK Group’s unique production chain, with assets in Russia, the EU and the USA. The steel production volume of the Lipetsk site is approximately 18% of all steel produced in Russia, and approximately 80% of all steel products produced by NLMK Group. Novolipetsk’s high-quality steel products are used in various strategically important industries, from construction and engineering to the manufacture of power-generating equipment and large-diameter pipes.

››› STEELMAKING

38

'HƂEKGPV JQV OGVCN RTGVTGCVOGPV VQ UCVKUH[ VJG TGSWKTGOGPV QH NQY UWNRJWT CPF RJQURJQTWU EQPVGPVU Limited availability of high-quality ore as well as highly volatile prices of these selective TXDOLWLHV KDYH LQH[RUDEO\ LQƃXHQFHG WKH FRQGLWLRQV RI LURQPDNLQJ RSHUDWLRQV IRU some years, leading to a growing demand for hot metal pretreatment prior to further processing or ingot casting. Contents of sulphur, silicon, phosphorus and carbon are W\SLFDOO\ DGMXVWHG LQ KRW PHWDO SUHWUHDWPHQWV RU UHƂQLQJ IDFLOLWLHV

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Since the 1980s, the quality of raw materials and fuels used in iron- and steelmaking has become increasingly worse. This global trend has led to a deteriorating hot metal quality in terms of higher contents of impurities. At the same time steelmakers have been faced with the growing demand for clean steel with low and ultra-low contents in particular of sulphur and phosphorus. The decreasing availability of premium raw materials and fuels with low contents of unwanted and harmful elements and the growing pressure to lower production cost by purchasing cheap raw materials have led to a doom loop. In the past, western steelmakers generally responded to this challenge by optimizing their facilities, improving the degree of automation, introducing bottom stirring in BOF converters and by pushing the productivity of their production units to ever new records. But these efforts have come to an end and further progress can be only attained by alternative concepts. In contrast, Japanese steelmakers opted for a different very radical path, focusing on intensive hot metal pretreatment taking advantage of the benefits of the low treatment temperature. As a result they established a different but competitive way of steelmaking. It is the right time to call the concepts and results of hot metal pretreatment to mind and investigate which chances the application of these technologies to the conventional steelmaking route may provide.

Desiliconization with gaseous and solid oxygen and variation of the hot metal temperature for desiliconization [5] MPT International 2 / 2016

Hot metal desulphurization Sulphur in blast furnace (BF) hot metal mainly comes from fuels such

as coke, coal, and oil. With the exception of some very specific steel grades, sulphur is undesirable and has to be removed. Although the blast furnace is a very efficient facility for desulphurization and able to remove typically 85% of the total sulphur input, 15% remain in the produced hot metal. This is still too much to satisfy the requirements of steelmaking. Therefore additional desulphurization outside the BF is required [1]. Today desulphurization of hot metal is carried out by the following methods: ▪ injection of desulphurization agents into torpedo ladles, ▪ injection of desulphurization agents into open ladles, ▪ addition of desulphurization agents into open ladles using the KR impeller stirring system, ▪ desulphurization in the BOF converter, ▪ desulphurization in the steel ladle. The costs to remove 1 kg sulphur by different procedures is calculated [2] to be ▪ 27 US$ if executed in the blast furnace, ▪ 10.5 US$ if done by hot metal ladle treatment, ▪ 177 US$ if done in the BOF converter, ▪ 64 US$ if done in the steel ladle. The cost comparison clearly shows that desulphurization of hot metal is

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less costly than the effort of sulphur removal in the BF [2]. This topic has been discussed in detail [4]. The BOF converter is the most expensive unit to perform desulphurization and steel desulphurization should only be performed if necessary. Hot metal desulphurization by injection technology is carried out by deep injection of powdery reagents like lime, calcium carbide, magnesium, soda ash, or mixtures thereof into ladles (torpedo ladles, transfer ladles, or BOF charging ladles). Refractory lined lances are immersed deep into the hot metal while the reagents are injected with high speed using mainly nitrogen as transport gas in mono-, co-, or multi-injection mode. Efficient desulphurization requires intensive mixing of reagents, metal and slag. This is achieved with a gas/ solid mixture deeply injected into a ladle. A minimum bath level of 1.5 m has to be ensured in order to maximize the residence time of the particles in the bath. Injection desulphurization in open ladles is more efficient compared to torpedo ladles due to their unfavourable shape. The consumption of reagents in torpedos is approximately 15 – 25% higher compared to open ladles. High mixing power is also achieved by mechanical stirring with an impeller. This technique is used by SPCO’s KR (Kanbara Reactor) system [3]. While a refractory lined rotating impeller is immersed into the metal and thus providing a good mixing of reagent, metal and slag, cheap coarse lime is fed by a vibration feeding system as desulphurization agent. The KR system achieves very low sulphur levels at comparably low reagent cost. Investment cost and other operating cost of the KR are typically higher compared to the deep injection technology. In any case it is essential to properly remove the desulphurization process slag before the hot metal is charged into the BOF.

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Hot metal desiliconization The silicon in hot metal comes mainly from the ash of the coke and the blast furnace operation. Silicon has a higher oxygen affinity than phosphorus and carbon. It is thus the first element to be oxidized during oxygen blowing in the BOF converter. The competiMPT International 2 / 2016

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tive reactions of phosphorus and in particular carbon start with decreasing silicon content in the hot metal, depending on the temperature. High silicon content in hot metal of more than 0.7 – 1.0% leads to problematic oxygen blowing: â–Ş increased consumption of lime in order to maintain a suitable basicity, â–Ş increased iron losses in the slag, â–Ş decreased BOF capacity due to increased slag amount, â–Ş increased oxygen blowing time and thus decreased productivity (sometimes even a double slag practice is necessary), â–Ş increased danger of slopping (instable blowing process). Therefore control of the silicon content below say 0.7% is desirable and one of the benefits of hot metal desiliconization. Another reason is that a silicon content of less than 0.15% is necessary before effective dephosphorization can start. The ability to control the silicon content offers maximum flexibility regarding the hot-metal-ratio (HMR) and thus allows responding to varying scrap and raw material prices to minimize the BOF operation cost. The process of hot metal desiliconization requires oxygen which can be supplied as gaseous oxygen or in form of iron oxides (“solid oxygenâ€?). Hot metal desiliconization with solid oxygen drops the temperature by 10°C per 0.1% of removed silicon (e.g. using scales as source of solid oxygen). Including slag skimming this accounts for huge temperature losses in case of high initial silicon content in the hot metal. Desiliconization by means of gaseous oxygen is more effective compared to the addition of an agent. Assuming initial silicon content of 0.7%, approximately 1.4 m3 (s.t.p.) O2 per t per 0.1% of removed silicon is required. The removal of silicon is a function of time for adding solid oxygen (here: scales), oxygen injection, and oxygen top blowing [5]. Blowing of gaseous oxygen for desiliconization is exothermic and increases the temperature by approximately 27°C per 0.1% of removed silicon. The huge amount of generated slag and fumes makes it challenging to control this process in ladles. High mixing power of the desiliconization agents, metal and slag is MPT International 2 / 2016

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required for efficient desiliconiza5GRCTCVKQP QH VJG TGĆ‚PKPI RTQEGUUGU tion. This can be achieved by sever- Works al methods, e.g. natural flow, gas stir&G 5K &G 5 &G 2 &G % ring by injection, mechanical stirring with an immersed impeller. In general, Torpedo Ladle Converter Converter the desiliconization efficiency of a pro- Yawata KR MURC cess should be high enough to lower partially Torpedo Injection the silicon content to match with the requirements of proper oxygen blowing in the converter or to lower the silTorpedo Torpedo Converter Converter icon content to allow efficient dephos- Muroran LD-ORP phorization. MURC (De-S in LF) The following methods are applied at industrial scale: â–Ş top addition of desiliconization Converter Converter Converter Converter agents into the BF runner with or Nagoya (partially) De-S LD-ORP without slag separation by means Furance of a skimmer blade or by adding the agents directly into the hot metal stream during reladling. In both Torpedo Ladle Converter Converter cases the natural flow of the hot Kimitsu KR LD-ORP metal is utilized to generate mixMURC partially Torpedo ing power. â–Ş injection of desiliconization agents into torpedo ladles with or without Qita Torpedo Ladle Converter Converter simultaneous oxygen blowing, Injection MURC â–Ş injection of desiliconization agents partially Ladle into open ladles with or without simultaneous oxygen blowing, â–Ş top addition of desiliconization 1XGTXKGY QH VJG JQV OGVCN VTGCVOGPV RTQEGUUGU CU CRRNKGF CV VJG FKHHGTGPV agents into open ladles using a KR UVGGNOCMKPI YQTMU QH 0KRRQP 5VGGN = ? impeller stirring system to provide mechanical stirring. The first method (above) is cheap and But desiliconization down to 0.15% Injection or top addition of agents simple as few equipment is needed but – which is the precondition to proceed into open ladles allow precise control of efficiency and predictability are poor. with dephosphorization – requires the final silicon content and adjustment An addition of 10 – 20 kg sinter dust fines one of the other methods mentioned of the temperature to a certain extent. per t of hot metal achieves 30% removed above. Injection of agents into torpe- Furthermore these methods often allow silicon. Injecting the desiliconization re- do ladles saves process time as the re- usage of existing facilities already used agents into the blast furnace runner in- actions can take place “on the roadâ€?. for desulphurization. Mill scale, magcreases the desiliconization rate to 40%. Due to the shape of the torpedo it is dif- netite fines, hematite fines or sinter dust Nakasuga et. al. introduced a process us- ficult to completely remove the high are used as sources of solid oxygen in the ing mechanical stirring with an impeller amounts of slag. As a result, the torpe- desiliconization agent with similar deimmersed in the hot metal runner. They do capacity is decreasing with every siliconization efficiencies. Lime and silireport improved desiliconization rates treatment as accretions accumulate ca are added to flux the slag to adjust the basicity and prevent excessive foaming. up to 55% [6]. All these methods have inside and at the mouth. fluctuations in the achieved silicon content, caused by varyFigure Desulphurization Desiliconization Dephosphorization ing temperature and varying flow velocity Process condition Reducing Oxidizing Oxidizing of the hot metal. The Oxygen activity Low High High desiliconization rates Hot metal temperature High High Low obtained with these methods are normalHigh High High Slag basicity (CaO/SiO2-ratio) ly sufficient to control Hot metal silicon content High Low (< 0.15%) the hot metal Si content below say 0.7% Hot metal carbon content High making it suitable for Mixing power of metal and slag High High High oxygen blowing in the BOF converter. (CXQWTCDNG EQPFKVKQPU HQT VJG UKPING JQV OGVCN RTGVTGCVOGPV UVGRU MPT International 2 / 2016

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Hot metal dephosphorization Phosphorus (P) in the iron ore fed to the blast furnace is converted into the hot metal by a rate of >90%. The only possibility to limit the phosphorus content of the hot metal is to use a low P-containing iron burden. It is thus clear, that higher P-content in hot metal requires higher efforts in steelmaking operations [1]. The BOF converter is a highly efficient facility to perform dephosphorization especially when equipped with strong bottom stirring [1]. Anyhow several limitations call for alternatives like hot metal desiliconization and dephosphorization. Applying hot metal dephosphorization reduces the required slag amount during oxygen blowing, and ensures achieving consistently ultra-low phosphorus contents at the end of blowing. In this sense, hot metal pretreatment is of great help in reducing the metallurgical work load of the oxygen blowing process. Basically hot metal dephosphorization makes use of the same agents as desiliconization. Oxygen in solid and/or gaseous form is needed. Iron oxides like mill scale, sinter dust fines, iron ore fines (e.g. magnetite or hematite fines), etc. are used as sources of solid oxygen. Blowing oxygen onto or into desiliconized hot metal will simultaneously initiate strong decarburization. Due to the generation of CO gas, such a process is extremely difficult to be managed safely in an open ladle. Therefore hot metal dephosphorization is done either in ladles with the sole use of solid oxygen or in a converter which provides enough space to handle the foamy slag. Similar to desiliconization, also dephosphorization of hot metal requires high mixing power. A simple addition of the reagent on the surface of the metal results in unacceptable long treatment time and tremendous temperature losses. Application of gas stirring via bottom bricks in the ladle improves the situation only slightly. Only deep injection of the reagents or mechanical mixing with impellers provide sufficient mixing power. The benefits of hot metal dephosphorization can be listed as follows: â–Ş Dephosphorization is more effective at lower hot metal temperatures than at steel temperatures. â–Ş A lean slag BOF blowing process for decarburization can be established. MPT International 2 / 2016

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â–Ş Slag from a BOF process using dephosphorized hot metal contains no free CaO and allows direct utilization as construction material e.g. for road layers, etc. â–Ş Slag from a BOF process using dephosphorized hot metal contains no P2O5 and can be re-utilized for hot metal dephosphorization or more easy as a feedstock for sinter plants.

