MPT International 3/2016 (Jun)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

Jindal South West Steel restarts blast furnace No. 1 after major reline project

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June 2016

Aferpi to build new steel complex in Piombino, Italy

We transform … the world of wire rod.

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Our success formula gives you exactly what you want: top quality combined with high productivity and costeffectiveness.

SMS GROUP GMBH

SMS MEER S.P.A.

Ohlerkirchweg 66 41069 Mönchengladbach, Germany Phone: +49 2161 350 -1724 Fax: +49 2161 350 -1753

Via Udine, 103 33017 Tarcento (Udine), Italy Phone: +39 0432799111 Fax: +39 0432792058

barandwirerodmills@sms-group.com www.sms-group.com

EDITORIAL

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A good time for modernization This year the steel industries in many regions of the world have been facing major challenges. Oversupply and growing pricing pressure have fuelled competition. Steel associations around the world have issued together a global overcapacity warning. Also, the Organisation for Economic Co-operation and Development (OECD) staged a symposium on excess capacity and structural adjustment in the steel sector. China is not only the number 1 steel-producing country, but is also the country with the highest overcapacity these days. Many countries are (again) resorting to protective measures in order to ward off the effects of unfair market practices. In the given situation the steel industries are in transition. Companies change structures and strategies. A number of countries like UK and Italy struggle for the survival of their steel industries.

Steel producers have fallen on hard times, no doubt. In order for a company to remain competitive it is crucial to never cease investing. There are some very important key factors for market success: powerful marketing, high quality products and high efficiency production. The latter can be best met with modern production equipment. Actually, in this issue of MPT International, we are presenting several very interesting modernization projects. For example, JSW Steel (India) has restarted its blast furnace No.1 after a complete rebuild with modernization and size increase. The hearth diameter has increased from previously 8 m to 10.4 m, which is one of the largest capacity increases ever seen from a single blast furnace rebuild.

Dipl.-Ing. Arnt Hannewald

In Italy, the Piombino iron and steel works looks back on a long tradition. However, the blast furnace and steel plants have been idled for years. But very soon liquid steel production will be revitalized with a completely new EAF-based meltshop. The new plant will feature latest technology designed to produce premium steels at high productivity combined with environmentally friendly solutions for low energy consumption and low emissions. This project will enable Aferpi to continue steel and rail production in Piombino using state-of-the-art production equipment. The new steel complex will have all it takes to make world-class long products.

In Germany, Saarstahl AG has completed a 30-million-euro investment: a seven-stand continuous blooming mill replacing a reversing rolling stand previously in use for production of wire rod, bar, semi-finished products and forged products in premium qualities.

In spite of the current challenging competitive conditions, the company has been adhering to its strategic investments as planned. The new plant offers the possibility of rolling a much broader range of cross-sections, and provides further improved quality and shorter cycle times. With this investment, Saarstahl reinforces its business segment of massive formed parts like crankshafts, drive shafts, wheel hubs, piston pins or other gear components, which are mainly used in plant construction and vehicle manufacturing.

Plant modernizations are signals showing that there is no stagnancy or wait-and-see attitude in the steel industry. In the face of adversity, every economy will always need steel.

MPT International 3 / 2016

Fully automated FastArcTM EAFs with auto-pilot control.

High specific power input (> 1 MVA/t), short power-off and bucket charging in less than 1 min.

Variable charge mixes from 100% scrap up to 100% hot and cold DRI. HotWindÂŽ enhanced scrap pre-heating technology.

Five latest major references out of total 233 EAFs ALGERIAN QATARI STEEL ALGERIA Twin DRI-based complete meltshops for 2.2 Mtpy liquid steel production.

Two 120 t Automatic EAFs with 156 MVA trafo. The most environmental friendly installation in the MENA region.

Electric Steelmaking and Long Product Casters

TOKYO STEEL JAPAN 2.6 Mtpy liquid steel production of low, medium and high carbon grades, for flat products.

420-t twin DC EAF with continuous scrap feeding, LF and twin VD.

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

DANIELI CENTRO MET FASTARCTM EAF TECHNOLOGY TO BE FRONT RUNNERS IN ELECTRIC STEELMAKING > 36 min tap-to-tap time > 310 kWh/t energy consumption

FERRIERE NORD ITALY 1.4 Mtpy liquid steel production of low carbon steel 120 MVA AC FASTARC 2020TM EAF Bucket charging in less than 1 min.

Danieli benchmark installation.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

EMIRATES STEEL #1 AND #2 UAE 1.7+1.7 Mtpy liquid steel production of low/medium carbon steels.

150-t AC EAF continuously fed with 100% hot DRI, and LF.

www.danieli.com

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››› CONTENTS

International industry news 24

Worldsteel short range outlook 2016 – 2017

Ironmaking 26

Jindal South West Steel restarts blast furnace No. 1 after major reline project It has been one of the largest capacity increases ever seen from one single blast furnace rebuild

Continuous casting 28

Coverphoto: Bell Less TopŽ for the rebuilt No. 1 blast furnace at JSW Steel’s Vijayanagar Works, Toranagallu, Karnataka state, India Paul Wurth S.A., Luxembourg www.paulwurth.com

Continuous bloom caster and long-product rolling mills started up at Hyundai Steel The installations are part of Hyundai Steel’s new special steel mill in Dangjin, Korea

Company profile

Hot rolling

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34

Aferpi to build new steel complex in Piombino, Italy The new steel works will consist of an EAF meltshop and a hot rolling mill for wire, bar and rail

Upgrade of the SBQ rolling mill at SeAH Changwon Special Steel, Korea SeAH CSS contracted leading European plant equipment suppliers for a modernization project

36

New blooming mill starts operation at Saarstahl, Germany Saarstahl AG has completed a 30-million-euro investment

Tube making

Special equipment

38

42 2TQRTKGVCT[ DCUG ĆƒWKF VGEJPQNQI[ WUGF VQ HQTOWNCVG Ć‚TG TGUKUVCPV NWDTKECVKPI ITGCUG

Automatic checking and adjusting of roll alignment in tube mills A mobile measuring system checks the contour and position of the roll passes installed in tube mills

Cold rolling

Steel producers always look for ways to lower risks of fire hazards in their plants

46

Deutsche Edelstahlwerke starts innovative bright steel production A high-performance chain track drawing machine is now in use in stainless steel bar production

48 1 WVQMWORW Ć‚PCNK\GU OCLQT KPXGUVOGPV programme in Krefeld, Germany “Nirosta Ferrite Optimizationâ€? is the name of a widescale modernization and restructuring project

Strip processing

Environmental protection

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New colour coating and printing line at Lysva, Russia Production of varnished, painted and printed strip was started in February 2016

MPT International 3 / 2016

ORC power plants recover waste heat and help VQ KORTQXG GPGTI[ GHƂEKGPE[ QH UVGGN OKNNU The technology extracts all excess energy from coils previously heated up to 700°C and generates electricity

38 36 46

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Columns 8

International industry news

64

Literature service

59

Technical innovations

65

In the next issue

63

Cartoon

65

Imprint

Advertisers’ index ABB AB ASMET Research GmbH Badische Stahl-Engineering GmbH Braun Maschinenfabrik Gesellschaft m.b.H. Danieli S.P.A. Deutsche Edelstahlwerke GmbH Fives DMS framag Industrieanlagenbau GmbH Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS Guild International Inc. IMS Messsysteme GmbH Maschinenfabrik Köppern GmbH & Co. KG MICRO-EPSILON MESSTECHNIK GmbH & Co. KG

55 11 29 16 5, 6 27 53 23 33 31 45

NDC Technologies

59

Plakoma GmbH

41

Primetals Technologies Austria GmbH

37

R+W Antriebselemente GmbH

25

Schubert & Salzer Control Systems GmbH

16

SGL CARBON GmbH

66

SMS group GmbH

2

TES Transformer Electro Service srl

9

Tyrolit-Schleifmittelwerke Swarovski KG

52

Verlag Stahleisen GmbH

21, 44

PAUL WURTH S.A.

19, 20

17 13

MPT International 3 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

Africa Tunesia InterMetal to expand wire rod production. InterMetal has contracted Danieli to supply a new highspeed wire rod line, which will be installed at the existing 400,000 t/year steel complex in Rades. The line will expand the plant’s production capacity for 5.5 to 20 mm dia. plain and 6 to 16 mm dia. deformed wire rod (micro-alloyed and heat-treated) in 2.3 t coils. The supply by Danieli will include a 10-pass DWB finishing block for wire rod, a QTR system for high-tensile deformed bar heat treatment, an oil-film bearing loop laying head with controlled cooling conveyor, rotary reforming tube and a coil handling system with compacting and tying area.

Also a new water treatment plant will be provided. Danieli Automation will integrate the automation system and all electrics. Plant start-up is scheduled for the end of 2016.

The Americas Brazil CSN blast furnace down due to accident. While bringing No. 3 blast furnace at the CSN steelworks in Volta Redonda back online after a ten-day scheduled maintenance downturn, an accident occurred on 25 April causing the furnace to remain offline for an undetermined timeframe. The second blast furnace at the mill is currently idle.

Canada ArcelorMittal to install new finishing end equipment. ArcelorMittal Long Products Canada, located in Longueuil, will upgrade its rolling mill with the installation of a new finishing end. The order for this project has been placed with Danieli. The new equipment will consist of a water forced-cooling system and lining-up rollers to be implemented in the existing cooling MPT International 3 / 2016

bed, a cooling bed exit table with automatic layer preparation system, ten-roll multi-strand straightener, a cold shear and an automatic single-head magnetic stacker. Danieli Automation will supply electric motors and automation systems. The start-up is scheduled for March 2017.

News in brief H.E.S. Hennigsdorfer Elektrostahlwerke, Germany, have issued Primetals Technologies the FAC for a bar mill revamp. The project included replacing two stands in the roughing mill with housingless Red Ring stands.

Canada Société Internationale Métallique to build new HBI plant. Société Internationale Métallique (SIM) has chosen Midrex Technologies and its construction licensee Primetals Technologies to furnish the equipment and oversee the technological aspect of its project to build a hot briquetted iron plant in the Bécancour Waterfront Industrial Park, a public-owned industrial park on the shores of the Saint-Lawrence River in Quebec. The site is a year-round deep water port and connected to major North American rail and road infrastructure.

Midrex and Primetals Technologies will be responsible for providing the principal equipment of the plant, in coordination with a construction and engineering firm that remains to be selected. Using the Midrex NG™ process, Midrex and Primetals Technologies are designing the plant to have a rated capacity of 2.0 million t/ year of HBI.

Mexico Tyasa to install EPS coil line.

Talleres y Aceros (Tyasa) has ordered a two-cell EPS® coil line for its minimill at Ixtaczoquitlan in the state of Veracruz.

The EPS line will descale hot rolled strip up to 1.9 mm thick and 1,830 mm wide in coils of up to 33,100 kg. Start-up is projected for the first quarter of 2017.

Steelmaking at the minimill takes place in the Simetal EAF Quantum electric arc furnace, designed and built

by Siemens VAI Metals Technologies for an annual capacity of 1.2 million t. Much of that capacity will supply a new Castrip® thin-strip casting facility. The new EPS line, built by Red Bud Industries, will be specially configured to process this thin-strip product. The line will consist of a coil staging/loading system, uncoiler, peeler/breaker,

Qingdao Iron and Steel, China, successfully commissioned the SBQ rolling mill supplied by SMS group. The centrepiece of the rolling mill is a 3-roll precision sizing mill capable of rolling any final diameter between 16 and 100 mm.

Kobelco Angang Auto Steel, China, a JV between Kobe Steel and Angang Steel, has started production at its operations in Anshan. The JV produces and sells advanced cold-rolled highstrength steel sheet for automobiles.

JSW Vijayanagar Works, India, has commissioned and ramped up the 1.2-million-t/year rebar mill built by Danieli at its Karnataka works.

Dongkuk Steel, South Korea, has issued the FAC to Danieli for the spooling equipment installed at the Pohang works. The spooling machines are designed to accommodate a coil weight of up to 3.5 t.

Aperam Genk, Belgium, has brought back on stream the annealing and pickling line modernized by Primetals Technologies.

The project involved the upgrade of the drive technology and optimization of the strip tension control.

OneSteel Whyalla, Australia, has granted SMS group the FAC for a walking beam furnace revamp at the Whyalla section mill.

HISTORY OF TRUST 1996

2016

20

YEARS

EAF Transformers, 137 MVA, 33000 V

JSW STEEL DOLVI PLANT INDIA

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HOURS

NEW GENERATION INTERCHANGEABLE SPARE UNITS

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IN 6

AFTER

MONTHS

BEFORE

SERVICE ON SITE

NEW TRAFO

NEW REACTOR

Steel production saving and customer satisfaction

MAHARASHTRA - INDIA MELEGNANO

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MI - ITALY - Via Emilia, 37

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Ph. +39 02 982051

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››› INTERNATIONAL INDUSTRY NEWS

crop shears, stitcher, the EPS cells, strip dryer, electrostatic oiler (used for the occasional requests for oiled EPS), tension stand, recoiler and exit coil staging/packaging area. The EPS trademark is owned by The Material Works and is used by Red Bud Industries under license.

The plant continues to produce steel by operating the second EAF.

Asia China

USA Voestalpine concludes another HBI contract. Construction of the Voestalpine direct reduction plant in Texas and production is likely to start this summer. After having successfully secured long-term supply contracts with prestigious customers over the past months, Voestalpine has recently signed another purchase contract which runs for several years with Mexican steel producer Talleres y Aceros (Tyasa). Around 40% (800,000 t) is destined for Voestalpine’s Austrian production sites in Linz and Donawitz, where it will serve to further optimize the production process.

The remaining 60% will be sold to external partners, primarily steel producers in the NAFTA region.

USA CMC to build second micro mill.

A groundbreaking ceremony held by Commercial Metals Company (CMC) marked the start of construction of CMC’s second micro mill which will be located in Durant, OK. CMC’s micro mill technology for long products uses a continuous-continuous manufacturing process that melts, casts and rolls steel from a single uninterrupted strand, producing high yields at low energy consumption. The Oklahoma micro mill is expected to be commissioned in autumn 2017.

USA Incident at North Star BlueScope Steel. A refractory failure allowed a wash-out of molten steel from the South EAF shell, resulting in an explosion and fire at the North Star BlueScope Steel plant in Delta, Ohio.

MPT International 3 / 2016

Baosteel to modernize twin electric arc furnace. Primetals Technologies has won an order from China’s Baoshan Iron & Steel (Baosteel) to modernize a more than 20-year-old DC twin electric arc furnace at its Shanghai plant. The project involves redesigning both the upper and lower vessels and installing new anodes in each case. The twin electric arc furnace has a tapping weight of 150 t and is part of a production line on which billets and long products are manufactured for use as structural steels. The upper vessels with their water-cooled wall panels will be completely redesigned, and the lower sections will each be equipped with a new, air-cooled FIN anode. The guaranteed anode durability is more than 1,500 melts. Overall, electric power efficiency levels and thus productivity will improve. New burner systems will also be installed. In future, it will be possible to operate the twin electric arc furnace with a hot metal content of up to 90%.

The hot metal will be charged in future not only into the open furnace, but also via the side wall. Primetals Technologies is also responsible for monitoring the installation and commissioning work. The project is scheduled for completion by the end of 2016.

China Yongxing places order for combination bar, bar in coil and wire rod mill. Yongxing Special Stainless Steel has selected Primetals Technologies for the supply of a new combination bar, bar in coil and wire rod mill to be built in Huzhou. The new mill will be designed for a capacity of 250,000 t/ year. Primetals Technologies’ contract scope for the mill includes a reversing sliding breakdown mill and an intermediate continuous mill consisting of 14 Red Ring stands. Downstream of the intermediate mill, an RSB® 370++/4 reduc-

News in brief Hebei Puyang Steel, China, has issued the FAC for the single-strand slab caster supplied by SMS group. The new caster was integrated into the existing bay, using the available crane systems.

Formosa Ha Tinh Steel, Vietnam, has rolled the first coil on the hot rolling mill of the new steel works in Vung Ang. The rolling mill, supplied by Primetals Technologies, has a capacity of 5.3 million t/year of hot strip.

ArcelorMittal Gent, Belgium, has successfully started up the new walking beam furnace supplied by CMI Metals. The furnace has been designed for an annual capacity of 5 million t.

The International Stainless Steel Forum (ISSF) has released figures for the year 2015 showing that stainless steel melt shop production decreased by 0.3% yearon-year to 41.5 million t.

Vítkovice Steel, Czech Republic, has issued the FAC to SMS group for the reconstruction of a pusher-type reheating furnace.

Rizhao Steel, China, has awarded Primetals Technologies the FAC for three of a total of five Arvedi EPS lines. Primetals Technologies was responsible for the engineering of the plants and supplied the mechanical equipment, media systems, technology packages and the automation system.

ArcelorMittal Asturias, Spain, has awarded SMS group the FAC for a walking beam furnace revamp.

The project included the integration of new combustion technology.

Danieli has opened a Center of Competence focusing on flat rolling technology for steel in Duisburg, Germany.

INTERNATIONAL INDUSTRY NEWS ing & sizing block in SCS® design from Friedrich Kocks will be installed. The block will be dimensioned for the production of straight bar and bar in coil within a finished dimension range of 14 to 100 mm dia. as well as for any precross-section for the wire rod mill with a dimension range of 5.5 to 16 mm dia.

Primetals Technologies’ supplies for the straight bar line also include the cooling bed equipment. As well as the equipment for bar in coil production, the company will also provide the rod outlet equipment, including a 10-stand Morgan No-Twist mill, a four-stand Morgan reducing/sizing mill, cooling conveyor and an inline annealing furnace. Production of the new mill is scheduled to begin in early 2017.

ply technology and equipment for a new wire rod line at Tsingshan Stainless Steel. China’s largest stainless steel producer today produces 6 million t/ year of stainless steel. Through expansion and modernization the company aims to increase its capacity to 10 million t/year by 2020. The new mill will include a 10-stand wire rod block suitable for soft reduction, a related pinch roll, and the latest version of the patented variable inclination angle loop laying head. Danieli will also supply roller guides, a snap shear, the entire automation package and the WICON programme for long-products rolling simulation.

China China Tsingshan Stainless Steel to build new wire rod mill. Danieli has been awarded the contract to sup-

Jiangyin Xingcheng orders billet grinder. Danieli will supply a new billet grinder HGS16 to Jiangyin Xingcheng to serve the Danieli rolling mill supplied in 2013. The HGS16 type

‹‹‹

11

grinder will be used for conditioning 140 mm and 250 mm square billets of spring and bearing steel in lengths ranging from 5 m to 12.5 m. The supply will also include electrics and automation systems as well as a secondary filtering unit. The grinder will come with the HiGrind digital package, providing automatic regulation of the grinding pressure. It is scheduled to enter into full operation by the end of 2016.

China Rizhao Steel to build leveller and skin-pass line. A Shapeline VeriFlat flatness measurement sensor will be used in the combined roll leveller and skin-pass line to be built at Rizhao Steel. The sensor will be used in combination with a new skin-pass/levelling process developed by the Chinese Technical Institute WISDRI for improved flatness quality of hot-rolled coils.

7TH EUROPEAN COKE AND IRONMAKING CONGRESS

FROM SEPTEMBER 12, 2016 TO SEPTEMBER 14, 2016

© Designcenter Linz

DESIGN CENTER LINZ, Europapl. 1, 4020, Linz, Austria

Contact details: Conference Secretary Mail: ecic2016@asmet.at Web: www.ecic2016.org Information about Registration, Sponsoring and Exhibition: www.ecic2016.org

Registration Deadline: August 31, 2016 MPT International 3 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

India Tata Steel to revamp recoiling line. After almost 15 years of operation, Tata Steel‘s recoiling line No. 1 in Jamshedpur is no longer able to fully satisfy production requirements. Tata Steel has selected the revamping technology and equipment proposed by Danieli for modernizing the line. Danieli will supply a new side trimmer with scrap baller, a horizontal and vertical inspection station, a hydraulic power unit, a new CPC and a steering roll unit. Danieli Automation will supply the electrical and automation systems for the new equipment and upgrade the systems of the existing equipment.

agreements worth approximately 5.7 billion euros referring to a joint venture and orders for the supply of machinery and plants to be installed in the territory of Iran. The joint venture named “Persian Metallics” will involve a group of international and Iranian investors. Persian Metallics will produce about 6 million t/year of pellets intended for feeding direct reduction plants.

Agreements with other Iranian companies relate to the supply of machines and plants for steel and aluminium production.

Taiwan Indonesia Antam signs development agreement for ferronickel facility. Mining and metals company Antam has signed a project development agreement with Cronimet, specialists in stainless steel scrap, ferroalloys and primary metals processes, and international project developer Ferrostaal on the joint development of a facility for nickel pig iron (NPI) in Pomalaa, Southeast Sulawesi. The production plant is expected to produce 130,000 t of nickel pig iron, which is used in the production of stainless steel.

Iran Fakoor Sanat Teheran signs cooperation agreement on steel projects. Fakoor Sanat Teheran Engineering and Primetals Technologies have signed a general agreement on jointly implementing various projects in the Iranian steel industry. The total volume of those projects already named is estimated to be more than 1.8 billion euros.

The collaboration agreement is likely to be extended to cover further projects.

The cooperation will cover all stages of the value chain in steel production.

Iran Joint venture and agreements on plant supplies. Danieli has signed MPT International 3 / 2016

China Steel to modernize continuous slab caster. China Steel Corporation (CSC) has awarded SMS group the order to revamp its continuous slab caster No. 4 at Kaohsiung.

SMS group will supply a new hydraulic oscillator, complete with the pump station and the pertaining X-Pact® process control system, to replace the existing electro-mechanical drive. Monitoring of the process sequence in the mould is provided by temperature measurement via thermocouples on the mould copper plates. SMS group will supply new thermocouples and the technological process models. The level 2 models of the X-Pact® electrical and automation system contain temperature monitoring and breakout prediction systems. The new hydraulic oscillator drive will allow the oscillation frequency, stroke length and curve shape to be variably set. SMS group’s supply package will also include the project management, on-site training of the operating personnel and supervision of commissioning. Start-up is scheduled for the end of 2016.

Taiwan Feng Hsin Steel to upgrade bar production. Feng Hsin Steel has signed a contract with Friedrich Kocks for the supply of an RSB 370++/5 reducing & sizing block in SCS® design for its works in Taichung City. The RSB® will replace the existing Kocks precision sizing block operated by Feng Hsin since 1990. The 3-roll RSB SCS® is ca-

News in brief Hyundai Steel, South Korea, will use radar positioning systems from Symeo to localize the cranes at the special steel rolling mill in Dangjin.

Gerdau Corsa, Mexico, has built a new minimill in Ciudad de Sahagun. The minimill supplied

by Danieli comprises a 120 t AC electric arc furnace. The EAF process gases are continuously analyzed by a LindarcTM off-gas analysis system provided by MORE.

Outokumpu has gained ISO 14001 certification for its integrated stainless steel plant in Calvert, Alabama, USA, and the stainless steel finishing plant in San Luis Potosí, Mexico.

Hyundai Steel, South Korea, has brought back on stream the tandem reversing mill after a successful revamp carried out by SMS group.

Gerdau, Brazil, has issued the FAC to Danieli for a new hot skinpass mill with inline side trimmer. The equipment was installed at Gerdau’s production site in Ouro Branco, Minas Gerais.