Hot metal pretreatment Process steps which are used to remove impurities from the hot metal can be summarized as hot metal pretreatment. These process steps are in-

serted between the blast furnace and the BOF converter. Main objective is the adjustment and control of the hot metal composition by removal of unwanted impurities like sulphur (desulphurization), silicon (desiliconization) and phosphorus (dephosphorization) along with their undesired inclusions (oxides, borides, nitrides, carbides, and chlorides). This is a precondition to produce clean steel. Less than 100 ppm total impurities are the standard requirement for quality steelmakers today. Desulphurization of hot metal is a standard practice carried out in nearly all steel plants around the world while desiliconization and dephosphoriza-

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tion have so far not been in the main focus of Western steelmakers, in contrast to Japan, where steelmakers started to investigate and develop hot metal pretreatment technologies as early as 30 years ago. A variety of hot metal pretreatment processes and technologies have been developed, applied, and reported in several papers during recent years. All these processes use different vessels to carry out the metallurgical work of desiliconization, dephosphorization, and desulphurization. All kinds of combinations using different vessels and logistics have been tried and practiced over the years. The most common metallurgical vessels are the: ▪ blast furnace runner, ▪ torpedo ladle, ▪ open ladle (transfer or charging ladle), and ▪ BOF converter. One of the early pioneers was Nippon Steel, which developed and introduced the slag minimum process (SMP) in 1983. The main idea of this process is to separate the desiliconization reaction from the dephosphorization and the decarburization reactions and separate the process slag. At industrial scale, this process consisted of hot metal desiliconization in the ladle using a KR impeller system. The BOF converter is then utilized for dephosphorization and decarburization. Advantages compared to the conventional process using the BOF converter for removal of (sulphur), silicon, phosphorus and carbon, were found to be reduced consumption of fluxes (mainly lime), reduced slag amount, and increased metallic yield. It is reported that the slag amount of this process for a hot metal silicon content of 0.15% is half compared to the conventional process [7]. Further investigations subsequently led to technologies using the injection of suitable reagents into (oversized) torpedo cars. This operation procedure offered significant benefits in terms of “less slag” production, slag recycling, etc. but it had also some disadvantages due to the excessive handling requirements and the huge temperature losses. Nippon Steel installed and operated the torpedo-based “simple refining process (SRP)” for hot metal dephosphorization in their Kimitsu and Yawata works [1]. Another Japanese steelmaker, Kawasaki Steel, installed and operated MPT International 2 / 2016

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similar processes in their Mizushima and Chiba works, also using the torpedo ladle as reactor for dephosphorization. They applied the intensive pretreatment operations in dedicated hot metal pretreatment centres located between the blast furnace and the steel plant. Chiba works firstly used gaseous oxygen blowing during dephosphorization in the torpedo in order to reduce the tremendous temperature losses [8]. The huge slag generation due to oxygen blowing in the torpedo ladle during dephosphorization and a highly restricted scrap ratio led Nippon Steel’s Nagoya works to modify their BOF converter into a hot metal pretreatment converter for desiliconization, dephosphorization, and desulphurization. After tapping and separation of the slag the pretreated hot metal is charged to another converter where decarburization takes place. This process was named LD-ORP (LD – optimized refining process) [9]. The first hot metal pretreatment centre using torpedo ladles for desiliconization and open ladles for dephosphorization and desulphurization was installed and operated at Nippon Steel Oita works. The process is completely based on the deep injection technology [9]. NKK’s Fukuyama works (today: JFE) operated a hot metal pretreatment process where the silicon content of hot metal from the blast furnace is already lowered to 0.2%. The hot metal is then sent to the desiliconization station, where it becomes ultra-low silicon hot metal with a silicon content

of less than 0.1%. At the desiliconization station, oxygen gas is used along with sintered iron ore (iron oxide) as reagents for desiliconization. The reaction vessel is an open ladle, and the hot metal is vigorously stirred by injecting lime through an immersed lance. This method provides a highly efficient and stable supply of ultra-low silicon hot metal which improved the efficiency of lime for dephosphorization significantly. As a result, the slag generation throughout the entire steelmaking process could be lowered to a minimum amount. Therefore NKK named this completely ladle-based process “zero slag process (ZSP)” [10]. A further development was the multirefining converter process (MURC) which allows desiliconization, dephosphorization and decarburization treatment in one vessel without tapping and recharging. Desiliconization and dephosphorization are carried out with a low basicity slag, high percentage of total iron content and a hot metal without previous desiliconization treatment. After dephosphorization the P-rich slag is tapped and sent for dumping. The slag of the following decarburization step is totally recycled as it remains as a hot feedstock in the converter for the next desiliconization and dephosphorization treatment [11, 12]. These converter-type hot metal pretreatment processes are today’s standard operation practice in all works of Nippon Steel. Beside the ability to produce clean steel with low and ultra-low contents of sulphur and phosphorus, there are

additional benefits of hot metal pretreatment. Benefits of hot metal desulphurization regarding blast furnace operation [1]: ▪ The BF can be released from some metallurgical work of desulphurization which increases BF productivity. ▪ Coke, coal, and flux charges to the BF can be reduced and the hot metal yield can be increased. ▪ The BF alkali balance can be improved due to operating at a lower basicity and a cost saving “lean slag” production becomes possible [4]. There are also benefits of hot metal desiliconization and dephosphorization regarding BOF operation, such as reduced refractory attack by the less acidic slag. Double slag technique, often applied in case of high silicon hot metal, can be avoided. This shortens the tap-to-tap time and increases productivity. The slag generated during oxygen steelmaking using dephosphorized hot metal has a low phosphorus content which allows utilization of this slag in the sinter plant as part of the feedstock for the blast furnace. Normally, the recycling of BOF slag in the blast furnace without previous hot metal dephosphorization is limited due to an enrichment of the phosphorus content in the hot metal. Low contents of silicon, phosphorus, and sulphur in the hot metal allow operating the BOF for more or less decarburization only with minimum slag (less than 1/3 of the standard amount) and thus minimizing lime consumption. Besides the obvious saving, the so reduced slag amount leads to a smoother blowing behaviour, less slopping, and an easier control of the endpoint targets. Converter operation with minimum slag even allows (partial) substitution of FeMn added at BOF tap by much cheaper Mn ore added as BOF (scrap) charge. Due to the small slag amount, the major portion of the manganese from the Mn ore is dissolved in the steel instead of being oxidized to the slag. This operation allows cost savings of several US$ per t. Anyhow, the rather smart hot metal pretreatment technologies did not have a major breakthrough outside of Japan and at some installations in Taiwan and South Korea. Today conditions have changed and there is an increasing need for steelmakers to in-

vestigate opportunities to benefit from including hot metal pretreatment steps in their existing conventional BF-BOF production route in order to relieve their production units from some metallurgical work.

Integration of hot metal pretreatment into the conventional process route In order to evaluate the technical feasibility and the economic benefits, an optimum sequence has to be defined. Considering favourable conditions for the individual hot metal pretreatment steps and the typical logistics of the conventional BF-BOF steelmaking route, the process flow can be realized with little modifications. E.g., desiliconization can be performed in the BF runner with separation of the desiliconization slag during pouring into a torpedo ladle by means of a skimmer blade. This is followed by dephosphorization based on injection of agents into the torpedo ladle. After reladling into the BOF charging ladle, the dephosphorization slag is skimmed off. Desulphurization is then carried out by means of injection technology or a KR system. After the desulphurization slag has been removed, the hot metal is charged into the BOF converter and the decarburization process is performed by means of oxygen blowing. It is known that during desiliconization with a proper agent also a certain amount of sulphur is removed. This advantage can be utilized when desiliconization is carried out before desulphurization. Although this sequence is a “natural” sequence taking advantage of the “low cost” possibility to desiliconize in the BF runner as the first step, another sequence is often more advantageous from a thermodynamic point of view. After dephosphorization the oxygen activity of the hot metal is increased. This has a negative impact on desulphurization. In addition, desulphurization as well as desiliconization, both favour high temperature. In contrast, dephosphorization favours low temperature. Summarizing, it can be said that an optimum sequence has to be individually selected for each installation depending on the available facilities, in particular existing vessels for desulphurization treatment, metallurgical targets, and the hot metal temperature.

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Many desulphurization stations for open ladles and torpedo ladles are in operation worldwide based on either injection technology or mechanical stirring technology (KR systems). These existing stations can be fairly easily extended to hot metal pretreatment stations, providing desiliconization and dephosphorization in addition to desulphurization when needed and beneficial. The major reasons why hot metal desiliconization and dephosphorization in open ladles did not have a real break-through in the international iron and steel industry are limited capacity of treatment facilities and huge temperature losses. Existing treatment facilities especially for desulphurization are normally sized to meet the requirements of the converter cycle. Additional treatments in these facilities for desiliconization and/or dephosphorization lead to an increased load and thus the converter cycle can no longer be met. Every treatment step causes a temperature drop of the hot metal: desulphurization injection, slag skimming, desiliconization injection, slag skimming, dephosphorization injection, and again slag skimming. In total this accounts for more than 100°C which often impedes the execution of all steps due to a too low final hot metal temperature. In particular the last dephosphorization step can often not be executed due to this reason. Oxidation of carbon in a ladle process is especially critical due to the generation of CO gas and the excessive foaming of the slag. Therefore the oxidation of carbon during desiliconization and dephosphorization has to be limited and controlled to the best possible extent. Küttner has designed a process for desiliconization and dephosphorization of hot metal which overcomes the drawback of huge temperature losses by using chemical heating with gaseous oxygen. The generated heat is tak-

en from the exothermic reaction of silicon with gaseous oxygen in contrast to the reaction of silicon with iron oxides. In order to control the temperature increase during the removal of silicon to the desired extent, a balanced supply of gaseous oxygen and injected solid oxygen from iron oxides deep into the ladle is used. As the silicon has to be removed for dephosphorization anyway, this effect can be utilized to compensate the temperature losses at least to some extent. This process requires the injection of a mixture of CaO and iron oxide. Some additives are used to control slag composition and excessive slag foaming. The required reagents are injected as a premix in mono-injection mode or as single components using co- or multi-injection systems. At an incoming silicon content of 0.5% and 1,323°C, the consumption of desiliconization agent to achieve 0.15% [Si] is approximately 20 kg/t. Phosphorus removal requires high mixing power to achieve a low phosphorus content. A dephosphorization rate of 70% (e.g. reduction of phosphorus from 800 ppm to 250 ppm) is achieved by injecting approximately 22 kg/t of a dephosphorization agent. It is almost impossible to achieve sufficiently high mixing power with top addition and lance stirring or bottom plug stirring. Injection of solids or mechanical stirring by an impeller are the preferred methods for hot metal dephosphorization.

Conclusions Production of clean steel requires removal of all undesired impurities especially sulphur and phosphorus. The removal of sulphur from hot metal is already applied by most steelmakers but dephosphorization is traditionally carried out in the BOF at least by Western steelmakers. As this process is often already opti-

mized to its limits, additional incoming phosphorus contents can only be handled at the expense of increased production cost and reduced productivity. Purchasing premium iron ores with low phosphorus contents is often the only way to avoid these problems. On the other hand, premium low phosphorus iron ores are significantly more expensive than ores with higher phosphorus contents. Therefore economic benefits can be gained by introducing selected hot metal pretreatment steps before charging the hot metal into the BOF converter. By blowing pretreated low-P hot metal in the BOF converter, ultra low phosphorus steel grades with contents of less than 50 ppm can be easily achieved. Another benefit arises from a lean slag BOF operation which allows partial substitution of FeMn with many times cheaper Mn ore. Savings of several US$ per t of steel can be achieved. Furthermore the generated BOF slag can be utilized as desiliconization agent or BF feedstock. As many already existing desulphurization stations based on injection technology or mechanical stirring (KR) are suitable to be used also for desiliconization and dephosphorization, extension of desulphurization to triple-D is often just a short step. The main drawback of the ladle-based hot metal pretreatment technologies is the huge temperature drop of the hot metal with the already discussed negative effects on the downstream operations. A process concept has been described which utilizes the exothermal oxidation of silicon with gaseous oxygen in order to generate heat required to compensate the temperature losses at least partially. This process can be applied to the production sequence of nearly all plant concepts and layouts and thus helps to create capabilities of processing cheaper raw materials.

References [1] Huesken, R., Cappel, J., Fechner, R.: Iron & Steel Technolo-

[4] Huesken, R., Cappel, J.: MPT International; 05/2012; Desul-

gy; November 2011; Use of Hot Metal with High Phosphorus

phurization Strategies in Oxygen Steelmaking; page 42-49

Content in Combined Blowing BOF Converters; page 46-57

[5] Kawauchi, Y., Maede, H., Kamisaka, E., et al.: ISIJ; 1983; Met-

[2] Yin, R.: Metallurgical Industry Press; 2011; Metallurgical Process Engineering; page 222 [3] JP Steel Plantech: Product Information; 2015; KR Hot Metal Desulphurization System; page 18 MPT International 2 / 2016

allurgical Characteristics of Hot Metal Desiliconization by Injecting Gaseous Oxygen; page 1730-1737 [6] Nakasuga, T., Kimura, S., Uchida, N.: AISTech 2012 Proceedings; Reaction Analysis of Continuous Desiliconization and

STEELMAKING Desulfurization in the Hot Metal Runner at Kobe No.3 Blast Furnace; page 439-447 [7] Itoh, Y., Satoh, S., Kawauchi, Y.: Transaction ISIJ; Vol. 23, 1983; Development of Slag Minimum Refining Process by Desiliconization of Hot Metal [8] Nabeshima, Y., Taoka, K., Yamada, S., et al.: Kawasaki Steel Technical Report No. 24; April 1991; Hot Metal Dephosphorization Treatment in Torpedo Car; page 25-31 [9] Endoh, K.: Nippon Steel Technical Report No. 61; April 1994; Recent

2003; Steelmaking Technologies Contributing to Steel Industries; page 18-27 [11] Sasaki, N., Mukawa, S., Ogawa, Y., Miyamoto K.-I.: Nippon Steel Technical Report No. 104; August 2013; Improvement of Hot Metal Dephosphorization; page 26-32 [12] Kumakura, M.: Nippon Steel Technical Report No. 104; August 2013; Advances in Steel Refining Technology and Future Prospects; page 5-12

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[10] Tanabe, H., Nakada, M., el al.: NKK Technical Review No. 88,

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5JCHV CTE HWTPCEG YKVJ GHĆ‚EKGPV scrap preheating concept provides low conversion costs Is productivity the main goal driving the meltshop operator or is a cost-oriented strategy the better one? A 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 how such a strategy may be implemented. Here, a basic concept and idea ZDV WUDQVIRUPHG LQWR D PDWXUH H[WUHPHO\ ĆƒH[LEOH DQG KLJKO\ HIĆ‚FLHQW ORZ FRVW VFUDS recycling facility.