Antillana de Acero, Cuba, has awarded AIC Automazioni Industriali Capitanio the FAC for a millstand revamp, involving the supply of a 1,500 MW AC motor, PLC cabinet, medium voltage panel, rheostatic starter, PLC and HMI software as well as electrical installation and commissioning.

pable of rolling all possible finished bar sizes out of only one pass series in the roughing and intermediate mill and thus significantly reduces the number of required feeders. Friedrich Kocks’ scope of supply also comprises the engineering and process for a water cooling line for low temperature rolling, a snap shear and roller tables as well as assembly and commissioning supervision. Friedrich Kocks will also provide the configuration programme Bamicon, which calculates the optimum adjusting values for motor speeds, rolls and guides as well as the gear stage depending on the required end product.

The new equipment will be designed for the production of bars and bar in coils for a finished dimension range of 14 – 100 mm dia. at a maximum rolling speed of 18 m/s.

Vietnam TVP Steel invests in new hotdip galvanizing line. Danieli will supply a new hot-dip galvalume and galvanizing line to TVP Steel in Ben Luc Townlet, Long An province. The new line will be designed to produce 190,000 t/year of zinc-aluminium and zinc coated coils for products used in roofing applications. The line will feature state-of-the-art burners for improved efficiency and reduced fuel consumption, dual-pot configuration and retractable snout design to allow strips to be coated with zinc-aluminium or zinc, an X-Jet wiping system for precise final coating thickness and improved metal yield as well as a skinpass mill, tension leveller and coaters. The plant’s level 1 and level 2 automation systems will be provided by Danieli Automation. Commissioning of the line is planned to commence in August 2016.

Vietnam Hoa Sen to build hot-dip galvanizing line. Hoa Sen has contracted Danieli to supply a new hot-dip galvanizing line. The new line will produce 180,000 t/year of aluminium, zinc and GI coated strip for high-quality paint and roofing applications. The line will

include an electrical annealing furnace designed to reduce the plant’s carbon footprint, a dual-pot configuration and a retractable snout for Al-Zn or GI coating. Danieli Automation will provide a closed-loop control system.

Plant commissioning activities will take place in the second half of 2016.

Vietnam Vietnam-Japan Steel to expand rebar production. Vietnam-Japan Steel (Vija), a steelmaker based in Hai Phong, will install a rebar production plant based on the ECR endless casting and rolling process. Danieli will supply technology based on its Mi.Da. (Micromill Danieli) system. The new plant will produce 350,000 t/year of 10 to 41 mm rebar products from 150 mm square billets coming from a single-strand fastcast machine. The connected rolling mill will be configured with eighteen housingless stands, in-line QTB system for quenching and self-tempering deformed bars, and a rake-type cooling bed with associated cutting-to-length services. Maximum bundle weight will be 4 t.

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Europe Germany Thyssenkrupp Steel orders ladle furnace. In March 2016, Thyssenkrupp Steel Europe awarded Inteco the order to design and supply a twin ladle furnace for its steel plant in Duisburg-Beeckerwerth. The furnace will be designed for a treatment capacity of 260 t of liquid steel. It will be completely encased with noise insulation panels to improve the working conditions. Construction and assembly are planned to take place in autumn 2017, with production scheduled to start in the second half of 2018.

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Germany DK Recycling und Roheisen to reline blast furnace hearth. Dan-

Tel. +49 8542 1680 www.micro-epsilon.com/metal

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››› INTERNATIONAL INDUSTRY NEWS

ieli Corus has signed a contract with DK Recycling und Roheisen for the reline of the hearth of blast furnace No. 3 at their Duisburg plant. The contract scope includes the design and supply, demolition work, construction and supervision of commissioning. The existing hearth refractories will be replaced from the bottom plate of the furnace up to and including the tuyere band. Blast furnace No. 3 has a 580 m³ working volume and produces up to 1,200 t/day of specialty pig iron.

DK Recycling und Roheisen recycles iron-bearing waste materials that are typically rich in elements such as zinc which are detrimental to the blast furnace process. The special measures enabling the blast furnace to process this material have extremely strong impact on the blast furnace lining, last but not least due to additional chemical attack.

The project is scheduled for the period of May – July 2016.

Germany ArcelorMittal to reline blast furnace. ArcelorMittal has four production sites in Germany. With eight million t of crude steel, it belongs to the country’s largest producers. ArcelorMittal aims to invest and to further develop its German plants. As largest individual investment, ArcelorMittal is set to implement the relining of blast furnace 5A in Eisenhüttenstadt with a volume of 40 million euros this year. Several additional investments are planned for the other sites. Due to the tense market situation and the persistently uncertain overall conditions, the company will decide with a sense

of proportion when and how to implement further projects.

Italy Trafilix orders chain track drawing machine. Trafilix, company of the Lucefin group, has placed an order with Danieli Centro Maskin for a new chain track drawing machine. This order confirms the high reliability of the Danieli chain track system as it will be Trafilix’ fifth chain track drawing machine from Danieli. The new machine will be capable of working continuously, reducing material handling times and times for machine set-ups and adjustments.

of a heat recovery system for the Cremona plant. The system will be implemented into an existing Tenova Consteel® system, which heats and feeds metallic charge to the 250 t electric arc furnace. The Tenova iRecovery® system will recover 34.3 MW on average of thermal power from EAF production, corresponding to 52 t/h of average steam production, which will feed an organic rankine cycle (ORC) turbo-generator supplied by Turboden to produce up to 7.5 MW electric energy for Arvedi’s internal use. Start-up of the system is scheduled to take place at the beginning of 2017.

Poland Italy Valbruna to modernize continuous billet caster. Primetals Technologies has received an order from Acciaierie Valbruna to modernize the three-strand continuous billet caster at the Bolzano site. After the revamp, the plant will be able to produce stainless steel and special alloy bars with larger cross-sections up to 180 mm. Primetals Technologies will increase the machine radius of the plant from 7 to 9 m. Modernization work on the caster is scheduled for the 2016 summer shutdown.

Italy Arvedi to install heat recovery system. Tenova has received an order from Arvedi for the design and supply

ArcelorMittal Poland to replace converters. ArcelorMittal Poland has awarded Primetals Technologies the order to replace LD (BOF) converters No. 1 and No. 3 in its DÇbrowa Górnicza steel works. The converters have reached the end of their service lives. Primetals Technologies will supply the new vessels and trunnion rings, including the maintenance-free Vaicon Link 2.0 suspension. Also the converter bearings and housings will be replaced. The order as well includes dismantling of the existing vessels, and pre-assembly and erection of the new equipment. This will be handled by ZKS Ferrum S.A., the Polish partner in the consortium.

The new converters will have a tapping weight of 325 t. The project will be executed on a turnkey basis. Converter No. 1 is scheduled to be brought into operation at the end of 2016, and converter No. 3 six months later, depending on when the option is exercised.

Errata: NLMK group to reconstruct blast furnace No. 6 in Lipetsk, Russia In the previous issue 2-2016, MPT published an article about the modernization of blast furnace No. 6 at NLMK, Lipetsk, Russia [1]. (The upgrade is planned to begin in Q1 2018.) The headline of the article accidentally stated this blast furnace to be the biggest one of NLMK group. This was based on outdated information. Actually, blast furnace No. 6 is no longer the biggest one of NLMK group. In fact, blast furnace 6 is smaller than blast furnace 7 commissioned in

MPT International 3 / 2016

2012. Blast furnace No. 7, with a hearth diameter of 13.1 m, has a production capacity of 4.2 million t/year. The new blast furnace No. 6, with a hearth diameter of 12.0 m, will be designed for a nominal production of 3.38 million t/year of hot metal. MPT appreciates your understanding in this matter and apologizes for any confusion caused.

[1] MPT International 2-2016, pp. 32 – 36

INTERNATIONAL INDUSTRY NEWS

Russia MMK to modernize wire rod coil handling and compacting systems. MMK has placed an order with Sund Birsta for the supply of a second coil compactor. The compactor will be added to the handling system of the two-strand wire rod mill supplied by Danieli in 2005. Sund Birsta will supply the latest version of its Alfa compactor, in which both hydraulic and electric functions are perfectly tuned to get the best efficiency available. This compactor will use a controlled circuit that generates hydraulic power only when needed during an operating cycle and will be equipped with electrical gear motor-driven feeding units to feed and stretch the binding wire. The hydraulic binding units will apply strong and reliable parallel knots. Delivery of the equipment will take place in late summer 2016.

Russia Abinsk Electric Steel Works to upgrade minimill. Abinsk Electric Steel Works has signed a contract with Primetals Technologies to modernize the electric arc furnace, ladle furnace and 6-strand continuous billet caster in the company’s minimill. The aim of the modernization is to increase the production capacity of billets with cross sections of 130 and 150 mm from 0.95 to 1.5 million t/year. The modernized meltshop is scheduled to come into operation at the end of 2016, the continuous billet caster in the first quarter of 2017.

Primetals Technologies will be responsible for the basic and detail engineering, the production and supply of the new equipment, and will supervise construction and commissioning.

The modernization involves the installation of new cross-plant process automation, a PLC-based electrode control system and a new oxygen injection system. The high-current cables and the complete high-current busbar system after the furnace transformer will be replaced. The main hydraulic system of the electric arc furnace will be modified to improve furnace movements.

For the modernization of the 6-strand continuous billet caster, Primetals

Technologies will supply stopper casting equipment, shroud manipulators, emergency cut-off gates and automatic mould powder feeders.

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pass design and the mill guides for all stands will be supplied by SMS.

Sweden Spain Acerinox Europe to build cold rolling mill. Acerinox Europe has placed an order with SMS group for the installation of a 20-high cold rolling mill at its site in Los Barrios, Cadiz.

SMS group will install a mill in MonoBlock design complete with X-Pact® electrical and automation systems.

Beside the MonoBlock millstand, the mechanical scope of supply will comprise a separate pay-off unit, two reversing reels with paper feed and utility systems, including hydraulics, a Supafine® rolling oil plant, fume exhaust system and filter. The mill will be designed to roll a complex variety of materials, including ferrite, austenitic and duplex steels, with high pass reductions to a minimum final gauge of 0.15 mm. The maximum strip width will be 1,320 mm and maximum rolling speed 800 m/min. Start of operation is scheduled for the end of 2017.

Initiative for a carbon- dioxidefree steel industry. SSAB, LKAB and Vattenfall are launching an initiative to solve the carbon dioxide problem in the Swedish steel industry. Together, the companies will initiate work to develop a steel production process that emits water rather than carbon dioxide. SSAB’s existing production system is already one of the world’s most efficient in terms of carbon dioxide emissions. Nevertheless, existing steelmaking technology using coke plants and blast furnaces means SSAB is Sweden’s largest single source of carbon dioxide emissions.

SSAB, LKAB and Vattenfall together are prepared to assume major responsibility to find a long-term solution to the carbon dioxide problem in the steel industry. With its specialized, innovative steel industry, access to fossil-free electricity and the highest-quality iron ore in Europe, Sweden is uniquely placed for such a project.

Sweden Spain ArcelorMittal to revamp rail rolling mill. ArcelorMittal Espana S.A. has contracted SMS group to revamp its rail rolling mill in Gijón. The modernization project will entail the conversion from conventional twohigh rolling to the more economical universal rolling method. The project is also intended to increase the selling length of the rails from 90 to 108 m.

The central element of the revamp will be the installation of a mill train consisting of a universal stand and an edger, both of which will be designed as CCS® stands (compact cartridge stand).

Additionally, the existing finishing stand will be replaced by a universal stand. All stands will feature hydraulic screwdown. The order scope also includes adaptations to the reversing breakdown mill, to the roll shop and to the media supply system. SMS group will install the equipment and adapt the automation system. Also the roll

Sandvik to install pickling line for stainless steel tubes. Sandvik Materials Technology has chosen CMI as supplier of the new stainless steel tube pickling line to be installed at its plant in Sandviken. The new batch-treatment line will provide a high level of safety, operating efficiency and eco-friendliness. Along with a specifically designed high-turbulence pickling process which ensures uniform pickling conditions and high heat transfer rates, CMI will use a high-pressure spray rinse arrangement to achieve perfectly clean surfaces. The line is scheduled to start producing by December 2017.