Introduction With the SHARC (shaft arc furnace) concept, Greek steel producer Hellenic Halyvourgia SA (HLV) and SMS group have developed a unique process for scrap preheating. The utilization of scrap in general consumes half the energy compared to producing steel from ore. The SHARC saves even more natural resources by using a minimum amount of primary energy for preheating and by utilizing maximum the hot off-gases within the furnace. The electric arc furnace below the shafts is equipped with modern burner and injection technology. The preheating effect is optimized by the efficient use of chemical energy. Thus, the SHARC furnace is highly productive, economically efficient and easy on the environment. Unlike in other scrap preheating systems with asymmetrical scrap charging equipment, in the SHARC furnace the entire furnace cross section over the height of the two shafts is available for energy transfer. The unique design with the symmetrical shape of the hearth with DC high current technology makes it possi-

Andreas Metzen, Hellenic Halyvourgia, Greece; Thomas Germershausen, Jan Bader, Alexander Bergs, SMS group, DĂźsseldorf, Germany Contact: www.hlv.gr E-mail: metzen@hlv.gr

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Scrap bucket Scrap discharge system

Preheating shaft Off-gas system Scrap retaining system

SIS system O2 injection

Transfer car

Components of the SHARC furnace design

ble. This leads to a longer residence time of the hot off-gases inside the preheating shaft and a more efficient heat transfer. With the SHARC furnace, it is possible to ensure economically efficient and smooth operation even when charging with low-quality scrap (low density) without additional pretreatment. This design is unique worldwide and has the advantage that the scrap is molten highly homogeneously.

The SHARC design The SHARC furnace consists of an EBT lower shell and a water-cooled upper shell on which two identical preheating shafts are vertically arranged. This symmetrical arrangement of the two preheating shafts results in a homogeneous distribution of the mechanical and thermal loads. The compact and efficient arrangement of the preheating shafts is made possible thanks to utilizing

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››› STEELMAKING

Thanks to the use of a pin-type bottom electrode, the preheating shafts can be arranged in a compact way

the tried-and-tested DC high current technology and pin-type bottom electrode developed by SMS group. The off-gas is extracted from the SHARC directly below the lockable charging opening. As a result, the hot furnace off-gas is continuously drawn through the scrap column across its entire cross-section and over its entire length. Water-cooled fingers retain the scrap at the bottom part of the preheating shafts before it is charged into the electric arc furnace at the beginning of a new heat. The 34 fingers can be extended and retracted all together or individually. In this way, the homogeneously preheated scrap is distributed evenly inside the electric arc furnace. The temperature of the water-cooled shaft and wall panels is monitored by temperature sensors. Exact temperature control in the gas cleaning system ensures compliance even with the strictest environmental standards. The EBT taphole gate is operated by means of a pneumatic cylinder. The lower and water-cooled upper shells are installed on a tilting platform; tilting in slagging direction and tapping direction is performed via two hydraulic cylinders on each side. The SHARC furnace is operated with the exchange shell technology developed by SMS group. To change the furnace shell, the complete tilting platform with the lower and upper shell is placed onto an adapter on the tapping ladle car and moved into the operating range of the bay crane. In this position, the shell can be changed and the newly lined shell is brought into its working position. No heavy-duty bay crane is required.

The SHARC process With regard to the composition of charge materials, the SHARC provides high flexibility while keeping production costs low. The scrap is charged into the two shafts from the top via scrap buckets. Four buckets are normally MPT International 2 / 2016

Tapping of the SHARC furnace

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residues, sponge iron (hot and cold), chrome ore, nickel powder, copper concentrate, and other fines. Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units. Köppern – Quality made in Germany. • State of the art technology • Process technology know-how

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››› STEELMAKING

After implementing various developments and modifications, the SHARC at HLV has been operating to the steelmaker’s fullest satisfaction. The 100 t/ 54 MW direct-current electric arc furnace features two preheating shafts in which the scrap is dried and preheated. During the last 14 years, it has been operating very reliably. In the DC furnace, the two shafts are located towards the front and the MPT International 2 / 2016

30

Finger movement

50

25

40

20

30

15 Tapping and turn around

20

10

10 0

MW burners

MW

60

The SHARC DC furnace is made for easier and more natural operation. The symmetrical conditions, the allover distribution of the scrap and the even division of the off-gases into the shafts provide reproducible results as well as uniform and highly efficient operation during melting and the liquid phase. All areas are reliably covered with scrap. While a furnace campaign lasts about 1,000 heats, the bottom elec-

5 0

10

5

15

20

25

35

30

s Shell burners

tap-to-tap time [min]

40

45

50

s MW electrical

55

0

s Door burner

Operational diagramme for electrical energy input

120

Charging 1 & 2 preheated bucket and 3 & 4 bucket

100

Charging 1 & 2 bucket for next heat

80 60 40 20 0

0

5

10

15

20

25

30

35

s O2 - lances

tap-to-tap time [min]

40

45

s O2 - burners

50

55

s Nat. gas

Operational diagramme for chemical energy input

100

362

344

350

330

327

321

315

301

300

90.61

250

90

88.42

200

150

95 289

84.26 80.23

81.88

85.22

85

86.03

Yield [%]

The SHARC at HLV

back side of the furnace with the electrode arm moving in between the two shafts. Different to other shaft furnaces, this guarantees equal scrap distribution around the circumference of the shell. Uneven conditions like one-sided scrap charging usually lead to an imbalance of the system which makes it difficult to control and operate. All systems in nature and physics strive for equilibrium and stable state conditions.

m3 / min

charged per heat in two batches. For this purpose, the top shaft covers are opening horizontally. The first batch of scrap charged is retained by water-cooled fingers installed at the bottom of the shaft and preheated by the off-gases of the previous heat inside the furnace. After the previous heat has been tapped, the first two preheated buckets of scrap are charged into the furnace from the fingers. The contents of buckets three and four are then charged directly onto the preheated scrap of the first two buckets. When using low-cost light scrap, the contents of further buckets can be charged without problems and without obstructing the process. Energy losses by charging additional buckets are minimized due to the shaft design. Troubles like overfilling, fireball effect and splashing such as occur in conventional furnaces, do not exist and even the process time will not increase significantly. This operating practice is not possible with conventional electric arc furnaces. After the scrap in the two shafts has dropped below the level of the fingers, these are extended again to hold the first two buckets for the next heat and the preheating cycle starts again. At the same time, the previous heat is fully molten in the electric arc furnace, decarburized and, if required, de-phosphorized by means of intense slag work. Lime and coal are added directly into the SHARC furnace via a conveyor system and an alloying hopper installed between the two preheating shafts. In this way, the furnace can also be charged with DRI, HBI and pig iron to be able to produce higher quality steel grades. At a temperature of 1,620 – 1,630°C, tapping is performed via the EBT taphole.

El. energy [kWh/tgb]

56

82.60 80

100

75 Heat 1

Heat 2

Heat 3

Heat 4

El. energy

Heat 5

Heat 6

Heat 7

Heat 8

Yield

6JG KORCEV QH VJG [KGNF QP VJG URGEKƂE GNGEVTKECN GPGTI[ EQPUWORVKQP s DCUGF QP TGCN heat data of Hellenic Halyvourgia with different yield rate

STEELMAKING trode has a service life of approx. 3,500 heats. In spite of the discontinuous operation of the furnace (eight hours per day on weekdays and 13 hours on weekend days), the furnace provides convincing results.

Operational results The features of the SHARC furnace provide for high productivity operation. Tap-to-tap time is significantly lower than that of other furnace types with a similar power input. The SHARC furnace at HLV is able to achieve productivity figures of up to 120 t/h and more. Such performance figures are achieved during a production day of eight hours operation and ten consecutive heats. The electrode consumption figure given by HLV also includes electrode breakages. In operational practice various measures were taken to improve electrode consumption. However, during 2012 – 2014, electrode consumption still amounted to approx. 0.75 – 0.79 kg/tgb (tons of good billet) on average. In August 2014, a new electrode arm was installed allowing bigger electrodes with a diameter of 700 mm (28”) to be used, replacing the previously used 600 mm (24”) diameter electrodes. The larger diameter makes the electrode much more robust. Since the bigger electrodes have been in use, there has been just one electrode breakage. And that was due to a wrongly loaded and charged skull. Due to the bigger diameter, electrode consumption has decreased to approx. 0.62 kg/ tgb, with weekly figures already being below 0.60 kg/tgb, which is the general target for that period. When being charged from the shaft into the hearth, the scrap mix has an average temperature of more than 700°C. In this way, energy consumption values as low as 280 kWh/t can be attained. When producing steel grades with high demands on purity, the scrap can either be preselected or partly substituted with virgin charge material. The main technical parameters of the furnace operation are as follows: ▪ charge mix: 100% scrap ▪ furnace capacity: 97 t ▪ shell diameter: 6,100 mm ▪ tapping weight: 97 t

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57

▪ ▪ ▪ ▪ ▪

transformer power: 78 MVA active power: 54 MW current: 79 kA secondary voltage: 684 V consumption of oxygen: 35.9 m3/ tgb (93% O2 purity; s.t.p.) ▪ consumption of natural gas: 6.4 m³/ tgb (s.t.p.) ▪ electrode consumption: 0.60 kg/t ▪ energy consumption: 320 kWh/tgb (yield factor of the scrap 81.5%) or 280 kWh/tgb (with a yield factor of 87.5%). All specific figures are related to one ton of good billets (tgb) which is impacted by the yield factor of the scrap. Specific electrical energy consumption has to be examined based on the above mentioned circumstances and influencing conditions such as the scrap yield factor. The yield depends on the scrap quality in terms of density, soil and ferrous rate. It has been proved that by using a different and better scrap mix the furnace can achieve 280 kWh/t of good billets which is a tremendous energy benefit. Melting steel has never been more cost-efficient than with the SHARC furnace.

Hall A/C Booth 3239

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Conclusion and outlook HLV is a steel company with a long tradition and extensive practical experience. With the SHARC, a completely new and unique process for scrap preheating has been successfully developed. This process minimizes energy consumption and simultaneously generates a significant increase in economic efficiency. The design of the SHARC furnace and the metallurgical process result in high productivity and flexible, cost-efficient furnace operation. The installed modern automation systems and environmental technologies comply with the strict requirements on occupational health and safety and environmental protection. The cooperation between the operating company and the plant manufacturer provides space for innovations, focusing on further technological development and enhanced design features of the furnace. HLV has been passing on its operational know-how, offering trainings and instruction courses and rendering support in the commissioning of new furnaces.

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MPT International 2 / 2016

New ladle turret of the continuous caster No. 1 at the Duisburg-Beeckerwerth steel works

Caster design for a wide product range and outstanding slab quality After completion of a comprehensive modernization project, the continuous slab caster No. 1 of Thyssenkrupp Steel Europe in Duisburg-Beeckerwerth, Germany, was successfully re-started in October 2014. Since then, the modernized plant has produced slabs for highquality products supplied to exacting markets such as the automotive industry. The new FDVWHU VLJQLĆ‚FDQWO\ FRQWULEXWHV WR WKH SURGXFWLRQ RI KLJK PDQJDQHVH VWHHO The comprehensively modernized continuous caster No. 1 at the works of Thyssenkrupp Steel Europe in Duisburg-Beeckerwerth is a significant asset for the production of high-manganese steel, states the company. “We are very content with the performance and reliability of the plant,â€? says Dr. Arnd KĂśfler, head of crude steel production at Thyssenkrupp Steel Eu-

5/5 ITQWR &Ă˜UUGNFQTH )GTOCP[ %QPVCEV YYY UOU ITQWR EQO ' OCKN EQOOWPKECVKQPU"UOU ITQWR EQO

MPT International 2 / 2016

rope. Plant manufacturer SMS group had modernized the continuous caster within eight weeks. It was successfully put into operation again in October 2014 and passed the entire acceptance test in July 2015. The revamped plant will enable the German steelmaker to provide the market and particularly the automotive industry with high-quality products for a long time into the future. Among common steel grades such as ULC (ultra low carbon) and IF (interstitial free), Thyssenkrupp casts high-strength steel grades, for example AHSS (advanced high strength

steel: high-strength, unalloyed steel grades). The plant is now designed for slab widths between 1,000 and 2,150 mm, a width range 290 mm larger than before the project. The thickness of the slabs remains unchanged at 257 mm, although the plant design allows for a slab thickness of up to 350 mm.

Fibre-optics technology to OQPKVQT VJG UQNKFKĆ‚ECVKQP process in the mold The curved mold is equipped with a narrow face adjusting mechanism

Strand guide system of the modernized continuous caster

(“Delta Speed Adjustment�) that enables quick adaption during casting and short transition lengths. The mold also features the “HD moldFO� technology developed by SMS group. Using fibre-optic sensors, the HD mold delivers high-quality, high-accuracy measured values for an in-depth insight into the solidification process. This means the strand shell formation can be precisely tracked across the height and width of the mold. With 180 measuring points per wide face, the fibre-optic sensors monitor the temperature up to three times faster than other methods. The process works reliably and faultlessly within electromagnetic fields. Even without additional cabling, the measuring point density is four times higher than with conventional thermocouples, making it possible to make extensive measurements over the full mold height. The mold does not require any maintenance activities by the plant operator. The wide variety of available tools assists the operator in casting process control and provides for the achievement of maximum product quality.

Also functions for other casting parameters, e.g. mold powder characteristics, are included. Additionally, the HD moldFO applies enhanced functions such as the detection of longitudinal cracks from a minimum length of 4 cm. The HD moldFO also contains a range of new tools such as the Taper Assist function which by optimizing the settings of the narrow face taper prevents gutter formation. All described functions are active within a 50 mm radius from where the sensor is installed. The HD moldFO technology provides information for breakout prediction, longitudinal crack detection and the illustration of the heat flux density.

0GYN[ FGXGNQRGF GSWKROGPV HQT JKIJ SWCNKV[ UNCDU As part of the modernization project, the continuous caster was equipped with a new ladle turret and the tundish capacity has been increased from 50 to 75 t. The hydraulic resonance oscillator is maintenance-free. The strand guide system with position-controlled CyberlinkÂŽ segments, hydraulic segment adjustment, Dynamic Soft ReductionÂŽ and the dynamic solidification model (DSCÂŽ) contributes significantly to a homogeneous and crack-free slab microstructure. Measurement and alignment of the segments in the segment shop are done using the HD LASr alignment assistant developed by SMS group.

To ensure crack-free slab surfaces, the casting machine is equipped with an air-mist cooling system which is characterized by a fine-adjustable, width-dependent breakdown of the cooling zones. Starting with segment 9, the slabs are dry cast. The revolver rollers would even allow dry casting to start in segment 2. Furthermore, the caster has been prepared for an extension of the strand guide system by two additional segments. Thanks to the Eco-Mode, the utility systems are only switched on when required. The continuous caster thus meets the increasing environmental protection requirements.

Smooth execution of the OQFGTPK\CVKQP RTQLGEV SMS group provided the technical planning for the conversion of the two-strand bow-type caster and supplied all mechanical components, the electrical and automation systems as well as the process control system. Furthermore, SMS group supplied the central control room, the entire hydraulic system and utility supply and provided training for the team of operators. Installation of the equipment and commissioning of the continuous caster were also included in the SMS group scope of supply. The performance of the revamped slab caster has led to an increase in direct charging, thus achieving a radical improvement in the production processes. MPT International 2 / 2016

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››› HOT ROLLING

6JG PGY JQV UVTKR OKNN CV $CQUVGGN <JCPLKCPI KU GSWKRRGF YKVJ 5KGƃGZ® -HT high-performance spindles for high rolling torques to be transmitted

Zhanjiang Steel commissions the high-performance hot strip mill Chinese Baosteel Zhanjiang Iron & Steel Co. Ltd. has successfully commissioned its new high-performance hot strip mill supplied by SMS group. Ecoplants components JXDUDQWHH KLJK HFRQRPLF HIƂFLHQF\ ZKLOH LPSURYLQJ HQYLURQPHQWDO SURWHFWLRQ For its new integrated iron and steel works in Zhanjiang in the south of China, Baosteel Zhanjiang Steel installed a new hot strip mill with an annual capacity of 5.5 million tons. It has been designed to produce hot strip with final thicknesses between 1.2 and 25.4 millimetres and strip widths from 800 to 2,100 millimetres. The product portfolio ranges from soft deep-drawing grades to high-strength construc-

SMS group, Düsseldorf, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com

MPT International 2 / 2016

tion steels and further to tube and pipe grades. Based on an optimized layout, the new hot strip mill consists of plant components as following: ▪ a slab sizing press, ▪ one 2-high and one 4-high reversing roughing stands, each with a flanged-on edger, ▪ seven CVC® plus 4-high finishing stands, ▪ a laminar strip cooling system and ▪ two hydraulically operated coilers. Thanks to the numerous incorporated Ecoplants technologies, the rolling mill sets a new benchmark in terms of economic efficiency of hot strip pro-

duction. Ecoplants technologies from SMS group combine ecology and economy, as they reduce energy consumption and/or increase the yield. One of the Ecoplants solutions implemented in the roughing mill is the slab sizing press. With the aid of this machine, the slab width can be flexibly adapted to facilitate the coordination between the continuous caster and the hot strip mill. Thus the slab sizing press supports hot charging of slabs, contributing to a distinct reduction in energy consumption. Using the slab sizing press offers the additional advantage that the output of the upstream continuous caster can be increased.

HOT ROLLING Key features of the finishing mill are the newly developed Sieflex®-HT high-performance spindles. The hot strip mill for Baosteel Zhanjiang Steel is the first in China to have high-performance spindles in all finishing stands. Especially in the first finishing stands such spindles allow to transmit higher rolling torques and rolling forces as are required for the production of high-strength hot strip. Additionally, the new Sieflex®-HT spindles allow for the installation of work rolls with optimized diameters. This also contributes to reduced energy consumption. Other Ecoplants components incorporated in the mill include the CVC® plus system (continuously variable crown) with integrated work roll bending as well as profile, crown and flatness control, hydraulic differential-tension loopers in the finishing mill and thermal insulation hoods between the roughing and the finishing mill to reduce heat losses of the strip. For strip cooling, which is a decisive metallurgical tool of the plant, SMS group implemented a concept tailor-made for Zhanjiang Steel’s product range. The combination of zones coming with reinforced laminar cooling and standard cooling groups provides for high cool-

The QR code links to a video on YouTube showing the Baosteel Zhanjiang integrated iron and steel works (https://youtu.be/e1l-6ftYTHo)

ing rates and flexible cooling strategies, allowing a wide product portfolio to be produced in the most efficient way.

Milestones of the Zhanjiang steel project At 10 a.m. on 25 September 2015, blast furnace No. 1 of was blown in at Baosteel Zhanjiang Steel. Since the start of building and construction work in May 2013, a new modern integrated iron and steel works was erected on Donghai Island of Zhanjiang with an area of 12.58 square kilometres. The cokemaking operations at Zhanjiang Steel have been equipped with flue gas desulphurization and deni-

‹‹‹

61

trification technology that has been put into operation in December 2015. The flue gas treatment process includes dust removal and low-temperature SCR DeNOx, achieving pollutant emissions below certain standards. On 19 October, Zhanjiang Steel ignited the No. 4 reheating furnace, marking the countdown of hot commissioning of the mill. The hot rolling mill has four reheating furnaces in total. The No. 4 furnace is the first energy-saving walking beam furnace, with a designed capacity of 320 tons per hour. The slab reheating furnace is 56 metres long, 11.7 metres wide with the furnace depth of 2.2 metres, and features a 20-metres long heat recovery section, by absorbing gas waste heat to effectively reduce fuel consumption per ton steel. Zhao Zhouli, the deputy general manager of Baosteel Group, president of Zhanjiang Steel, and commanderin-chief of Zhanjiang steel project engineering headquarters, said that Zhanjiang Steel will strive to achieve the comprehensive completion and operation of the project in the first half of 2016. Baosteel has the confidence and ability to build Zhanjiang Steel into a green base for super quality carbon steel flat products.

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MPT International 2 / 2016

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››› SPECIAL EQUIPMENT

#NTGCF[ KP WUG KP 6TKPGE CPQVJGT )GQTI TQNN NCVJG V[RG WNVTCVWTP 4 HQT RTQĆ‚NG TQNNU %QWTVGU[ 5VTQLKTP[ C 5VCXD[ 6TKPGE C U

4QWIJ OCEJKPKPI CPF Ć‚PKUJKPI QH RTQĆ‚NG TQNNU HQT TQNNKPI OKNNU In December, German machine tool manufacturer Heinrich Georg GmbH Maschinenfabrik received an order for the delivery of a roll lathe for up to 10 t of workpiece weight for a roll shop in the Czech Republic. This is already the fourth PDFKLQH D VXEVLGLDU\ RI &]HFK VWHHO SURGXFHU 7Ä–LQHFNÂŤ ÄťHOH]ÂŁUQ\ D V KDV RUGHUHG IURP Georg since 1996. TÄ inec Iron and Steel Works (Czech: TÄ ineckĂŠ ĹželezĂĄrny – a company of Moravia Steel Group) is a producer of long steel products – wire rod, bar, rails and seamless tubes – located in TÄ inec, Moravian-Silesian region in the Czech Republic. TÄ inec Iron and Steel Works accounts for more than one third of all steel produced in the Czech Republic, approximately 2.5 million t/year. The company has ordered a new roll lathe, type “Georg ultraturn 900 Râ€?, for

Heinrich Georg GmbH Maschinenfabrik, Machine Tool Division, Kreuztal, Germany Contact: www.georg.com E-mail: wzm@georg.com

MPT International 2 / 2016

its roll shop. It will be employed for machining and finishing profile rolls used mainly for the production of round profiles, flat sections, angles as well as reinforcing steel for the construction industry. This new type of roll lathe will be designed for rolls with diameters of up to 900 mm, weights of up to 10 t and a centre width of 2,500 mm. The tool holder in slide design with one tool slide ensures safe transmission of highest cutting forces. Georg will deliver the machine in autumn 2016. Georg already delivered two machines for workpiece weights of up to 40 t in 1996 and 2003 respectively, and a machine for rolls of up to 10 t in 2004. The new machine completes the roll shop equipment at TÄ inec Iron

and Steel Works, taking the number of Georg machines in operation to four. The investment in the new lathe had become necessary due to the company’s capacity expansion. All four machines come with a fully hydrostatic guiding system, a design which Georg generally applies in all its roll lathes. The biggest machines of the “ultraturn� range can handle workpieces with weights of more than 300 t. The machine will be able to perform both heavy roughing with high cutting parameters and finishing with highest demands on accuracy. In this way, the roll shop saves time on the setup of workpieces. In contrast to simpler linear-guided or slide guided machines there are almost no running costs, e.g. due to loss

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››› SPECIAL EQUIPMENT

of lubrication or exchange of guiding elements. The extremely robust construction of the Georg roll lathes will show its advantages already after very few years of operation: In comparison to lighter or not fully hydrostatic machines, they generate much lower operating costs. The lifecycle costs are reduced as a result of the high maintainability and the use of wear-free hydrostatic guideways. Due to the wide machine beds and an overall more stable machine, the maintenance intervals are longer. Shorter machining times increase productivity, reducing unit prices. Thanks to their design features, even after decades of heavy use in roll shops, these machines achieve the same accuracies as brand new ones. According to Jan Ebener, head of sales in Georg´s machine tool division, the order from Tāinec Iron and Steel Works has proved the high value of the concept of hydrostatically guided machines: “Besides the quality of our machines, our customers obviously also appreciate their high efficiency. We have succeeded against strong domestic and foreign competition. Lathes equipped with the hydrostatic and wear-free guideways are more expensive to purchase, but will turn out to be more efficient and economical over the years and decades they will be in operation.”

Implementing strategic service plans is a simple, quickly applicable and highly cost-effective maintenance concept. On request, permanent key data generation can be activated after installation and commissioning, providing a constant overview of the overall equipment effectiveness (OEE). Upon explicit request by the line user, the remote service platform ac-

If desired, the user of the ‘Georg connected service’ may use the convenience of having the service request generated directly on the control display of the machine. Then the Georg expert will get in contact with the operator live. Online diagnoses are also possible via tablet camera – a fast way to bring the machine back into operation.

Headstock of a Georg roll lathe type ultraturn 900 R

Service covering the machine life cycle With its “Georg protection world” service programme, the machine tool manufacturer cares about issues of cost reduction and high-efficiency operation. “We support our customers with standardized and automated service offers,” explains Mark Georg, CEO and spokesman of the Georg management board. Various service packages are available covering the entire machine lifecycle from commissioning, maintenance through to modernizations and technical consultation. This ensures high plant availability, reduces service-related costs and increases the benefit. The software-based service gate “Georg connected service” offers full support for all service cases, ranging from true online diagnosis and trouble shooting, effective maintenance organization, spare part management through to preventive monitoring. MPT International 2 / 2016

#NTGCF[ KP WUG KP 6TKPGE C )GQTI TQNN NCVJG V[RG WNVTCVWTP 4 HQT RTQƂNG TQNNU

tivates a remote service via secure internet connection to the computer of one of Georg’s specialists. Service requests are routed more precisely and faster since the connection to the machine control has been configured beforehand.

Besides ‘Georg support’, the strategic service ‘Georg upgrade’ is offered, a tool focusing on retrofitting (including products from other suppliers) and condition monitoring. Georg will continue to expand its range of programmes and solutions.