Turkey Cemtas Celik to upgrade furnace. In November 2015, Cemtas Celik awarded Danieli Centro Combustion an order for a walking hearth furnace reMPT International 3 / 2016

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››› INTERNATIONAL INDUSTRY NEWS BRAUN Innovations tions for Steel chnology for Cutting-edge technology ding cutting and grinding

B

vamp. The investment is aimed at improving the heating quality and reducing gas consumption of the 50 t/h furnace. The project includes installation of a new automation system (level 1) composed of a new PLC and HMI for combustion and handling control, including installation of a level 2 system, new field instrumentation for flow and temperature measurement and for the handling system.

A new pilot burner line with related equipment and pilot burners for the soaking areas will be supplied. The soaking burners will be replaced with a new generation of patented flameless burners. Production is scheduled to re-commence between May and June 2016.

Ukraine office@braun-steel.com

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MMKI to install continuous caster and secondary metallurgy facilities. Primetals Technologies has received an order from Ukrainian steel producer “Iljitsch” Metallurgical Combinate in Mariupol (MMKI) to engineer a continuous slab caster, a twin-ladle furnace with an alloying station and the associated dedusting system. The two-strand caster No. 4 will be designed to produce 2.5 million t/year of slabs, increasing MMKI’s annual production capacity as well as enhancing and expanding its product portfolio to include, for example, HC, UHC and ULC steels. A level 3 heat-pacing solution will coordinate the steel production with the casting operation. The new 150 t twin-ladle furnace from Primetals Technologies and the associated alloying station will be used to set the desired steel grades and the correct casting temperature. A transformer with a rated power of 28 MVA will provide the electrical energy for the ladle furnace, enabling a heating rate of 4.5°C per minute. Primetals Technologies will design a dedusting system to clean the offgases from the ladle metallurgy facility, processing around 206,000 m3/h (stp). The engineering order for the continuous slab caster covers all the installations from the ladle turret and the ladle car through to the exit zone with its weighing, torch cutting, marking and deburring machines.

Companies Voestalpine ends investment in Wuppermann Austria. In March 2016, Voestalpine ended as planned their business participation in Wuppermann Austria after 29 years. Voestalpine Stahl had held a 30% stake in Wuppermann Austria. The partnership between the two companies had started in 1987, the year in which Wuppermann Austria was founded. Voestalpine Stahl was not only co-partner, but also raw material supplier for Wuppermann in Austria.

Learn more about innovative valve technologie at:

www.schubert-salzer.com MPT International 3 / 2016

Buehler consolidates European metallurgy and hardness testing business. Buehler ITW Test

INTERNATIONAL INDUSTRY NEWS

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& Measurement, manufacturer of equipment, consumables and accessories for metallography and hardness testing, has physically consolidated its metallography and hardness testing operations at Esslingen, Germany, which will take on the function of European headquarters. The facilities at the new Buehler Solutions Centre in Esslingen offer Buehler ITW Test & Measurement adequate space for development, training, production, sales and warehousing. In Düsseldorf, the previous location of the metallurgy business sector, the company is currently establishing a new, central laboratory in close cooperation with partners in industry, universities and research institutes for handling international research projects covering the full span from sample preparation in the laboratory right up to fully automatic in-process hardness testing.

Worldsteel announces world champions of steelChallenge-10. Marcos Daniel Gouveia Filho from Companhia Siderúrgica do Pecém (CSP) in Brazil won in the Industry category and Eonseung Lee from Kyungpook National University in South Korea in the Student category.

The 12 winners from the regional championship competed for the global title in these two categories. The task was to produce an experimental grade of automotive steel that focuses on the chemical composition of nickel, chromium and molybdenum, at the lowest cost, using the electric arc furnace steelmaking simulator.

Eurofer issues global overcapacity warning.

On the sixth European Steel Day, which coincided with the European Steel Association’s 40th anniversary, Eurofer president Geert van Poelvoorde highlighted the European industry’s priority challenges. Van Poelvoorde’s comments came just days after an Organisation for Economic Co-operation and Development (OECD) symposium on excess capacity and structural adjustment in the steel sector that Eurofer attended. This OECD meeting ended inconclusively earlier in the week with a lack of agreement on a global approach to reducing overcapacity.

“European steel is globally competitive when faced with a fair market. In the presently distorted market, we call on European policy makers to do more to quickly and effectively defend their strategic steel industry”, emphasized van Poelvoorde. “The situation is very serious,” he concluded.

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German JV between energy industry and steel industry. VSE AG and SHS – Stahl-Holding-Saar have founded SHS Ventures, a company established to identify and develop new areas of business for the German Federal State of Saarland. SHS Ventures will specifically contact young start-up companies, for example, in the fields of Industry 4.0, infrastructure and the energy industry. The objective is to open up new areas of business

• Process technology know-how • High plant availability • Quick roller replacement

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MPT International 3 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

for companies through new cooperation. SHS – Stahl-Holding-Saar, founded in 2001, is the management holding of the steel industry in the Saarland.

Its key task is the corporate and strategic management of the Saarland-based steel companies, Saarstahl and Dillinger Hüttenwerke. VSE has been an energy provider for over 100 years in the Saarland.

Georg takes over Capco. Germany-based Heinrich Georg GmbH, present in the US market with its company Georg Manufacturing Systems, Inc., has recently taken over machine tool builder Capco Machinery Systems, Inc. in order to expand its activities in the North-American and international markets. The new company, Georg Capco Inc., will strengthen all three of Georg’s business units – transformer division, finishing lines and machine tools – on the American market.

Outokumpu announces new vision. Outokumpu has announced a new vision and measures to drive competitiveness and further improve the financial performance of the company. Outokumpu considers the debt-toequity ratio to be a relevant key indicator for the health of a company in the cyclical stainless steel sector, and thus targets gearing to be below 35%. As a first milestone, Outokumpu is targeting to reduce its net debt to EUR 1.2 billion by the end of 2017, driven mainly by the expected improvement in operational performance as well as a significant uplift in net working capital efficiency.

Immediate actions taken in addition to the ongoing efficiency and cost savings programmes, target among others the organizational set-up. In the new setup, Outokumpu will have three business areas: Europe, Americas and Long Products. Europe and Americas will cover Outokumpu’s entire flat products offering in these two markets, including all coil and plate business. Outokumpu will commence consultations with employee representatives in full accordance with local legislation and practices regarding the planned changes that are expected to lead to a reduction of up to 600 jobs.

MPT International 3 / 2016

Thyssenkrupp to acquire Vale’s minority interest in Thyssenkrupp CSA. Thyssenkrupp is streamlining the ownership structure of the Brazilian steel mill Thyssenkrupp CSA (CSA) and purchasing all the shares currently held by Vale S.A. (26.87%). Thyssenkrupp will thus become the sole owner of CSA. The shares are being acquired for a symbolic purchase price in combination with an earn-out for the event of a sale of CSA. The transaction will not result in any financing requirements for Thyssenkrupp and will not have any influence on the balance sheet valuation of CSA.

Status of restructuring of Tata Steel UK. Tata Steel UK has reached an agreement to sell its Clydebridge and Dalzell steel facilities in Scotland.

The deal involves the sale of the two plants to the Scottish Government which would then sell them on to Liberty House. The agreement follows Tata Steel’s announcement in October 2015 that it would stop its European plate production, which led to the mothballing of the Dalzell and Clydebridge plants at the end of 2015. Rather than closing the facilities, Tata Steel has continued to maintain them to enable plate production to potentially restart in the future.

Tata Steel UK sold its Long Products Europe business to the family investment office, Greybull Capital. As from June, the Long Products Europe business, which in the UK includes the Scunthorpe steelworks, two mills in Teesside, an engineering workshop in Workington, a design consultancy in York, and associated distribution facilities, as well as a rail mill in northern France, is trading under the name of British Steel.

Also for Strip Products UK, Tata Steel Europe has been advised to explore all options for portfolio restructuring including the potential divestment, in whole or in parts.

er of special steels. Both companies are specialized in the processing and sale of special steel products for tool and mould-making, a segment whose main customers are the automotive and electronics industries. With the ATT and Sermetal acquisitions, Voestalpine is pursuing its strategy of expanding into the mobility sector and extending the value chain towards the end customer.

Reorganization of Thyssenkrupp Industrial Solutions. The Industrial Solutions business area of Thyssenkrupp is being reorganized as part of the transformation programme “planets”. The current Resource Technologies and Process Technologies business units are to be dissolved. The operating units, previously one level down in the organization, will now in part be restructured and upgraded to business units. In the future these units will have global responsibility for the development of their business, project management and profit and loss. Industrial Solutions will then have eight business units: Industrial Specialties, Mining Technologies, Cement Technologies, Electrolysis & Polymers Technologies, Fertilizer Technologies, Services, Marine Systems and System Engineering.

To strengthen service business, the service activities of Industrial Solutions will for the first time be combined in the new Services business unit. Project execution and management functions will be combined in a network of excellence operated as a cost centre and managed centrally for the entire business area. The transformation programme will also speed up the integration begun in 2014 of Thyssenkrupp’s previously separate engineering companies – Uhde, Polysius and Fördertechnik.

Personalities Voestalpine extends special steel segment with acquisitions in China and Spain. With the purchase of Advanced Tooling Tek (ATT) in Shanghai, China, and the Sermetal Group in Barcelona, Spain, Voestalpine is enhancing its global position as a produc-

2016 AIST Steelmaker of the Year. John J. Ferriola, chairman, chief executive officer and president, Nucor Corp., was named Steelmaker of the Year at AISTech 2016 for his leadership and strategic vision in growing

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INTERNATIONAL INDUSTRY NEWS

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Nucor Steel and for his contributions beyond Nucor as a voice for the entire industry.

Appointment of CEO for Tata Steel UK. Tata Steel Europe has announced changes to the leadership of its operations in the UK. Bimlendra Jha, an executive committee member of Tata Steel Europe, has been appointed as the chief executive officer of Tata Steel UK. Bimlendra Jha is currently executive chairman of Tata Steel Europe’s Long Products Europe business and has successfully led the divestment process that resulted in the signing of a sale and purchase agreement with Greybull Capital.

New chief financial officer at Ovako Group. Johan Ryrberg has been appointed by Ovako as the new chief financial officer and executive

Johan Ryrberg

vice president group finance, IT and purchasing. Johan Ryrberg replaces Marcus Hedblom, who was appointed CEO for the group in November 2015.

Saarschmiede GmbH Freiformschmiede appoints management board spokesman. Saarschmiede GmbH Freiformschmiede has appointed Martin Baues as a member of and spokesman for the management board for a period of five years. Martin Baues will be responsible for the departments of production and technology and remain a member of the board and chief technical officer at Saarstahl AG.

Martin Baues

Midrex names new president.

Midrex Technologies has appointed Stephen Montague as the company’s president and chief operating officer.

He replaces Jim McClaskey, who served as president and chief executive officer for about twelve years and retains the role of CEO.

NLMK changes management structure. NLMK group has changed its management structure in order to strengthen and streamline corporate strategic functions such as operational efficiency, strategic development and internal audit. Tatyana Averchen-

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MPT International 3 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

kova, who previously held the position of director for controlling, has been appointed vice president for operational efficiency. Dmitry Kolobov has been appointed director for strategy. One of his key goals set by the management is to coordinate the development of the next phase of the strategy that would follow Strategy 2017 phase in 2018. Mikhail Makeev, newly appointed director for audit, will be focusing on streamlining corporate governance, internal audit and risk management.

Two appointments to BlueScope’s executive leadership team. Tania Archibald will join the executive leadership team of BlueScope in a newly created role, with responsibility for the optimization of investment returns from BlueScope’s global coated products assets, in addition to her current role as chief financial officer, BlueScope ANZ. Alec Highnam, general manager distribution, BlueScope ANZ, will assume the position of executive general manager people & performance, with responsibility for safety, remuneration and benefits, and organization capability and performance.