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Crane anti-collision solution for the roll shop at BenXi Iron & Steel in China BenXi Iron and Steel (Group) implemented a real-time crane positioning solution for its new roll shop. The precise tracking of the semi-gantry and gantry crane movements ZLWK ZLUHOHVV WHFKQRORJ\ LQ DGGLWLRQ WR WKH LQGLYLGXDOO\ GHĆ‚QHG ZDUQLQJ DQG VWRS ]RQHV SURYLGHV HPSOR\HHV DQG PDFKLQHV ZLWK UHOLDEOH SURWHFWLRQ DQG HQVXUHV DQ HIĆ‚FLHQW SURGXFWLRQ ĆƒRZ

The new roll shop was built at BenXi Iron & Steel in China (Image courtesy of BenXi Iron & Steel)

At every rolling mill, the roll shop is key part aside from the main production chain. Machining of the work rolls is sensitive process since the quality of the rolls is a decisive factor influencing the quality of the finished products and the efficiency of the rolling mill as well. Every roll shop has to be equipped with cranes, operated either automatically or manually, deployed to transport the rolls within the roll shop and to load and unload the roll changing machines. Under the project leadership of Herkules, specialist of roll grinding ma-

Symeo GmbH, Neubiberg/Munich, Germany Contact: www.symeo.com Maschinenfabrik Herkules GmbH & Co. KG, Siegen, Germany Contact: www.herkules-machinetools.de

MPT International 2 / 2016

chines, a new roll shop was built for the Chinese steel producer BenXi Iron & Steel (Group). Herkules supplied not only all roll shop components such as roll grinding machines and various cranes, but also provided the automation system for the roll shop.

points across the workshop. Relying on Symeo’s patented LPRŽ positioning radar technology, the distance between the sensors on the cranes and the reference points is continuously measured to position the equipment in real-time. Since the sensors feature a robust housing and rely on radar to capture the data, the measurement results are not interfered by dust, dirt, vibrations or extreme temperatures. The entire measuring chain is maintenance-free. The position of the cranes, as well as the predefined warning and stop zones, are displayed in 3D in the control room. If the distance between cranes falls below a specific predefined parameter, individual crane movements can be slowed down or stopped by a direct connection to the crane control system. As an option, a decentralized approach can be used to forward all of the positioning data to each participant in the anti-collision system using various wireless communication channels.

Conclusion Wireless measurement technology reliably captures crane coordinates Being a specialist for sensors, positioning systems and wireless data transmission, Symeo was responsible for the localization and anti-collision solution for the cranes. The automation control is to guide two automated semi-gantry cranes – so-called loaders – and three manned gantry cranes over different runways. Wireless sensors – so-called transponders – are mounted on the cranes and at fixed reference

On the heels of a previous successful joint effort at another Chinese steel works, German machine tool manufacturer Herkules awarded Symeo GmbH an additional crane anti-collision project in the newly built roll shop of BenXi Iron & Steel (Group) Co., Ltd. in China. Machine tool manufacturer Herkules was responsible for the overall construction of the roll shop, including the machinery. In the framework of this project, Symeo – specialized on LPRŽ radar and GNSS (GPS and similar) positioning

SPECIAL EQUIPMENT technologies – supplied the new roll shop with a real-time crane positioning solution. Herkules is one of the world-leading specialists for roll machining, i.e. roll grinders, texturing machines and lathes. More than that, Herkules designs, builds and delivers all the necessary equipment for roll machining. This includes roll shops and comprehensive equipment, as well as automation. Symeo GmbH develops and markets products and solutions for precise, contact-free and maintenance-free position detection, distance measurement and collision avoidance of road/rail vehicles and cranes. Furthermore, the company develops certified, customer-specific telemetry solutions. Products from Symeo are designed to be especially robust for applications in rough en-

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67

The crane positions as well as individual warning and stop zones are displayed in 3D (Image courtesy of Symeo GmbH)

vironments. With its LPR® products, Symeo offers a wireless-based, realtime-capable measurement system that is ideally suited for industrial applications.

Upon completion of the successful projects, Herkules and Symeo are planning an additional crane positioning and anti-collision project at a further Chinese steel mill in 2016.

Setting The Standards For Highest Efficiency In Thermal Processing

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MPT International 2 / 2016

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››› COMPANY PROFILE

State-of-the-art rolling and strip processing technologies for the 4K\JCQ ITGGPƂGNF RTQLGEV KP %JKPC $ QHZ ƃDW VWHHO SURGXFWLRQ FRPSOH[ ZLOO EH HUHFWHG LQ WKH 6KDQGRQJ SURYLQFH RQ WKH &KLQHVH HDVW FRDVW GHVLJQHG IRU DQ DQQXDO FDSDFLW\ RI DOPRVW ƂYH PLOOLRQ W RI ƃDW SURGXFWV SHU \HDU PDLQO\ VXSSO\LQJ HQG FXVWRPHUV LQ WKH DXWRPRWLYH LQGXVWU\ 6KDQGRQJ ,URQ DQG 6WHHO 5L]KDR &KLQD KDV FRQWUDFWHG 606 JURXS WR VXSSO\ D KRW ZLGH VWULS PLOO D SLFNOLQJ WDQGHP PLOO DV ZHOO DV RQH KRW GLS JDOYDQL]LQJ OLQH DQG WZR DQQHDOLQJ OLQHV LQFOXGLQJ QHZO\ GHYHORSHG TXDOLW\ DVVXUDQFH V\VWHP DQG RSHUDWLRQ NQRZ KRZ

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MPT International 2 / 2016

COMPANY PROFILE Shandong Iron and Steel Rizhao, China, has contracted SMS group to supply rolling mill and strip processing technology for the new flat steel complex in the Shandong province on the Chinese east coast. A special feature of this project has been the supply of cross-process know-how while simultaneously monitoring, documenting

Thomas Schilling, Helmut Höfer, SMS group, Hilchenbach, Germany Contact: www.sms-group.com E-mail: thomas.schilling@sms-group.com

and securing the product characteristics. The scope of supply will comprise the following production facilities: ▪ a hot wide-strip mill, ▪ a coupled pickling line / tandem cold mill, ▪ a hot-dip galvanizing line and ▪ two continuous annealing lines. SMS group will also supply the electrical and automation systems. Through this investment, Shandong will be operating 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

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will lie on sophisticated steel grades for the automotive industry.

High-performance hot strip mill The X-Roll® hot strip mill is rated for an annual capacity of 4.8 million t and will be able to produce strips in widths of up to 1,900 mm. Production of the first coil is scheduled for mid-2017. The main components of the hot strip mill are: ▪ a slab sizing press, ▪ a two-high reversing roughing stand, ▪ a four-high reversing roughing stand with edger, ▪ seven finishing stands (F1 to F7), ▪ laminar strip cooling section and ▪ three downcoilers. The slab sizing press is the perfect link to the hot strip mill as it is able to achieve width reductions of up to 350 mm, thus offers a high degree of flexibility with respect to casting as well as strip widths. The two powerful roughing stands will also provide Shandong Iron and Steel great flexibility in terms of pass distribution. The finishing stands will have rolling forces of 52 MN (F1 to F4) and 40 MN (F5 to F7). All mill stands will be equipped with hydraulic screwdowns for thickness control. Strip profile, contour and flatness will be set by a CVC® plus system with integrated work roll bending. Based on the process parameters, the profile, contour and flatness control (PCFC®) will calculate for each individual strip the right shifting position of the work rolls, which are provided with a special ground finish, and the pre-defined values of the work roll bending system. That way, the roll gap will be adjusted precisely to the changing conditions for each strip and permit the production of strips with extremely close geometrical tolerances.

Coupled pickling line / tandem cold mill A major part of the hot strip produced will be processed in the coupled pickling line / tandem cold mill. This plant

1) 2) 3) 4) 5)

Hot strip mill Pickling line / tandem cold mill Continuous annealing line No. 1 Continuous annealing line No. 2 Hot-dip galvanizing line

Layout scheme of the rolling and processing complex at Shandong Iron and Steel Rizhao MPT International 2 / 2016

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››› COMPANY PROFILE

Hot strip mill 2.0 Mio t/a 2.8 Mio t/a Pickling line / tandem cold mill

0.95 Mio t/a

0.65 Mio t/a

0.40 Mio t/a

CAL 1 Continuous annealing line

CAL 2 Continuous annealing line

CGL Continuous galvanizing line

Other facilities / tube production / market

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will be designed for an annual capacity of 2 million t of high-quality cold strip. The new facility will produce cold strip in widths from 900 to 1,880 mm and final thicknesses between 0.3 and 2.5 mm with the starting stock having a gauge from 1.8 to 6.0 mm. In the entry section, speed will achieve a maximum of 700 m/min, whereas the pickling section will be passed at maximum 270 m/min. The maximum rolling speed of 1,450 m/min will be achievable even with minimum work roll diameter. The coupled pickling line / tandem cold mill will have two payoff stations in the entry section of the pickling line where the strips will be welded together to an endless strip. A newly developed exhaust system will reduce scale dust in the entry section and provide high efficiency combined with low susceptibility to failure and wear. A tension leveller will also be integrated in the exhaust concept. Its purpose is to break the scale on the strip surface, improve strip flatness and hence create ideal preconditions for an optimum pickling process. The pickling section will comprise three pickling tanks, each having a length of 35 m, with subsequent cascade rinsing and drying. The turbulence pickling section stands out for its low maintenance and operating costs, low consumption of resources and high pickling MPT International 2 / 2016

performance along with first class surface quality. Spray headers continuously spray heated acid into the shallow pickling channel thus generating extreme turbulences which maximizes the contact between the pickling acid and the complete strip surface. A patented immersion cover will minimize evaporation and associated energy losses.

Rolling stands equipped with enhanced shifting system An integrated ASC (automatic setting control) side trimmer with knife quick-change device will straighten and cut the strip edges to the required width. To make sure strip is running without interruption in both the process section as well as the transition to the tandem cold rolling mill, the line will be equipped with a total of three horizontal loopers. All of the five six-high mill stands in the tandem mill will be equipped with the proven CVCÂŽ plus technology and the enhanced shifting system (ESS) for strip thickness and flatness control permitting the roll gap geometry to be adjusted to an extremely wide product range. The media supply system will be of the modular allin-one design. Multi-zone cooling and a state-of-the-art dry strip system in the last mill stand will optimize the flatness and the surface quality of the rolled strip.

To reduce off-size lengths, a compact and robust carousel reel will coil the strips. Furthermore, SMS group will supply its “Rotary Inspect� inline inspection system to constantly check the surface quality as well as coil transport equipment, a marking machine, exhaust systems and media systems. The new emulsion system developed by SMS group, called compact emulsion unit (ECU), is characterized by an extremely small footprint. Due to the clever design and the use of media waste heat, the ECU needs distinctively less energy than a conventional emulsion system.

Downstream strip processing lines Two annealing lines and one hotdip galvanizing line will be provided to finish the cold strip into high-quality products. All lines will come with high-performance Drever radiant tube furnaces equipped with ultra-fast cooling systems to ensure high cooling rates. These furnaces allow the production of high-strength grades for the automotive industry. The hot-dip galvanizing line will comprise FOEN air knives which ensure that the extremely high demands placed on surface quality by the automotive industry can be satisfied. The two anneal-

I am aggressive!

ing lines will be designed for an annual production capacity of 950,000 and 650,000 t, while the hot-dip galvanizing line will have a production capacity of 400,000 t. All of the two million t of surface-finished cold strip will have widths between 900 and 1,850 mm and final gauges between 0.3 and 2.5 mm.

Electrical and automation systems

But that’s no problem for our corrosionresistant fans.

In addition to the mechanical equipment, Shandong will also receive the necessary X-Pact® electrical and automation systems for the respective plant areas. The scope of supply and services for the X-Pact® electrical and automation systems will cover the drive package including converters and motors. The automation package will comprise all basic automation systems, travel and sequence controls, visualization, technological control systems and modelaided process computer systems. To ensure fast commissioning of the facilities on site, SMS group will apply the plug & work method which means that, before commissioning, SMS group engineers will test and optimize the complete automation system with the original control units against a real-time simulation of the production process. On that occasion, the customer’s operating staff will be trained to make sure they are familiar with the control system at the start of commissioning and a fast rampup curve can be achieved.

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Conclusion With the facilities to be supplied by SMS group, Shandong Iron and Steel Rizhao will produce material grades CQ, DQ, DDQ, EDDQ, SEDDQ, BH, HSLA, HSS, DP, and TRIP, and achieve tensile strengths of up to 1,000 MPa. Commissioning of the facilities is scheduled for 2017. Once on stream, the new flat steel complex will be able to produce 4.8 million t of hot strip. Up to 2 million tons of the hot strip produced will be processed by surface finishing facilities to obtain high-quality cold strip products. “The order for this greenfield project is another proof of SMS group’s product line consisting of powerful single components and complete innovative turnkey plants,” states Dieter Rosenthal, member of the managing board of SMS group.

We make air work for you. Process and hot gas fans Process gas dust collection Process gas cleaning plants Secondary fuel technology Belt drying plants Vapour exhaust plants

Siempelkamp headquarters in Krefeld

Siempelkamp pushes ahead with internationalization The Krefeld-based Siempelkamp group will position itself with a stronger international focus in future, and will make greater use of its foreign production locations. With this move, Siempelkamp is reacting to new competitive situations, and to the weakening of originally strong markets such as Russia and Brazil. The Krefeld location remains the “heart and mind� of Siempelkamp. Siempelkamp Maschinen- und Anlagenbau GmbH, Krefeld, Germany Contact: www.siempelkamp.com E-mail: christian.hassler@siempelkamp.com

MPT International 2 / 2016

The Siempelkamp group is a supplier of technological equipment operating in three business units: Machine and Plant Engineering, Foundry Technology, and Engineering and Service. Siempelkamp Machine and Plant Engineering is a system supplier of press lines

and complete plants for the woodbased panel industry, metal forming industry, and the composites and rubber industry. Siempelkamp Foundry, one of the largest hand-mould foundries in the world, manufactures cast parts from ductile cast iron with unit

COMPANY PROFILE weights of up to 320 t. Siempelkamp Engineering and Service specializes in the dismantling of nuclear facilities, and supplies transport and storage containers for radioactive waste. Headquartered in Krefeld, Germany, Siempelkamp has consistently been expanding its manufacturing facilities internationally in the Czech Republic and China in recent years. The global network of sales and service companies is also a component of this internationalization process. The new large-scale manufacturing site in Qingdao, China, which went operational in October 2015, will in future be used much more intensively for producing large-scale parts for press manufacturing. “We will produce where our customers are,” emphasized Hans Fechner, spokesman of the executive management of Siempelkamp group, on 12 February 2016, at a press conference in Krefeld. “Furthermore, we will significantly expand our production facility in Blatnice, Czech Republic, in order to continue being able to produce at competitive prices in future.”

Investments in Germany and abroad With these actions, Siempelkamp will consolidate and expand its market position and technological leadership, particularly in the wood-based panel and metal forming industry. This includes in particular the expansion of business activities in the future market of China. As a result, Siempelkamp will eliminate a total of 350 jobs in Germany in 2016 and 2017. “Complex technologies and business secrets will remain here in Krefeld, and at other locations in Germany,” the managing director of Siempelkamp explained further. In addition to increasing the value of foreign production locations, Siempelkamp will sustainably strengthen the locations in Germany: at the Bad Kreuznach production site, a modern logistics and service centre is being created for the global supply of spare parts.

Structural adjustments within Germany In the Foundry Technology business unit, necessary structural adjust-

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73

ments are being made. The foundry of the company has been suffering under the embargo policy against Russia, and the Russian counter-embargo. Furthermore, the drastic drop in the prices of raw materials has led to a decrease in business in the mining sector. The general weakness of the BRIC countries has led to customers postponing investments indefinitely. These developments have immediate consequences for the foundry business. “We don’t expect any improvement in the foreseeable future, and therefore we have to act now,” says Hans Fechner. This unfavourable development in the foundry business has directly affected Siempelkamp Maschinenfabrik. Here, too, personnel numbers will be reduced. In the Engineering and Service business unit, further adjustments will be required. The decision of the German Federal Government to phase out nuclear energy and the associated tasks have resulted in fewer employees being required at locations in Germany. The production of large-scale storage casks in Mülheim an der Ruhr has stabilized – but at a lower level. In the USA, business relating to the dismantling of nuclear power plants is going considerably better: only recently, Siempelkamp completed the largest dismantling project in the history of the American nuclear energy industry, with the successful disassembly of the reactor pressure vessel at the Zion nuclear power plant on Lake Michigan. Following this success, Siempelkamp NIS-Ingenieursgesellschaft in Alzenau is expecting further dismantling follow-up orders from the USA, says Fechner.

Internationalization is in progress “Now we are implementing the strategy that we have been announcing for a long time – the internationalization of the Siempelkamp technology group. The general conditions in the global economy have confirmed the necessity of this step. Siempelkamp is still technology leader in many key markets, and will remain so. The ‘heart and mind’ of Siempelkamp remain here in Krefeld,” concludes Hans Fechner. MPT International 2 / 2016

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››› COLD ROLLING

Stainless steel tandem EQNF OKNN RTQFWEGU ƂTUV EQKN at Beihai Chengde, China The new plant, designed for an annual capacity of 600,000 tons of cold strip, will be used to produce stainless steels of AISI grade series 200 and 300. After completion of D VKRUW FROG WHVW SKDVH WKH ƂUVW VWDLQOHVV VWHHO FRLO ZDV SURGXFHG ZLWKLQ WKUHH PRQWKV Beihai Chengde intends to use the new cold rolling mill to start producing wide strips in the 800 – 1,300 mm width range. In late December 2015, a stainless steel continuous tandem cold mill (TCM) supplied by Primetals Technologies to Beihai Chengde Stainless Steel Co. (Beihai Chengde) produced the first coil at the Beihai plant in the Chinese Guangxi province. The mill consists of a Power X-HI type, fivestand, continuous tandem cold rolling mill and a heavy laser welder. The rolling mill has a rated capacity of 600,000 tons of cold strip per year, and is designed to produce AISI grades series 200 and 300. The cold test was performed within 17 days and the first coil produced within only three months. The order was placed in the mid2013. It was the second order for an X-HI rolling mill and the third order for a continuous tandem cold mill for stainless steel that Primetals Technologies had received from China. Beihai Chengde is active in nickel mining and the production of narrow stainless steel strip. The company intends to use the new cold rolling mill to start producing wide strip. The continuous rolling mill handles hot-rolled, annealed and pickled stainless steel. It is able to achieve final thicknesses from 0.3 to 3.0 millimetres from entry thicknesses of between 1.0 and 5.0 millimetres. The width of the strip varies between 800 and 1,300 millimetres. The continuous rolling mill line comprises three main sections (entry

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 2 / 2016

5-stand Power X-HI stainless steel tandem cold mill from Primetals Technologies at Beihai Chengde in Guangxi province, China

section – rolling section – exit section), each separated by strip accumulators. The entry section includes a double uncoiler station, each equipped with coil storage facilities, coil loading car and overhung mandrel uncoiler together with coil opening, flattening and shearing equipment. The Primetals Technologies welding machine is of heavy laser type (LW21H) and includes strip centering and strip cutting facilities as well as diagnostic systems. The rolling section includes five mill stands of Power X-HI type with associated high tension bridles and rinsing section to remove emulsion from the strip surface. The rolling speed is 400 metres per minute. The rolling stands are designed for a flying roll change, so production will not have to be interrupted to change the work rolls. This increases productivity and reduces output losses.

The exit section comprises exit bridle, inspection station, rotary shear, scrap and sample cutting, two recoilers, belt wrapper, paper interleaving feeding equipment, spool loading and coil unloading car with associated coil banding and storage. The strip looper between the rolling line and the exit section decouples the rolling process from the downstream activities, such as strip inspection and coil shearing. This means that these are no longer limiting factors on the mill throughput. The scope of delivery also included variable-speed Sinamics drives with a total power of 22,000 kilowatts, and the basic (level 1) and process (level 2) automation. A Simatic WinCC-based solution handles operator control and monitoring tasks. It also enables distributed supervision, and features easy-touse diagnostic and alarm functions.

76

››› 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 strip and foil for the packaging industry. Even the smallest of pinholes can cause foodstuffs to spoil quickly DQG FRQWDLQHUV RU VSUD\ FDQV WR OHDN 7KH QHZ SLQKROH GHWHFWRU ORFDOL]HV DQG FODVVLƂHV 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. The risk of pinholes ranging down to a few micrometres in diameter forming in plates and foils rises the thinner they become during rolling. A frequent cause of this is contamination of the metal during smelting or pouring as well as damage and soiling on work rolls. Later, during further processing such as deep-drawing for example, pinholes can cause the destruction of tools. These holes are not only a quality defect, but also often cause strip breaks, especially in the case of foils.

Janusz Blonski, IMS Messsysteme GmbH, Heiligenhaus, Germany Contact: www.ims-gmbh.de E-mail: janusz.blonski@ims-gmbh.de

German engineering company IMS has developed the new CCS pinhole detector that detects even the smallest of perforations and locates their exact position on the strip. The system uses cameras for this task and can detect pinholes from a size of 5 μm. A human hair, by comparison, is about 60 μm thick. One established method of hole detection is to illuminate strip from below with line-shaped light sources and to detect the light shining through the holes with photo detectors. The previous state of the art was to use just a few detectors, which were additionally grouped in larger zones to simplify evaluation. The disadvantages of this arrangement were, however, that de-

The spacing for hole detection on strip and foil is 20 mm MPT International 2 / 2016

tection near the edges was hardly possible, the position of the holes transversely to the direction of strip run could not be determined exactly and the diameter of the holes could only be ascertained roughly. Further, the influences of stray light made mechanical edge masks necessary, which not only requires high maintenance, but is also susceptible to faults. Since large areas at the edges were covered, holes in this area could not be detected.

Camera clusters open up new possibilities Since reliable detection and classification of pinholes is very important not only in the middle of the

Water-cooled components for the steel industry Electric arc furnaces Ladle refining stands Converters Waste-gas cooling systems Cooled equipment We are able to design and supply the complete set of equipment. The modernisation of existing EAF and converter plants can be done by us as well as planning and manufacturing complete new exhaust gas cooling systems. We are also your partner in

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››› QUALITY ASSURANCE

Photo detector

Camera cluster module

Conventional technology

Camera cluster technology

Whereas the common systems (left) have limited capabilities at the strip edges, CCS (right) can Strip Light source

strip, but especially also near the edges, IMS decided to adopt a completely new approach. The company uses novel camera cluster systems (CCS) developed specially for measurement tasks on strip. These systems are equipped with inexpensive cameras mounted in a short distance from each other. The spacing for hole detection on strip and foil is 20 mm and consequently every camera only covers a small range to the left and right of the vertical optical axis. In this way IMS eliminates all fringe effects and reliably detects and measures even small holes in the immediate vicinity of the strip edges. The respective cameras used in the clusters are known from many everyday applications such as rear view cameras of vehicles. Due to mass production, they are so cheap nowadays that

they can also be used economically in measuring systems. The new camera cluster concept increases the resolution of the images dramatically. Whereas traditional photo detectors only determine the position in the cross direction of the strip relatively roughly, the 50 cameras that are used over a strip width of 1,000 mm have ten thousands of pixels. With this high resolution it is possible firstly to determine the position of a hole in the cross direction of the strip with high precision. If the results are synchronized with the strip speed, the position of the holes in the flow direction of the strip can also be determined exactly. Secondly, the new technology allows the holes to be classified exactly by size for the first time. The exact information on defects – particularly in the area of the strip

detect holes with the same high precision at any position of the strip

edges – reduces the risk of strip breaks in mill stands and processing lines. In addition to this, the data on the position and size of the holes can be used in downstream processes. A quality data management system such as MEVInet-Q from IMS can use the data automatically to decide on the further processing steps of the coil and in this way optimize, for example, slitting or cutting. Thanks to embedded image processing directly at the image sensors and the high-speed “information superhighway” between the clusters, the CCS pinhole detectors are suitable for high strip speeds. Power LEDs are used for backlighting. Using the data from the integrated intelligent strip edge tracking system, individual rows of diodes at the strip edges are controlled to prevent diffraction of the light at the strip edge and reflection. In this way it is possible to detect holes located near the strip edge.

Compact measurement beam for simple integration The steep angle of sight and the high number of cameras lead not only to reliable measurement across the complete width of the strips. The unique arrangement of the cameras also enables a much greater distance between the optical components – the camera unit and backlight unit – and the material than with conventional photo de-

The self-supporting camera beam is only 145 mm high and only 100 mm long (picture showing the cut-to-length line at Thyssenkrupp Rasselstein) MPT International 2 / 2016

German Engineering on top At thyssenkrupp Uhde Engineering Services we offer a full range of engineering services, from feasibility studies to EPC contracts, in our core business areas which include steelworks, power plants, petroleum refineries and the chemical and petrochemical industries. www.tkues.com

German Engineering on top Revamp, Upgrades & Modernisations Process improvement Improved quality Increased availability Improved safety and reliability Cost efficiency Increased capacity

Environmental Protection Environmental improvements Health, safety & sustainability Emissions reduction Energy savings Compliance with statutory requirements

Operation & Maintenance Customised maintenance services Minimised downtimes High qualified staff Backbone of maintenance management (CMMS) High availability of right spare parts

QUALITY ASSURANCE tectors. The distance between the cluster cameras and the passline is 90 mm, while the backlight is located about 110 mm under the passline. The larger distance offers more protection against damages from fluttering strip. The self-supporting camera beam is only 145 mm high and only 100 mm long in the flow direction of the strip. It does not contain any electro-mechanical moving parts. As a result, it is also easy to integrate the pinhole detector in existing strip lines. Thanks to various interfaces, the system can be connected to any modern process control system.

tinplate at Tosyali Toyo in Turkey. Systems for the detection of pinholes are also in use at Alcoa, one of the largest producers of aluminium worldwide. They work reliably even on highly reflective surfaces.

Conclusion IMS has developed a unique camera cluster system (CCS) to detect pinholes

First experiences IMS commissioned its first pinhole detector for tinplate at Thyssenkrupp Rasselstein GmbH in Andernach in the fourth quarter of 2013. This system proved such a success right from the start that a total of eight systems are currently in use there. Three CCS pinhole detectors are also due to inspect

The QR code links to a video on YouTube showing a pinhole detector system installed at a continuous coating line (https://youtu.be/f5y04a2knWU)

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in strip, foil and plate. They consist of a number of high-speed, intelligent and yet inexpensive cameras that are arranged closely next to each other in groups – the clusters. By lining up multiple cluster modules next to each other, it is possible to measure foil, strip and plate of any width. The innovative technology makes the clusters highly interesting for a number of measurement tasks in the steel, aluminium and nonferrous metal industries. CCS can be used not only as a new pinhole detector, but also for measurement of strip flatness and levelness by the laser triangulation method and – with backlight – for the detection and measurement of edge cracks and for width measurement. Due to its high resolution and steep angle of sight, the technology can also be used economically for the first time for online measurement of slit strip width in slitting lines or for surface inspection.