New chairman of Salzgitter supervisory board. Rainer Thieme, who recently turned 78, has laid down his mandate as chairman and as a member of the supervisory board.

The supervisory board appointed Heinz-Gerhard Wente as its new chairman. He has been a member of Salzgitter AG’s supervisory board since September 2015.

Appointments to boards of Dillinger Hüttenwerke, Saarstahl and SHS. Fred Metzken has been appointed as spokesman of the board of directors of Dillinger Hütte and of Saarstahl. He will also be responsible for finance at both companies and continues to be a member of the management board of SHS – Stahl-Holding-Saar. Bernd Münnich and Peter Schweda have been appointed as MPT International 3 / 2016

members of the SHS board of management. Bernd Münnich continues to hold the position of executive officer, technical division at Dillinger Hütte, and Peter Schweda continues as executive officer, human resources and labour director at Dillinger Hütte and Saarstahl, including Saarschmiede GmbH Freiformschmiede. These decisions were taken in the context of the continued merger of Dillinger Hütte and Saarstahl and following the resignation of Karlheinz Blessing from the board of directors of Dillinger Hütte and of Saarstahl as well as from his position as managing director of SHS – Stahl-Holding-Saar (SHS).

Outokumpu appoints chief financial officer. Outokumpu has appointed Christoph de la Camp as chief financial officer and member of the Outokumpu leadership team. Christoph de la Camp joins Outokumpu from Ineos Styrolution Holding in Germany, where he has held the position of chief financial officer since 2011.

Christoph de la Camp

Changes in Thyssenkrupp leadership team. Thyssenkrupp is continuing its strategic way forward by reorganizing the management structure of its Steel Europe and Industrial Solutions business areas. Changes of personnel in the company’s leadership team will support Thyssenkrupp’s transformation process. At the same time the group’s regional organization is being internationalized further. The Steel Europe and Steel Americas business areas are also being restructured. The production areas will be divided into downstream (rolling and coating, research and development) and upstream activities (pig iron, crude steel). CEO Andreas Goss will additionally be responsible for markets and sales.

From 1 October 2016, board member Heribert Fischer will assume responsibility for rolling and coating operations and research and development at Steel Europe and Steel Americas.

Herbert Eichelkraut, whose contract runs until the end of the year, will take on responsibility for pig iron and crude steel production at Steel Europe and Steel Americas. He will be succeeded by Arnd Köfler, currently head of rolling and coating at the Beecker werth plant.

Executive appointments at Bayou Steel Group. Robert Simon will be CEO of the newly formed Bayou Steel Group, a steelmaking and finishing operation that produces and sells long carbon steel products in North America. Alton Davis and Jim Howe will be joining the team as president/ COO and vice president of sales, respectively.

Acciarium Alliance founded.

Mauro Bianchi Ferri, after having spent the last 15 years at Tenova, has formed Acciarium Alliance – a group of four mid-size companies boosting their capability to propose tailor made solutions to steelmakers. Two are Italian and two are German: AIC Automazioni Industriali Capitanio, a provider of rolling mills and steelmaking automation solutions; KIA Kern Industrie Automation GmbH, acting mainly in the automation business for strip processing lines; SICON GmbH, supplying systems for scrap preparation and separation of residuals; iPROCESS, an innovator for process solutions in steelmaking. Acciarium Alliance is a unique plant making alliance where automation, advanced process solutions and scrap preparation and treatment

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Newly elected AISI chairman.

The board of directors of the American Iron and Steel Institute (AISI) has elected John Ferriola, chairman, president and CEO of Nucor Corporation, to serve as chairman of the institute until May 2017.

New president of Shapeline. Helmut Hackl will succeed Magnus Titus as president of Shapeline. Magnus Titus is leaving Shapeline for new challenges outside the company. Helmut Hackl has already started at Shapeline, working together with Magnus Titus to ensure a smooth transition.

Events ›

12 – 14 September 2016 Linz, Austria Organizers: ASMET www.ecic2016.org

ECIC 2016. The 7th European Coke and Ironmaking Congress will bring together a wide range of experts who will share expertise in cokemaking technology, iron ore production, sintering, pelletizing, ironmaking, environmental control, etc.

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26 – 28 October 2016 Milan, Italy Organizers: Associazione Italiana di Metallurgia www.aimnet.it

TMP 2016. The international TMP conference will examine key aspects of

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thermomechanical processing, such as phase transformations, complex microstructures, in-line heat treatments, measurement techniques and forming operations such as rolling, forging, extrusion, etc.

›

28 – 30 November 2016 Budapest, Hungary Organizers: Austrian Society for Metallurgy and Materials (Asmet) www.opmr2016.org

OPMR 2016. The conference “Opportunities in Processing of Metal Resources in South East Europe� aims at bringing together researchers and companies from the EESE region (East & South-East Europe) to present their latest research in the fields of mineral processing, extractive metallurgy and recycling of primary and secondary resources. The conference will be held in conjunction with the 5th ESEE dialogue.

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››› INTERNATIONAL INDUSTRY NEWS

World Steel Association short range outlook 2016 – 2017 worldsteel forecasts that global steel demand will decrease by -0.8% to 1,488 million t in 2016 following a contraction of -3.0% in 2015. In 2017, it is forecast that world steel demand will return to growth of 0.4% and will reach 1,494 million t.

According to worldsteel, the global steel industry faces a challenging environment following China’s slowdown.

Commenting on the outlook, T. V. Narendran, chairman of the worldsteel economics committee said: “The economic environment facing the steel industry continues to be challenging with China’s slowdown impacting globally across a range of indicators contributing to volatility in financial markets, sluggish growth in global trade and low oil and other commodity prices. The global steel market is suffering from insufficient investment expenditure and continued weakness in the manufacturing sector. In 2016, while we are forecasting another year of contraction in steel demand in China, slow but steady growth in some other key regions including NAFTA and EU is expected. Growth for steel demand in all markets except China is expected in 2017.

There are several downside risks to our forecast: the Chinese real estate market and corporate debt problem, anxiety in the financial markets, high (household) debt and volatile capital flows in many emerging economies, geopolitical tensions and unstable political situations in several regions could further worsen the global economic environment.

On a positive note, some emerging economies in South and Southeast Asia show resilient growth and along with NAFTA and the EU will support a recovery in 2017. We expect that steel demand outside China will continue to grow by 1.8% in 2016 and this growth will accelerate to 3.0 % in 2017.”

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

MPT International 3 / 2016

China expected to remain in negative territory While rebalancing progresses, the Chinese economy continues to decelerate. The severe depression in construction activities is contributing to a slowdown in the manufacturing sectors, especially metal products, as

nue. On the positive side, lower oil prices have alleviated inflationary pressure in oil importing countries, giving room for monetary stimulus to boost economic growth and providing opportunities for structural reforms. The commodity markets may be at or near the bottom of this cycle.

Country

2015

2016 (f)

2017 (f)

China

672.3

645.4

626.1

United States

95.7

98.8

101.5

India

79.5

83.8

88.3

Japan

62.9

64.4

63.6

South Korea

56.0

56.3

56.4

Russia

39.4

35.9

37.4

Germany

39.0

39.5

39.9

Turkey

34.4

35.5

36.7

Mexico

24.2

25.0

26.2

Brazil

21.3

19.4

20.1

Steel demand of the top 10 steel using countries (million t; f: forecast)

well as slower growth in automotive.

A recovery for the construction sector is not forecast in the near future.

The decline in steel demand in China is expected to be -4.0% in 2016 followed by -3.0% in 2017. This suggests a demand of 626.1 million t steel (15% down from 2013) for 2017, a contraction to 41.9% of world steel use from 47.9% in 2009 and 44.8% in 2015.

Low commodity prices indicative of slow economic growth Falling oil and gas related investments and the squeeze on government spending have affected steel demand in economies relying on oil based reve-

Slowing growth in global trade bites manufacturing growth With the deep integration of China in the global manufacturing supply chain, this sector has slowed as a consequence of weak growth in global trade. Manufacturing exports in emerging economies, in particular in Asia, declined owing to slower Chinese demand. The same is true for developed countries experiencing a reduction in the exports of consumer goods and machinery.

Specifically, the mechanical machinery, metal goods and other transport sectors are weakening, but the automotive sector will maintain its growth momentum supported by

INTERNATIONAL INDUSTRY NEWS strong demand in many countries.

Outside China the construction sector is expected to maintain its mild, but steady recovery momentum particularly in India, the MENA and ASEAN regions.

Emerging economies exposed to China’s slowdown and ƂPCPEKCN OCTMGV XQNCVKNKVKGU Steel demand in some emerging economies continues to perform below expectation. A worsening external environment in the form of weak exports, low commodity prices, capital outflows and currency devaluation add adversity to these economies. Geopolitical and internal national political tensions are present in many of emerging economies.

Brazil and Russia are struggling with their internal and structural issues. Steel demand in both economies is expected to contract strongly in the period ahead. In particular, the Brazilian economy with its political uncertainty has resulted in a severe contraction in steel demand of -16.7% in 2015 and will contribute to a contraction of -8.8% in 2016 with a recovery of only 3.1% in 2017.

India’s prospects are brightening due to low oil prices, the reform momentum and policies to increase infrastructure and manufacturing output. India’s steel demand will increase by 5.4% in both 2016 and 2017 reaching 88.3 million t in 2017.

In Turkey, steel demand is expected to grow by 3.3% in 2016 and 3.2% in 2017, supported by the government’s focus on progrowth economic policies and low oil prices.

Steel demand in the ASEAN 5 (Thailand, Malaysia, Vietnam, Indonesia, Philippines) is also expected to maintain a growth rate of around 6% despite their exposure to China due to their infrastructure building activities and will reach 74.6 million t in 2017.

Steel demand in the emerging and developing economies excluding China is forecast to grow by 1.8% and 4.8% in 2016 and 2017 respectively. Steel demand

in these economies will amount to 457.1 million t in 2017, accounting for about 30% of world steel demand.

Developed economies’ recovery momentum maintained despite headwinds While developed economies are also feeling the effect of the worsening global economic environment, they are expected to maintain a stable recovery momentum. Steel demand in the developed economies will grow by 1.7% in 2016 and 1.1% in 2017.

‹‹‹

25

In the EU, a mild recovery in steel demand continues with generally improving economic sentiments and investment conditions. However, uncertainties in the political landscape related to the refugee crisis and Brexit raises risks to the improving economic condition. Steel demand in the EU is forecast to grow by 1.4% in 2016 and a further 1.7% in 2017.

In the US, steel demand is dampened by the fall in oil prices and a strong dollar, but an improving job market and a robust housing sector will support steel demand. Steel demand in the US is expected to grow by 3.2% in 2016 and 2.7% in 2017.

26

››› IRONMAKING

Bell Less Top® equipped with a MIDI type gearbox

Jindal South West Steel restarts blast furnace No. 1 after major reline project JSW´s new No. 1 BF replaces its predecessor (sized at 8 m hearth diameter) which has been in operation for one campaign from 2004 until August 2015. The new furnace has now an inner volume of 2,307 m³ (instead of 1,250 m³) and an increased hearth diameter of 10.4 m. It has been one of the largest capacity increases ever seen from one single blast furnace rebuild.

After a complete rebuild with modernization, size increase and capacity expansion, No. 1 blast furnace at JSW Steel’s Vijayanagar works, Toranagallu, Karnataka state, India has been blown in on 8 February 2016 at 06:15 a.m. This was achieved after a very

Paul Wurth S.A., Luxembourg, a company of SMS group Contact: www.paulwurth.com E-mail: paulwurth@paulwurth.com

MPT International 3 / 2016

short phase of cold and hot commissioning which started 12 days before with a first furnace leak test followed by pressure test, furnace drying, heating and first filling. A smooth and safe blow-in and ramp-up allowed achieving 83% of nominal production level within the first week of operation. The target production has been surpassed for a first time on 9 March 2016.