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MPT International 2 / 2016

The special roll forming line features intelligent drive technology and energy-saving hydraulics

Sophisticated roll forming technology goes into operation at Voestalpine, Austria Europe’s most advanced roll forming line recently went into operation at Voestalpine’s Krems site. It will produce highly-complex special tubes and sections for customers in a wide range of sectors including the automotive industry in general and the commercial YHKLFOH VHFWRU 9RHVWDOSLQH KDV LQYHVWHG RYHU ƂYH PLOOLRQ HXURV LQ WKH QHZ OLQH strengthening its position as the global market leader in the production of complex coldrolled steel tubes and sections of top quality.

MPT International 2 / 2016

Directors of Voestalpine Metal Forming and Voestalpine Krems inaugurating the new roll forming line on 25 February 2016 in Krems, Austria; from left: Jürgen Lechfellner, Günther Felderer, Peter Schwab, Dirk Mahnke

Voestalpine employs about 2,300 people at seven production companies from all four divisions of Voestalpine group in the Lower Austria province, generating revenues amounting to almost 560 million euros in the business year 2014/15. The Metal Forming division of Voestalpine is headquartered in the town of

Voestalpine Krems GmbH, Krems-Lerchenfeld, Austria Contact: www.voestalpine.com/krems E-mail: marketing.krems@voestalpine.com Seuthe GmbH, Hemer, Germany Contact: www.seuthe.com E-mail: sales@seuthe.com

Krems. Here, Europe’s most advanced special roll forming line went into operation at the end of February 2016. The new line will be used to manufacture tube products including double laser welded special tubes for the commercial vehicles industry, and welded special tubes for the automotive industry. It can also be used for products with complex and variable hole patterns for the construction industry.

Intelligent drive technology meets energy-saving hydraulics The 100-metres-long roll forming line was jointly developed by Voestalpine Krems and the German plant

manufacturer Seuthe, a company of Asmag group. The roll forming line features traction control, individual drives and a clutch system for automatic coupling and decoupling. Most important for Voestalpine is the traction control. It prevents the steel strip from slipping, providing for a higher production speed and higher quality. And it allows the holes in highly complex profiles to be punched with an accuracy of one tenth of a millimetre. To satisfy the customer’s exacting requirements, Seuthe developed a new drive concept and designed a process that allowed fully automatic drive coupling with and decoupling from the roller shafts. Since all roller shafts MPT International 2 / 2016

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can be coupled or uncoupled in parallel, this process is done in less than 60 seconds for all 54 roll stands. According to project manager Jürgen Drossel, the traction control, the coupling and uncoupling system and the sturdy design are technological highlights which allow production to the tightest tolerances.

All applicable noise and safety regulations have been complied with and a safety remote control has been installed. The concept of individual drives will pay off in terms of low energy consumption, as the drives only use energy when actually in operation. Motor temperatures are constantly monitored and cooling starts only when a pre-set temperature is reached. That saves energy and reduces noise levels.

Short set-up time by automatic coupling An important feature of the line is the absolute reproducibility of the roller axis settings. User-friendliness is provided by the 28” operating display and by the possibility of using a tablet. The latter allows the operator to control the line or make changes to the settings right at the stand, for example, for correcting a mark appearing on the profile caused by different speeds between the upper and lower side when setting up a new pitch. The mobility of the tablet in the 30-metres-long roll forming area is also of great advantage during service, maintenance and coupling, and for controlling the current operating status.

Capacity utilization at Krems guaranteed The special roll forming line is not only designed for processing new dimensions. If necessary, the new line can take over products from the existing lines to relieve production bottlenecks. While permanent two-shift operation of the line is already ensured, with a view to major upcoming orders provisions have already been made to operate in three shifts. Product made by Voestalpine at Krems include various highly demanding products such as steel tubes and sections for intelligent and statically-optimized substructure components in photovoltaic and

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solar installations, innovative system solutions for orchards and viticulture, and modern, advanced profile systems for door and portal constructions.

Voestalpine Metal Forming division The Metal Forming division of Voestalpine AG achieved a total sales volume during 2014/15 of 2.3 billion and an operating result (EBITDA) of 331 million euros. The division employs roughly 10,500 staff members and does business with almost all European car manufacturers. Within the group, it constitutes the centre of competence for highly refined sections, tubes, and precision steel strip products as well as ready-to-install components made of pressed, stamped, and roll-formed parts in steel and aluminium, with a focus on the automotive industry. Its combination of material expertise and processing competence is unparalleled throughout the industry, and its global presence makes the division the preferred partner to customers who are looking for innovativeness and quality.

Customised 4-Way Handling www.combilift.com

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Systems for separation of dust and water from quenching steam built to our own patents with residue guarantee as per TA Luft

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mail@kiro-nathaus.de www.kiro-nathaus.de

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Robotic solutions for steel mills AUTOMATION Polytec, a BM Group company, supplies fully automatic cells for the complete steelmaking process. With a view to the Industry 4.0 concept, the company integrates latest vision systems and intelligent machine systems. The systems range from the PolySAMPLE EAF / LF for automatic sampling and measurement to automatic cells for marking and labelling. Fully automatic cells for laser labelling of billets, bundles of bars and tubes, and for wire rod combine machine vision, laser marking and robotics. The integrated systems identify the location, number and distance for applying the TAGs with logos and data matrix codes. They also check labels and replace them if not readable, ensuring close to 100% product traceability. 3D simulation during the engineering phase and the choice of best materials guarantee customer satisfaction and low maintenance needs. User friendly interfaces and comprehensive training facilitate operators’ work. Each cell is pre-tested in the Polytec workshop in order to reduce the commissioning time. Contact: www.polytecrobotics.com

Billet marking cell

Handling solutions for long products TRANSPORTATION Specialist forklift manufacturer Combilift produces a wide range of customized handling solutions, from pedestrian pallet stackers, four-way forklifts and sideloaders, up to straddle carriers which can transport oversized loads weighing 80 t. The products are all designed for the safe, space saving and productive handling of the long and bulky loads typically encountered in the tube and pipe sector. The excellent manoeuvrability and versatility of Combilift’s models mean that they can

be deployed from the initial stages of offloading raw materials, during the manufacturing process, through to the storage and dispatch of finished product. Combilift’s original core C series, for example the 5 t C5000 XL with high ground clearance and very roomy cab, work inside and out and on uneven terrain in all weathers, making them robust and reliable workhorses for universal applications in the yard and warehouse. Sideways travel with loads resting on the platform also offers great-

er stability and safer manouevering. The 1,450 kg capacity Combi-WR4 multidirectional pedestrian reach stacker is ideal for handling lighter palletized or long loads, and an aisle-width of 2.1 m. The compact Combi-CB, which combines 4-way capability with counterbalance design, is capable of handling a mix of pallets and long loads. It is available with load capacities of up to 4 t with a choice of LPG, electric or diesel power. www.combilift.com

STEEL INDUSTRY

COILFILZ – BRAKE AND WIPER FELT FOR EVERY APPLICATION

Vereinigte Filzfabriken AG // Giengener Weg 66 // 89537 Giengen // Phone +49 7322 144-0 // Fax +49 7322 144-246 // info@vfg.de // www.vfg.de

MPT International 2 / 2016

TECHNICAL INNOVATIONS

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Infrared online oil layer measurement STRIP PROCESSING EMG has launched EMG SOLID (sur- chanically. Thanks to the intelligently structured storage and face oil layer inline determination) as a third system for the visualization of measured data, the user is provided with an online measurement of key product parameters for process- overview of the strip or the metal sheet from a single source. ing steel and aluminium strip material. Together with the In addition, long-term trends exhibited by the measured valSORM 3plus laser optical online roughness measuring sys- ues and manufacturer-specific characteristics of the materitem and the inductive online measurement of material al properties can be followed closely in order to optimize the properties offered by the IMPOC system, the SOLID infra- process and enhance process reliability. red spectroscopic measuring system delivers reliable online results for the applied oil layer in g/m2 over the width and www.emg-automation.com length of the strip. The measuring principle implemented by EMG SOLID is based on the Lambert-Beer law, which describes the attenuation of the radiation intensity when passing through an absorbent material – in this case, the oil and/ or lubricant layer. The basic principle is thus the “illumination” of a surface with thermal radiation and the subsequent analysis of the reflected infrared light. The application can be used easily on cold-rolled strip and galvanized surfaces, as well as on uncoated aluminium or aluminium with a silicate coating, and it covers all conventional surface textures. The measurable lubricants include thixotropic and non-thixotropic mineral oils, as well as “Drylube” lubricants. Precise knowledge of WITH THE TOUGHEST SOLUTIONS FOR THE WORLD’S the product parameters MOST EXTREME PROCESSES, QUAKERTEK™ SPECIALTY gained via the SOLID sysGREASES KEEP YOUR MILL RUNNING SMOOTHLY. tem as well as via the comWith the demands of the modern steel industry, you and your equipment are plementary quality assurboth feeling the pressure. Taking care of operations doesn’t just mean keeping ance systems SORM 3plus the mill rolling, but also means finding ways to lower costs, improve performance and IMPOC provides the and extend the life of your machines. Quaker Specialty Greases minimize Total Cost of Ownership while giving you sustainable product solutions that require necessary data for triless volume and reduce energy during use. As the industry-leading provider of bological evaluations of process fluids and other chemical specialties, no one else offers the same level of experience and service, and no one else is in more places at more mills. the material and it offers So team up with Quaker, and keep your toughest operations running smoothly. enormous potential with regard to reducing scrap Trust a partner who knows the steel industry and enhancing process from the inside. Contact our experts today. reliability. This applies quakerchem.com | info@quakerchem.com | 1.800.523.7010 to each of the systems on their own, but above all © 2016 Quaker Chemical Corporation. All Rights Reserved to the combination of all three. The systems can be integrated electrome-

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Production results of bar and wire rod mill LONG PRODUCT ROLLING The combined bar and rod mill (CBRM) supplied by Danieli to the Rahji Steel plant in Saudi Arabia was started up in 2012 as part of an integrated minimill installed by Danieli and in operation since 2007. The plant today achieves a daily out-

put of 4,174 t, setting a monthly production record of 90,766 t of bars in five sizes (primarily 12, 14 and 16 mm dia.). This represents 49% of the product mix, an average monthly output of 160 t/h, 83.7% operating rate and 97.4% yield ratio in continuous 24 hours/day oper-

ation. The products meet the customer’s specifications as well as ASTM and SASO standards. For the current year, the plant is forecast to produce more than 1 million t/year of rolled products. Contact: www.danieli.com

Sensing solution based on advanced magnetostrictive technology MEASURING EQUIPMENT MTS Sensors, a division of MTS Systems, has further expanded its R-series of robust, high-performance magnetostrictive position sensors with a new device which has the capacity to deliver superior reliability and industry-leading accuracy in even the most demanding work environments. Utilizing the company’s proprietary Temposonics® technology, the RT4 is a linear position measurement solution that features two independent sensor elements – each of which has a measuring length of 50 mm to 2,540 mm. Targeted among others at use in steel processing plants, this fully redundant position sensing product employs a synchronous serial interface (SSI), which means that data transfer is less susceptible to the presence of electro-magnetic interference. In addition, the IP68-rated enclosure protects against the threat of liquid ingress. The detached electronics can be mounted up to 600 mm away

Position sensing equipment

WORKING SOLUTIONS FOR EXTREME CONDITIONS

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

MPT International 2 / 2016

ENGINEERING | PRODUCTION | SERVICE

TECHNICAL INNOVATIONS from the sensing environment allowing the electronics to be kept further from sources of potential harm. A temperature range that reaches up to 100˚C is supported for the sensor rod and interconnection cables. Through MTS Sensor’s Temposonics® magnetostrictive sensor technology, precise, non-con-

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tact position measurement data can be acquired. The devices can deal with the exacting mechanical stresses found in modern industrial settings without being subject to wear and tear. Contact: www.mtssensors.com

Blast furnace reline and modernization IRONMAKING Within the framework of a general reline of “B” blast furnace at Salzgitter Flachstahl (SZFG), Germany, Paul Wurth installed and commissioned a modernized Bell Less Top® (BLT) charging system. The reline was completed within 80 days, five days ahead of schedule. In August 2014, Paul Wurth had received the order to modify and replace components of the existing BLT. The system had been in operation ever since the start-up of the blast furnace in 1993. As one of the technical highlights of the new system, Paul Wurth’s new spherical maintenance valve replaces the traditional goggle valve above the chute transmission gearbox. This results in by far easier and quicker maintenance in case of both scheduled and unexpected shutdowns. Further newly installed components are the valve actuation unit (VAU) with lower material gates and seal valves,

the pressure equalizing and relief valves, and two material hoppers. The two hoppers feature a vulcanized rubber lining with additional cast iron armour plates in the lower cones. In addition to reconditioning the main gearbox, engineering and supply of the equipment, Paul Wurth’s scope included site coordination, erection supervision as well as commissioning of the modified top charging system. The first hot metal was tapped on 14 November 2015. After the restart of the blast furnace, the system underwent a four-week performance test at 100% availability. With all obligations under this project being fulfilled, SZFG immediately thereafter issued the final acceptance certificate. The typical production rate of the blast furnace is 6,000 t/day of hot metal. www.paulwurth.com

Shorten search times and cut your costs… Efficient warehouse management

www.vip-kommunikation.de

Visit us at AISTech 2016: 19 Pittsburgh [USA] May 16 Booth No 1553

TWMS/metals visualizes and controls transportation and warehouse processes in real time, from continuous casting to loading of the finished long or flat products. The benefits are optimum use of warehouse space, short handling times, efficient deployment of personnel and means of transportation, low operating costs.