JSW Steel Ltd. has relied on Paul Wurth technology for improving BF top charging performance. The company awarded the order to Paul Wurth

in 2011 already. Paul Wurth’s contractual obligations covered design, engineering, procurement and supply of equipment for the entirely new blast furnace and all its main auxiliary plants, basic engineering for the erection and its planning as well as supervision of erection and commissioning for the major plant units.

The new furnace features a modern profile, all-staves thin-wall cooling system, extensive instrumentation and process recording devices, a parallel-hopper Bell Less Top® with a

IRONMAKING MIDI type gearbox, a completely modernized casthouse with new and displaced equipment, adjusted runner design, access ramps and platforms as well as dedusting facilities. The existing auxiliary plants have been upgraded for the new production parameters: improvements and capacity increasing measures have been applied to the top gas cleaning, slag granulation, water treatment and PCI plants. A new hot stoves plant with waste gas heat recovery system has been installed.

JSW´s new No. 1 BF replaces its predecessor which has been in operation for one campaign from 2004 until August 2015. It is supported on the old but reinforced foundations and fits into the existing square tower.

The furnace has now an inner volume of 2,307 m³ (instead of 1,250 m³), an increased hearth diameter (enlarged from 8 to 10.4 m) and increased number of hot blast tuyeres (from 18 to 28). The daily hot metal rate is 5,250 tons for a total year-

27

The new No. 1 BF replaces its predecessor after one campaign from 2004 until 2015

ly iron production of about 1.7 million tons, some 89% more than before the modernization. These figures rep-

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28

››› CONTINUOUS CASTING

Continuous bloom caster and long-product rolling mills started up at Hyundai Steel, Korea The installations are part of Hyundai Steel’s new special steel mill in Dangjin, Korea. The continuous caster is designed for a capacity of 1.1 million metric tons of blooms per year to feed a new combination mill.

Continuous bloom caster at Hyundai Steel in Dangjin, Korea

In October 2015, a continuous bloom casting machine, a large bar rolling mill and a small bar and wire rod mill supplied by Primetals Technologies were started up at the new special steel mill of Korean steelmaker Hyundai Steel in Dangjin. The caster is designed to produce 1.1 million metric tons of blooms per year. It features the 200th application of the monitoring system Mold Expert. The large bar rolling mill produces one million metric tons of end round products as well as billets for the small bar and wire rod mill. The order had been awarded to Primetals Technologies in early 2014. Both caster and large bar rolling mill were started up almost a month ahead of the scheduled date.

Hyundai Steel, situated in Incheon and Seoul, South Korea, belongs to the Hyundai-Kia Automotive Group and runs six production facilities in South

Primetals Technologies Ltd., London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com

MPT International 3 / 2016

Korea and a further one in China. At present, the company is constructing a new plant at the Dangjin site to produce special steels for the automotive industry. In future, bar and wire are to be produced here as primary material for engine and gearbox parts.

Annual production of 400,000 metric tons of wire rod and 600,000 metric tons of straight bar and bar-in-coil is planned.

The four-strand continuous bloom caster from Primetals Technologies has an annual capacity of 1.1 million metric tons. The caster is equipped with mold-monitoring system Mold Expert. In combination with air mist spray cooling and interior-cooled rollers in the strand guidance system, further technology packages ensure uniformly high quality of the blooms cast.

Still hot, these are then fed for direct use in the bar line. This saves energy during reheating and improves operating safety because there is no need for transport of blooms, for example by crane.

The large bar mill encompasses a duo reversing breakdown stand and

a finishing train with rolling/sizing stands. The large bar mill also provides billets to be further processed in the small bar and wire rod mill, which Primetals Technologies also supplied. This combination mill has a capacity of 800,000 tons and is designed to roll 160 tons per hour. It includes a continuous roughing and intermediate mill feeding a sizing block supplied by Germany-based Friedrich Kocks GmbH & Co KG for production of bars, a rod outlet with a rod reducing sizing mill (RSM) and also a barin-coil (BIC) outlet. Both the rod and bar-in-coil outlets have slow and fast cooling capability.

The small bar and wire rod mill has the highest production rate for a combination mill, and is particularly designed for low-temperature rolling.

This improves the metallurgical structure and mechanical properties of end products and enhances flexibility during the rolling operation. Special mechatronics packages and an integrated automation solution ensure the necessary high product quality throughout the plant.

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O Accurate calculation with a precision of less than 1 %; all other methods have error ranges >10 %.

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30

››› COMPANY PROFILE

Aferpi to build new steel complex in Piombino, Italy Acciaierie e Ferriere di Piombino SpA (Aferpi) and SMS group have signed a contract on the supply of a new steel complex replacing outdated facilities at the Piombino site in Italy. The new complex will consist of a meltshop with a capacity of more than one million t per year of liquid steel and a hot rolling mill with a capacity of 700,000 t of long products per year.

5VGGNOCMKPI ECUVKPI RNCPV PI/HBI yard

'ZKUVKPI TQNNKPI OKNNU Wire rod mill TVE 730 ktpy

up to 65% 5$3 DKNNGV %%/ up to 100%

Twin 140 t LF

Bar mill TMP 470 ktpy

140 t EAF SHARC Scrap yard Twin 140 t VD

$NQQO %%/

0GY TQNNKPI OKNN RailCoolÂŽ U[UVGO

0GY TQNNKPI OKNN RHF 200 tph

4GXGTUKPI DTGCM FQYP OKNN

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Rail and section mill 700 ktpy

4CKN Ć‚PKUJKPI NKPG 5GEVKQP Ć‚PKUJKPI NKPG

*QTK\QPVCN XGTVKECN %QQNKPI DGF YKVJ UVTCKIJVGPKPI RTG DGPFKPI FGXKEG OCEJKPGU

2TQFWEVKQP TQWVG QH VJG PGY UVGGN EQORNGZ

Piombino is an Italian town on the western coast of Tuscany, in front of the island of Elba. Steel production in Piombino dates back 150 years, when the first Italian metallurgical plant using a Bessemer converter was set up there.

Later, in the early 20th century, it became the first integrated iron and steel works in Italy. During the course of its history, ownership of the Piombino iron and steel works changed several

Aferpi S.p.A., Piombino, Italy Contact: www.aferpi.it SMS group GmbH, DĂźsseldorf, Germany Contact: www.sms-group.com

MPT International 3 / 2016

times. In 2015, Cevital Group acquired the Piombino plant and established Acciaierie e Ferriere di Piombino SpA – Aferpi Iron and Steel Works.

International Cevital Group, with headquarters in Algeria, is present worldwide in markets and sectors such as food, automotive, industry and logistics. With the acquisition of the Piombino plant, Aferpi now holds all the brands and know-how developed in over 100 years of steel history.

Aferpi’s activities involve the production of a wide range of quality and special steel products in different shapes and sizes for rails, wire rod and bars to be supplied to sectors such as railway, automotive, energy, engineering etc.

From the very beginning of the acquisition process, Cevital Group has been committed to an industrial plan comprising the full employment of the personnel at Piombino through the relaunch of steel production and diversification. It was reported in the Italian media that during a meeting with Tuscany’s President, Enrico Rossi, the president of the Algerian group, Issad Rebrab, had made the commitment that the Piombino works will return to steel production, EUR 400 million will be provided in investment for the creation of an EAF meltshop and a new rolling mill (to supplement the existing ones), putting the entire labour force back to work within 2 years.

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32

››› COMPANY PROFILE

0'9 56''. 5*12

0'9 4#+. #0& 5'%6+10 /+..

':+56+0) 2.#065

SHARC meltshop

Reheating furnace and break down mill

Wire rod mill – TVE (exist)

SBQ billet caster – CCM 1

4-stand CCSÂŽ reversing tandem mill

Bar/train mill – TMP (exist)

Bloom caster – CCM 2 HBI/Scrap yard Substation/water treatment plant

RailCoolÂŽ-system for rail head hardening Cooling bed and straightening machines 0?GJ jLGQFGLE JGLC UGRF ?SRMK?RCB RCQR ACLRCP 1CARGML jLGQFGLE JGLC UGRF NGJGLE K?AFGLCQ

.C[QWV UEJGOG HQT VJG PGY UVGGN EQORNGZ KP 2KQODKPQ RTGNKOKPCT[

port, the so-called “old plant� comprised the coke plant, one blast furnace and the steelmaking plants (all idled) and an outdated rail mill. A second production site is located in safe distance from the Piombino town centre. Aferpi operates a wire rod and rebar rolling mill there.

Recently, at the end of April 2016, Aferpi reached another milestone of its investment plan. SMS group and Aferpi signed a contract on the new steel complex in Piombino. The new plant will feature latest technology designed to produce premium steels at high productivity combined with environmen(CWUVQ #\\K TKIJV %'1 QH #HGTRK CPF )WKFQ -NGKPUEJOKFV OGODGT QH VJG OCPCIKPI tally friendly solutions for low energy DQCTF QH 5/5 ITQWR UKIPGF VJG EQPVTCEV HQT VJG PGY UVGGN EQORNGZ KP 2KQODKPQ consumption and low emissions.

The new steel plant will comprise the following production facilities: Although steel production is to re- creation of a new logistics hub to fa- ▪ 140 t SHARC EAF, main the core business, the fact that vour the site’s import-export business. ▪ twin ladle furnace, Cevital is active in multiple sectors is ▪ twin VD plant, likely to lead to the establishment of ▪ 6-strand continuous billet caster, New steel plant and new productive installations in Pi▪ 6-strand continuous bloom caster. ombino. After a period of land recovextended hot rolling SMS group will supply a 140 t EAF beery, the new management will start ing the heart of the new meltshop. The capacities the production of biodiesel, vegetable Production facilities in Piombino SHARC (shaft arc furnace) type dioil, animal feed and sugar. Additional- used to be split between two sites. Lo- rect-current electric arc furnace will ly, the Algerian plan also included the cated close to the town area and the operate in a highly eco-friendly way

MPT International 3 / 2016

COMPANY PROFILE thanks to the extremely efficient preheating of the charge. The EAF will be charged with a high rate of virgin materials, such as HBI (up to 65%) or pig iron (up to 55%), in addition to scrap in order to reliably meet the required cleanness of the steel produced. The EAF will be designed for a tap-to-tap time of 45 to 59 minutes (in case the charge includes HBI).

The steel plant will also comprise a twin ladle furnace and a twin vacuum degasser. These facilities will make it possible to adjust the liquid steel precisely to the required target composition. The steel will then be cast either on the new bloom caster or the new billet caster for SBQ (special bar quality) products. Both casting machines will be equipped with Convex® mould technology and mechanical soft reduction systems.

The hot rolling complex will comprise the following production facilities:

▪ new rail and section mill, ▪ existing bar mill, ▪ existing wire rod mill.

Whereas billets will continue to be rolled in the existing bar and wire rod mills, the blooms will be processed in the newly built rail and section mill.

Hot charging of blooms directly to the rail mill will be possible, allowing great savings of preheating energy and a reduction of gas emission. The new rail and section mill will produce rails with a length of 120 m as well as various beams, sections and sheet piles.

At the “hot side” the new rail and section mill will comprise equipment as following: ▪ reheating furnace, ▪ break down mill, ▪ hot saws, ▪ 4-stand tandem reversing mill, ▪ profile gauge with surface defect detection, ▪ rail stamping machine, ▪ rail head hardening line (RailCool®),

CCM 1: SBQ billet caster

CCM 2: Bloom caster

Type

Curved, heavy duty

Curved, heavy duty

Main radius

R1 = 10 m; R2 = 18 m

R1 = 12 m; R2 = 20 m

No. of strands

6

6

Section cast

140 mm sq.

220 mm sq., 270 mm sq.; 260 x 360 mm

Mould technology

Convex®

Convex® / Invex®

Extraction modules

Mech. soft reduction

Mech. soft reduction

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DER

ANTRIEB

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‹‹‹

33

▪ cooling bed with pre-bending device.