TWMS/metals: The Technical Warehouse Management System for the Steel Industry www.3tn.de

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Modernized blast furnace

Rebuilt blast furnace passes performance guarantee test IRONMAKING A team of Danieli Corus specialists has achieved all of the required parameters for the performance guarantee (PG) for the blast furnace No. 5 at the SAIL Rourkela Steel Plant in India. The performance guarantee test was successfully completed on 19 September 2015. During the test, new records were set for production levels up to 7,550 t/d as well as fuel rates, with coke rates as low as 370 kg/t HM and PCI rates over 160 kg/t HM. Given the available raw material

qualities, with these results Danieli Corus has set new standards in India. The results are attributable to the design based on a high conductivity plate-cooled lining, the high quality of the equipment, accurate installation procedures and the operational practices. Currently, Danieli Corus is rebuilding the No. 1 blast furnace at SAIL Rourkela with the same technology. www.danieli-corus.com

/QNCTBS OK@SENQL ENQ ×@SMDRR LD@RTQDLDMSR QUALITY ASSURANCE The new product platform ShapeCAT offered by Shapeline provides for new and improved flatness measurement applications. The heart of the new

system is the ultra-fast, built-to-purpose camera for measurements in the steel and metals industry. The camera has several unique features. By internal pre-processing of 5OCTV ECOGTC HQT ƃCVPGUU OGCUWTGOGPVU

TECHNICAL INNOVATIONS

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image data, high-speed data can be transferred from several measurement modules at the same time. The increased data transfer capacity has allowed the camera’s sensor resolution and measurement speed to be significantly increased while several camera modules can still be run simultaneously. The new sensor and data-handling technology provides new possibilities such as installations in high speed processing lines, smaller space requirements as well as very high-resolution measurements. Potential applications are measurements before and after rolling processes in hot strip lines and plate rolling with high resolution in spite of the high processing speed. Measurements of hardening defects after the rapid cooling and quenching sections in continuous annealing lines – for both steel and aluminium – can be made with significantly higher resolution and accuracy. ShapeCAT also provides advantages in traditional flatness applications. Accuracy and resolution are significantly improved, as more precise information can be obtained e.g. on high yield strength heavy plate, precision steel strip etc., improving process automation. www.shapeline.com

BOF-gas fuelled burners for annealing and galvanizing lines STRIP PROCESSING LINES Industrial engineering group Fives has developed a wide range of AdvanTek® WRT burners for annealing and galvanizing lines. The burners operate with different fuel types, i.e. coke oven gas, natural gas, mixed gas, LPG, heavy fuel oil, domestic fuel oil, etc. New AdvanTek® WRT 2.0 burners use basic oxygen furnace gas, a low calorific value gas mainly composed of CO. A number of tests conducted at Fives’ Bar-Le-Duc test centre in France demonstrated an optimum combustion efficiency of 71 % for BOF gas with NOx below 50 mg/m3 (stp) at 3% O2. The WRT 2.0 burners are available for a power range of 100 – 180 kW. They can be installed at new or retrofitted existing annealing and galvanizing lines. www.fivesgroup.com

Burner for strip processing line MPT International 2 / 2016

worldwide

Welcome. The organizers of GIFA, METEC, THERMPROCESS and NEWCAST wish to invite you to be part of The Bright World of Metals – this year in Moscow, Mumbai and Jakarta:

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

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

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

Flatness and contour measuring system QUALITY ASSURANCE Nokra recently launched a new flatness and contour measuring system. With its high-precision laser sensors, alpha.fi 2.0 measures significantly more precisely than its predecessor and due to its slim shape, it can be reliably used in difficult-to-reach and narrow spaces. With the optimized evaluation software, customers can optionally and individually decide on European, American or Japanese standards and they can evaluate according to their individual specifications. The compact design requires less maintenance effort, the improved lifetime of the precision sensors and the much shorter commissioning time provide for a high ROI. www.nokra.de

EAF process control system STEELMAKING Tenova Goodfellow and Sumitomo Shoji Machinex recently commemorated the first sale of EFSOP® technology within the Japanese steel market. In 2005, Topy Industries Ltd. became the first steelmaker to install the EFSOP® process control system at their Toyohashi works in Aichi, Japan. The original project was a great success story achieving environmental reductions of 18% greenhouse gas emissions overall. Consumption levels for kerosene were reduced by 45%, as well as a 13% reduction in coal consumption being realized. During the last decade, Topy Industries has continuously used the technology to improve their knowledge of the furnace practice resulting in a greater return on investment. In 2013, Topy purchased two new EFSOP® systems for use on their newly installed EAF. www.tenova.com

International Metal & Steel Trade Fair for Southeast Asia

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

www.tbwom.com

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

www.messe-duesseldorf.de

Pilot plant for dry ore concentration process RAW MATERIALS The pilot plant for a dry iron ore concentration process developed by New Steel and built in Ouro Preto, Minais Gerais, Brazil, was inaugurated in October 2015. The new processing route utilizes Loesche grinding technology and is considered 100% sustainable and unique in the world. It can produce valuable concen-

TECHNICAL INNOVATIONS trate even from low grade iron ore wastes without contaminating water and without high electricity consumption. A newly designed dry magnetic separator developed by New Steel operates at the core of the new process. The separator offers unprecedented separation efficiency even in

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dry operation mode. The separator relies on the supply of a ground product of a certain particle size distribution, as ensured by the Loesche mill. www.loesche.com

The mobile ore grinding plant at New Steel in Ouro Preto, Brazil

© Utz Peter Greis, Düsseldorf

Cartoon

“Industry 4.0” has been a much discussed topic recently. The term embraces the trend that the virtual world of IT and the real world of industrial production are becoming ever more interconnected. Highly complex networks connecting plants and processes will become increasingly commonplace in all industries, allowing those plants and processes to directly communicate with one another. MPT International 2 / 2016

94

››› LITERATURE SERVICE Absolute encoders 12 pages, English, German A product brochure featuring absolute encoders offered by Hübner specifically for extreme operating conditions in rolling mills, mining and crane applications. Detailed technical information and application examples are provided on solid and hollow shaft encoder series. Contact: E-mail:

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

Wear protection for plant components and pipe systems 44 pages, English A comprehensive brochure describing the range of wear resistant linings provided by Kalenborn for protection against abrasive wear caused by bulk materials. Applications include hydraulic and pneumatic conveying lines, pipe bends, hoppers, mixers, burner cones, etc. Contact: E-mail:

www.kalenborn.com kalenborn@kalenborn.com

High-pressure grinding 24 pages, English This brochure provides detailed information about the products offered by comminution specialists Köppern. The company’s high-pressure grinding rolls are used in a wide range of applications for materials such as slag, limestone, ore, cement clinker, coal, etc. Contact: E-mail:

www.koeppern.de info@koeppern.de

Non-contact tube measurements 16 pages, English, German A brochure providing a comprehensive picture of laser-based measuring systems offered by LAP for the entire process chain of tube making. Measurements include thickness, width, length, outer diameter, outer contour, straightness and tube-end inspection. Contact: E-mail:

www.lap-laser.com/steel info@lap-laser.com

Hose technology 4 pages, English, German A brochure featuring the Protector cooling water hose line made by Lippmann for use in induction furnaces, arc and ladle furnaces, and ESR plants. The hose comes with crimped fittings, securely prevents hose slippage and leaks, and provides maximum operational safety. Contact: E-mail:

MPT International 2 / 2016

www.lippmann-gmbh.com info@lippmann-gmbh.com

LITERATURE SERVICE

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Thermal imaging cameras 24 pages, English

More Precision thermoIMAGER TIM // Compact thermal imaging cameras

This catalogue features all compact thermal imaging cameras of the TIM series currently available from Micro-Epsilon. It includes detailed product descriptions of the cameras, accessories such as PCs, interfaces and cooling jackets. Contact: E-mail:

www.micro-epsilon.com info@micro-epsilon.com

Vacuum technology Vacuum for a changing world

28 pages, English

glish Version

A company brochure outlining the competences of Oerlikon Leybold Vacuum as specialists in high-tech and customized vacuum solutions for markets such as the process industry, IT, analytical and medical engineering, as well as research. Also aspects like the importance of successful cooperation and networks are addressed. Contact: E-mail:

www.oerlikon.com sales.vacuum@oerlikon.com

Spectrometers for metals 8 pages, English A product brochure on the metals edition of the Zetium range of spectrometers offered by Panalytical. The spectrometers provide a dedicated tool for the analysis of the raw materials needed in the manufacturing of metals and applications such as metal coating analysis, e.g. to ensure corrosion resistance. Contact: E-mail:

www.panalytical.com/zetium info@panalytical.com

Explosion safety 36 pages, English, German A comprehensive brochure stating the mission and describing the competences of explosion safety specialists Rembe. Chapters of the brochure are dedicated to solutions for explosion venting, flameless explosion venting, explosion isolation and explosion suppression. Contact: E-mail:

www.rembe.de info@rembe.de

Redesigned product range brochure 102 pages, English, German Thyssenkrupp Steel Europe has brought out a new product range brochure detailing for the first time the company’s entire product portfolio with a special focus on innovation and sectors. The clear table structure offers enhanced clarity. Also available in digital versions. Contact: E-mail:

www.thyssenkrupp-steel-europe.com broschueren.tkse@thyssenkrupp.com

MPT International 2 / 2016

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››› IN THE NEXT ISSUE…

Ingot casting Ingot optimization in terms of shape, head and insulation In order to be able to meet the constantly increasing demands on both quality and cost reduction, Czech steel producer Tāinec Iron and Steel Works recently decided to modify their entire ingot casting line with the aim of optimizing the overall process. At the end of the optimization process, the engineers had achieved a significantly improved ingot casting process that meets current quality requirements and saves production time and resources.

Tube making – Quality assurance Automatic checking and adjusting of roll alignment in tube mills A mobile measuring system has been developed for checking the contour and position of passes while installed in a tube rolling mill. Deviations of the alignment can be corrected easily and quickly before they manifest themselves in the tubes produced. The system enables rolls to be optimally aligned with one another and in relation to the passline. The system likewise checks the rolls on extracting mills and in sizing and stretch reducing mills. At longitudinal rolling mills the roll can be directly aligned in a correct manner after each roll change. The inline measuring system can also be used in cross-roll piercing mills and in stand workshops.

Environmental protection ORC power plants recover waste heat and help to improve energy efficiency of steel mills In many processes of steel production, generated waste heat is often not efficiently recovered and hence lost. In contrast, ORC waste heat power plants convert valuable waste heat into electricity. Waste heat power plants, which also operate highly efficiently under partial load conditions, have proven their reliability in extensive field tests in various industries, also in the steel industry. Such a plant has been implemented at a bell-type annealing plant of a German steel mill. In a fundamentally new approach, the technology extracts any excess energy from coils previously heated to up to 700°C and makes it available to other uses in the mill as electricity or thermal energy.

Special equipment Proprietary base fluid technology has been transferred into fire-resistant hydraulic lubricating grease Fire hazards are constantly present in the steel industry, and steel producers always look for ways to lower such risks in their plants. In the effort of lowering the risk of fire by using fire-resistant lubricants the focus has so far primarily been on hydraulic fluids. However, recently there has been a shift towards fire-resistant grease. The use of a fire-resistant grease as a preventative measure against fire is hence a new initiative. This preview may be subject to change.

Metallurgical Plant and Technology

Publishing Director: Frank Toscha Advertising Manager: Sigrid Klinge

+49 211 6707-552, Fax +49 211 6707-923-552 e-mail sigrid.klinge@stahleisen.de Distribution Dept.: Gabriele Wald

+49 211 6707-527, Fax +49 211 6707-582 e-mail gabriele.wald@stahleisen.de

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

+49 211 6707-568 Assistant Editor: Edith Mielke

+49 211 6707-572 e-mail mpt@stahleisen.de Publishing Staff: Managing Directors: Jürgen Beckers, Arnt Hannewald

MPT International 2 / 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. Termination of subscriptions can only be made from 31st December and notice of termination must be received by the Publishers by 15th November. Otherwise, the subscription is automatically renewed and payable for a further 12 months.

© 2016 Verlag Stahleisen GmbH, Düsseldorf This journal and all articles and illustrations contained in it are protected by copyright. With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems. Upon acceptance for publication, the author agrees to grant, transfer and assign to the publisher all exclusive rights to publish the work during the lifetime of the copyright. In particular, the publisher will have full authority and power to reproduce the work for commercial purposes in copies of any form (microfilm, photocopy, CD-ROM, or other means) and/or to store the work in electronic or other databases. Certification of circulation by the German Audit Bureau of Circulation (IVW) Permit number: 011-224, ISSN 0935-7254

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

Offering the highest quality of service in the graphite electrode industry we provide personalized consultations to maximize the total value for our customers. We also manage individual partnership projects as ongoing support for your process improvement efforts. Mutually agreed projects, with defined targets and cost impacts, aim to reduce process variability using Six Sigma methodology. Please visit our website to learn more about the types of services we offer and how we can add value to your operation. See details under www.ge-competence.com

+ Visit us at EEC 2016 Venice, Italy

Broad Base. Best Solutions. | www.sglgroup.com

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