Designed for high flexibility and availability, the mill will comprise compact cartridge stands (CCS®) and a compact roller straightener (CRS®) as successfully in operation in numerous rail and section mills. The CCS® mill stands will be equipped with hydraulic adjustment systems to allow rolling at very close tolerances. The scope of supply also includes a RailCool® rail head hardening line.

The rail finishing line will process long and short rails and feature testing facilities, cutting and drilling machines as well as gag presses. A separate finishing line will process all the sections rolled.

Conclusion In close proximity to the existing rolling mills, i.e. a wire rod mill and a bar mill, Aferpi will build a completely new meltshop including continuous bloom and billet casters. The new plant will use the existing infrastructure of the rolling operations. Aferpi will implement most modern and efficient solutions for steelmaking, casting and rolling.

This project will enable Aferpi to continue steel and rail production in Piombino with latest state-of-the-art equipment. The new steel complex will have all it takes to make worldclass long products.

NORD DRIVESYSTEMS: Q Worldwide available Q Subsidiaries in 36 countries Q Agents in 52 countries

DerAntrieb.com Headquarters: Getriebebau NORD GmbH & Co. KG Fon +49 (0) 4532 / 289 - 0 info@nord.com Member of the NORD DRIVESYSTEMS Group The

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Q Strong bearings Q High corrosion protection

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Q High power density

Q All operating conditions

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34

››› HOT ROLLING

Upgrade of the SBQ rolling mill at SeAH Changwon Special Steel, Korea Continuing several decades of successful partnership, Korean specialty steel producer SeAH CSS contracted leading European plant equipment suppliers for a modernization project at their bar and wire rolling mill in Changwon. Commissioning of the revamped equipment is scheduled for the period end of 2016/beginning of 2017.

SeAH Changwon Integrated Special Steel Co. (SeAH CSS) is Korea’s only domestic producer of high-grade special steel bar and wire rod. (The former POSCO Specialty Steel and Sammy Steel were acquired by SeAH group in March 2015.) With an annual steelmaking capacity of 1.2 million tons and a steel product output of 1.0 million t, SeAH CSS is among the top ten producers of special steels in the world.

Recently, the company started a modernization project at its hot rolling mill. Continuing several decades of successful partnership, SeAH CSS awarded the order for the project to Friedrich Kocks GmbH & Co KG (consortium leader), Morgårdshammar AB and Automazioni Industriali Capitanio (AIC). Two existing Kocks blocks – a precision sizing block (PSB) and a 370/10 three-roll intermediate block – will be replaced by new equipment, namely: ▪ two 2-high HV stands, ▪ three loopers, ▪ one crop & cobble shear and ▪ one 370++ RSB SCS® of the latest design with six stand positions.

The RSB SCS® is the latest milestone in reducing and sizing technology for SBQ products. It will provide SeAH CSS enhanced bar and wire quality, improved productivity, mill availabil-

Friedrich Kocks GmbH & Co KG, Hilden, Germany Contact: www.kocks.de Morgårdshammar AB, Smedjebacken, Sweden Contact: www.morgardshammar.se Automazioni Industriali Capitanio s.r.l., Odolo (BS), Italy Contact: www.aicnet.it

MPT International 3 / 2016

Drawing of the 4D EAGLE gauge at the Kocks RSB SCS®

Morgårdshammar P600 vertical stands

HOT ROLLING

‹‹‹

35

AC drive panels from AIC

ity and economy as well as simplified, safe and environmentally friendly operation.

At the core of the future-oriented RSB SCS® is the real-time closed-loop control system SCS® (size control system) acting in combination with 3-roll stands adjustable under load (AUL) and under-load tension control. Operation of the SCS® will be supported by an innovative bar gauge called “4D EAGLE” developed in cooperation with Automation W + R GmbH, Germany. This bar gauge, which is based on the light section principle, provides an extremely high measuring frequency. These features will markedly further improve the rolled tolerances and their reproducibility and, at the same time, simplify operation by means of an automated optimization of the process parameters for the rolled bars and wire rods either by roll gap adjustment or control of the tension between the stands under load.

The RSB SCS® will be designed for the production of steel bar and rod in coils with a finished size range from dia.

16.0 to 100.0 mm and any pre-sections for the wire mill with a size range from dia. 5.5 to 16.0 mm at a maximum rolling speed of 15 m/s.

The two 2-high horizontal and vertical stands will be supplied by Morgårdshammar. The P600 series stands are well known for their performance in terms of rigidity, stability and size tolerance. Wear resistance of the bearings and other parts is unparalleled.

The stands are capable of adjusting the roll gap during rolling, i.e. while the bar is between rolls (also for Nickel alloy grades). This feature allows true closed-loop control within the stands.

The stands are fully compatible with the latest electronic intelligent RX guide series and new electronic setting equipment – Smart Eye™. The capabilities of the RX guide include remote adjustment, automatic self-adjustment and self-setting (both in the mill and in the workshop), load and speed feedback. All these features allow for precise inline adjustment during rolling and – without any production stoppages – after a product size

change. Also due to the precise control of the impact force on the rolls, the life span increases up to 170% compared to that of common guide rollers.

Automazioni Industriali Capitanio (AIC) will design and manufacture the electrical & automation equipment for both, the new Kocks RSB SCS® and the new Morgårdshammar stands and shear, providing state-of-the-art power control panels as well as a new PLC cabinet and new AC motors. The electrical scope of supply will include two power control switchboards based on Siemens Sinamics S120 motor modules with fully regenerative DC bus supplier (active front end), suited to drive the new Siemens AC motors sized according to the mechanical equipment designed by the consortium partners.

AIC will also be in charge of manufacturing an auxiliary AC drives panel, PLC cabinet and control desks. The Italian company’s supply scope further includes the complete engineering for the whole electrical portion as well as PLC software development based on Siemens S7 platform.

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MPT International 3 / 2016

36

››› HOT ROLLING

New continuous blooming mill at Saarstahl

New blooming mill starts operation at Saarstahl, Germany Saarstahl AG has completed a 30-million-euro investment: a seven-stand continuous blooming mill replacing a reversing rolling stand.

Saarstahl group, with its headquarters in Völklingen, Germany, has specialized in the production of wire rod, bar, semi-finished products and forged products in premium qualities. Germany-based Saarstahl AG, which has production locations in Völklingen, Burbach and Neunkirchen, is an important player in the global long products market.

In spite of the current challenging competitive conditions, the company has been adhering to its strategic investments as planned. A further milestone has now been completed in the rolling mill at the Völklingen site: There, a 30-million-euro, ultra-modern, continuous blooming line with a rolling train of seven stands has replaced the old blooming stand. Martin Baues, chief technical officer of Saarstahl AG stated: “With this investment we are increasing our manufacturing know-how so as to be able also

Saarstahl AG, Völklingen, Germany Contact: www.saarstahl.com E-mail: saarstahl@saarstahl.com

MPT International 3 / 2016

in the future to fully comply with our customers’ wishes in terms of quality and flexibility.” The new plant offers the possibility of rolling a much broader range of cross-sections and provides further improved quality and shorter cycle times.

After the investment had been approved by the supervisory board of Saarstahl in 2014, construction and engineering work on the rolling train began in April 2015. In order to prevent any production losses, construction was to take place without stopping production. For this purpose, a “construction site bypass” was set up meaning that specially installed turntables and roller tables would guide the billets coming out of the furnace past the construction site to the existing blooming stand. Parallel to this, the foundations for the horizontal and vertical stands of the new rolling train were built and the media cellar and pump room completed. Finally, the mechanical and electrical components – supplied by SMS group – were installed.

The total drive power of the new continuous blooming mill is 11,000 kW. Initial tests carried out in January 2016

ran smoothly, and the system was officially put into operation at the beginning of March 2016.

The effort of continuing production without restrictions while having a major construction project going on was well worth it. One advantage of the new system is the progress in rolling technology it provides: the greater rolling passes and improved guidance of the billets during rolling provide an additional improvement in the mechanical properties and the surface quality of the finish-rolled steel bars. The higher degree of automation in the control systems leads to considerably shorter cycle times, faster product changes and therefore increased rolling performance.

With this investment, Saarstahl reinforces its business segment of massive formed parts like crankshafts, drive shafts, wheel hubs, piston pins or other gear components, which are mainly used in plant construction and vehicle manufacturing. These parts are produced in constantly lighter weights while providing high energy and material efficiency.

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Two powerful companies in the metals industry have forged together. Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies have united to become the new global force in metals technologies.

Creating the future of metals as one. primetals.com

38

››› TUBE MAKING – QUALITY ASSURANCE

Screen of the mobile control unit during a measurement

Automatic checking and adjusting of roll alignment in tube mills A mobile measuring system installed in tube mills checks the contour and position of the roll passes. Deviations of the alignment can be corrected easily and quickly before they manifest themselves in the tubes produced.

Roll chocks, mill stands and contact faces in rolling mills become dirty and worn when permanently in use. This used to present mill operators with an alignment problem, because while the mill stands are checked in a separate calibration stand or on the machine tool in the stand workshop, the mill housings are examined with the aid of a special zeroing stand. This may result in unequal alignments. Until now, the operator was not able to ascertain whether the passes were precisely set until the mill stands were reinstalled

Frank d’Hone, SMS group, Mönchengladbach, Germany Contact: www.sms-group.com E-mail: seamlesstubeplants@sms-group.com

MPT International 3 / 2016

in the mill housing. Only the end product indicated whether everything was correct. For example, if the tube wall thicknesses or outside diameters were non-uniform, it used to be necessary to readjust the settings step by step until the passes were correct. That was a time-consuming and costly procedure.

During the past two years, SMS group developed a solution to that problem, the CaliView® system which measures – inline in the mill housing – the roll contours for each pass. The rolls can be checked quickly and easily at any time.

This makes it possible for the tube mill operators to directly readjust the roll pass. With CaliView®, it is thus possible to detect any incorrect settings beforehand and not only after they have become noticeable in the finished tube.

The system uses an optical process to measure the roll passes in PQF®, MPM

or SRM/stretch-reducing mills. Most recently the system has also been in use in cross-roll piercing mills and in stand toolshops.

CaliView® measures the positions of the rolls in longitudinal rolling mills directly after each roll change, providing the necessary data for the rolls to be optimally set right away, without any loss of time. This is the only measuring system that in cross-roll piercing mills reliably indicates whether the rolls and guiding elements are correctly positioned in relation to the mandrel. In longitudinal rolling mills, CaliView® measures the contours of the rolls of a pass in a non-contact manner, two-dimensionally in a plane surface, right-angled to the rolling direction and through the point of the groove root. In cross-roll piercing mills, it measures the highest point of the rolls.

TUBE MAKING – QUALITY ASSURANCE

‹‹‹

39

Backlight Camera

Misaligned

Repositioned

Arrangement of the system in a PQF® rolling mill

Portable measuring solution The mobile system comprises a light source, a camera, a mobile control unit and the computer for the configuration of measurement parameters and evaluation of the measurement results.

The light source and the camera have been developed specially for SMS and designed specifically for the conditions in a tube mill. The light source backlights the passes individually in the mill, enabling a shadow image of each pass to be obtained. This shadow image of the LED light is captured by a digital camera, which transmits the data on to a control device. The camera can be positioned at either the entry or the exit side of the rolling mill.

During the measurement, the control unit receives the data from the camera via WiFi or LAN and prepares them for display. The control unit has an operating duration of at least four hours and, with a WiFi connection, a range of up to 100 metres. Thus during the measurement the results can also be directly viewed in the control pulpit of the rolling mill and utilized for pass correction.

The parameters required for the measurement, such as the distances between the mill stands to be measured, references for pixel factor and the defined passline, or design data for the roll contour, are entered into the configuration computer beforehand and only once per rolling mill. The spatial orientation of the rolls, for two-, three- or four-roll systems, can be selected by the operator via a drop-down menu in the CaliView® software. The rolling mills to be measured are cre-

ated in the configuration and evaluation software. First the passline and then the rolling mill, followed by the setting plan, must be entered into the menu. Finally, the pass data is entered.

The contour of the rolls can be defined by means of various input masks and be directly viewed. A configuration contains all the significant data of the respective rolling mill, for example, the quantity of measuring positions, number of rolls per stand and the pass diameters.

For measurement purposes, the control unit and the camera constitute one unit and are connected via a WiFi or LAN interface. All of the camera functions are guided and visualized via the control unit. The control unit receives the configuration of the rolling mill from the configuration software.

Besides the possibility to adapt the configuration data, the software offers the option to view the measurement results during the measurement in the same format as in the evaluation software. Deviations in the pass, from the passline and from the diameter are displayed while the measurement is going on. Overlays for evaluation ranges, contour recognition and inscriptions can be switched as required

for a better overview. In order to document changes made to the rolling mill, several measurements can be taken following a once-only definition of the references.

Camera of the CaliView® system

40

››› TUBE MAKING – QUALITY ASSURANCE

Deviations in the pass and from the FGƂPGF RCUUNKPG

Most helpful interpretation of measured data Plant operators may perform optical gauging of passes with diameters from 20 to 577 mm. For diameters smaller than 250 mm, the precision is +/- 0.1 mm, for diameters from 250 mm upwards, it is +/- 0.2 mm. The system performs several measurements directly after one another, in parallel or at certain intervals, and in different configurations. Following a measurement, CaliView® analyzes the pass design and calculates any incorrect settings. On the basis of this analysis, the mill operator can immediately reset the pass in order to optimize the product quality. For each pass, the system requires a maximum of 30 seconds to record and evaluate the data. Thanks to the specially programmed pass analysis software, it does not make a difference whether two, three or four rolls per stand are used and how the stands are arranged in the mill.

CaliView® evaluates the symmetry of the two, three or four rolls. Any deviations from the ideal positions are displayed by the system in numerical and graphical form, both on the control unit during the measurement and on the configuration computer after the measurement has been completed.

MPT International 3 / 2016

The system indicates the radial and axial roll offset against the mill stand and the passline. This allows the operating personnel to initiate corrections exactly where needed.

In the past, mill operators had often felt the need of such a system. CaliView® can be retrofitted to existing pipe and tube mills. In practical application, the system has provided convincing results: It reliably measures any incorrect pass alignments and helps to minimize them, for example by means of roll position corrections – both between the stands and in the stand itself. The measurement results are stored in a database. This enables tube makers to build a comprehensive production history and compile statistics on the causes of defects. For example, CaliView® also localizes any incorrect settings of mill stands and passes during day-to-day operation caused by grease layers of varying thickness between the coupling surfaces between the mill housing and the mill stand, by contamination of the V-guides or as a result of the manufacturing and assembly tolerances of the stand components. The mill operators have constant knowledge of the degree of roll wear. For tube and pipe producers this means that they are not only able to set and check the roll passes but also

monitor the effects of repairs on the pass positions.

Conclusions SMS group has developed a mobile measuring system that, installed in tube rolling mills, checks the contour and position of passes. CaliView® monitors the alignment of the passes without any elaborate manual measurements. Deviations detected by the system can be easily and quickly corrected before they manifest themselves in the produced tube. CaliView® enables rolls of a pass to be optimally set to one another and in relation to the passline. In PQF® and MPM mills (premium quality finishing lines and multistand pipe mills), it is also possible to recalibrate the hydraulic capsules and the mechanical screwdown systems in an inline procedure.

The system is also capable of checking the rolls in extracting mills and in sizing and stretch reducing mills. With CaliView® is it possible to directly align the rolls in longitudinal rolling mills after each roll change. The inline measuring system can meanwhile also be used in cross-roll piercing mills and in stand toolshops. In cross-roll piercing mills, CaliView® reliably indicates whether the rolls are correctly positioned in relation to the mandrel.

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Individual solutions – without limits

42

››› SPECIAL EQUIPMENT

2TQRTKGVCT[ DCUG ƃWKF VGEJPQNQI[ WUGF VQ HQTOWNCVG ƂTG TGUKUVCPV NWDTKECVKPI ITGCUG Fire hazards are constantly present in the steel industry, and steel producers always ORRN IRU ZD\V WR ORZHU VXFK ULVNV LQ WKHLU SODQWV ,Q WKH HIIRUW RI ORZHULQJ WKH ULVN RI ƂUH E\ XVLQJ ƂUH UHVLVWDQW OXEULFDQWV WKH IRFXV KDV VR IDU SULPDULO\ EHHQ RQ K\GUDXOLF ƃXLGV +RZHYHU WKHUH KDV EHHQ D VKLIW WRZDUGV ƂUH UHVLVWDQW JUHDVH UHFHQWO\ 8VLQJ WKHVH JUHDVHV DOVR IXQFWLRQV DV SUHYHQWLYH PHDVXUH DJDLQVW ƂUH

Mineral oil grease

QUINTOPLEXâ„¢

Fire-resistance test #1: a torch is held to the grease

Mineral oil grease

QUINTOPLEXâ„¢

Fire-resistance test #2: the grease is placed on a hot ceramic disc (815°C)

Josef Barreto-Pohlen, Global Product Manager Greases, Quaker Chemical Corporation, Uithoorn, The Netherlands Contact: www.quakerchem.com E-mail: sabedraj@quakerchem.com

MPT International 3 / 2016

Lubrication in an integrated steel plant requires a wide range of utilities and can therefore be a major challenge.

All steel plant sections such as ironmaking, steelmaking, rolling and finishing as well as auxiliary units, have various

equipment and operating conditions; extreme loads, low and high speeds, severe temperature changes and dusty, humid – often acidic – environments.

The equipment used in the raw material blending, blending yard, beneficial

SPECIAL EQUIPMENT plant, sinter plant, in the coke ovens, and blast furnaces of the ironmaking section works under high temperatures, and in a dusty and corrosive environment. Although crushing and screening equipment operates at slower speeds than the other operations here, they are still subjected to heavy shock loads. The steelmaking area includes blast furnaces, continuous casters, and a lime plant. In addition to the typical operating conditions in the ironmaking process, water ingress needs to be factored in. The rolling and finishing processes are done in hot strip mills, cold rolling mills, primary boom bar mills, bar and wire rod mills and in merchant mills.

In these areas, heavy shock loads, water and scale ingress, high temperatures and higher speeds are the dominating operating conditions. Lastly, the auxiliary units in an integrated mill, such as a deslagging device, scrap disposal device, ladle demolition stand, and maintenance stands for ladles, are found in all the major areas, and can be subjected to the various operating conditions previously mentioned.

The variety of lubricants commonly needed to cover these areas all consist of mineral and/or synthetic base oils. These lubricants are considered flammable.

43

Cool materials

Heat

Reduce air supply

Remove fuel

Chemical chain reaction

Oxygen

Fuel

Interrupt reactions (QWT YC[U VQ UVQR C ƂTG pƂTG VGVTCJGFTQPq CEEQTFKPI VQ VJG 75 0CVKQPCN (KTG Protection Agency)

fire-resistant hydraulic fluids into a lubricating grease. This new fire-resistant grease line is marketed under the brand name QUINTOPLEX™.

*QY VJG Ć‚TG TGUKUVCPV ITGCUG (KTG TGUKUVCPV J[FTCWNKE ĆƒWKFU works QUINTOPLEX™ fire-resistant grease formulated as a lubricating has a very low vapor pressure, which grease Approximately three quarters of the lubricating grease in an integrated steel plant are used in the continuous caster and the hot mill. An important function of the grease, in addition to lubrication, is to protect the bearings by forming a grease collar, sealing them against water and dust ingress. The formation of the collar is ensured by regular re-lubrication via a centralized lubrication system.

If the grease collar is not stable enough (e.g. poor water resistance) or the re-lubrication volume is too high, the risk of fire is increased as grease can drop onto a flammable surface or sparks can fall onto accumulated grease and ignite it.

Fire-resistant hydraulic fluids are already used to reduce the risk of fire in steel mills, but it is a new initiative to use a fire-resistant grease as a preventative measure. Quaker Chemical Corporation (“Quaker�) has now successfully transferred the proprietary technology of the base fluids used to formulate

‚‚‚

means it removes fuel, one of the ele-

ments needed to start a fire based on the “fire tetrahedron� (see box “Fires – facts and ways to put it out�). By removing the fuel element, the risk of a fire starting is reduced.

Grease suppliers may use different terms to describe a grease that stops the perpetuation of fire. Commonly used terms are: â–Ş Fire-resistant / flame-retardant: The grease is difficult to ignite and burns

For a fire to start and evolve, it must have four elements present: heat – fuel – oxygen – uninhibited chain reaction

Once a fire has started, it can spread in three different ways: by conduction, by convection, by radiation.

Once the fire has spread, there are four ways to put it out: cool the burning material, exclude oxygen, (CEVU CDQWV Ć‚TG CPF ways to put it out

remove the fuel, break the chemical reaction.

MPT International 3 / 2016

44

››› SPECIAL EQUIPMENT

only at very high temperatures and needs an additional energy source to keep burning. ▪ Non-inflammable: The grease does not burn under normal conditions; non-inflammable greases are only those based on perfluor-compounds. All other products can and will burn when heated up to a certain temperature. ▪ Self-extinguishing: The grease starts to burn, but doesn’t continue to do so for several reasons. It does not produce enough energy to keep the temperature at a burning point, and the reduced fuel means as low volatility as possible, with the removal of oxygen and the production of inert gases such as carbon dioxide. ▪ Heat-resistant: This indicates whether a grease can withstand oxidation (ageing); not every fire-resistant grease is also heat resistant and vice-versa.

There is no standardized test available to determine the fire-resistance of a grease. However, to demonstrate the level of QUINTOPLEX™ fire-resistant grease, Quaker Chemical uses two inhouse tests as following: #1. A torch flame is held to the grease to see if it will ignite. #2. The grease is placed on a hot ceramic disc at a temperature of 815°C. Such tests not only show how QUINTOPLEX™ behaves, but can also be used

The QR code links to a product video on ;QW6WDG UJQYKPI 37+0612.': Ć‚TG resistant specialty greases (https://youtu.be/ucfmF76tcCA)

to compare to other grease types, including mineral oil based. In addition to being fire-resistant, QUINTOPLEX™ grease offers a number of benefits that also make it an option for any application in a steel plant; it has a wide operating temperature range, various viscosity grades are available. It can be used with and without solid lubricants.

#P CRRTQCEJ VQ ƂTG UCHGV[ In the hot rolling mill of a major North American steel producer, hot scale was falling off the 1,260°C temperature steel bars as they exited the walking beam furnaces, causing excess grease on the bearings to catch on fire. The steel producer thereupon instructed Quaker Chemical to develop a fire-resistant grease that could be

used on the roller bearings to reduce the amount of fire hazards.

Quaker Chemical proposed QUINTOPLEX™ LXS 1002-EP grease for use on the hot rolling mill. Before introducing QUINTOPLEX™ into operation, the steel producer challenged the fire-resistant properties of the grease with tests that exposed it to open flames and extremely hot metals. QUINTOPLEX™ passed all the tests performed, resulting in its introduction into the hot rolling mill lubrication system. Running their system with the fire resistant grease, the mill realized 90 percent less fire hazards. Furthermore, the continuous water supply the mill was using to control the fire hazards could be removed, which led to a reduction in corrosion on the roller bearings.

Keeping operations running smoothly Mill operators should work with a grease supplier who has the expertise to offer technical advice to help evaluate situations, and who can offer realistic solutions to solve problems ranging from production efficiency to worker safety. At a minimum, grease manufacturers need to provide sustainable product solutions that require less volume and reduce energy during use, in order to bring real value to the customer.

DAMASCUS STEEL Myth ¡ History ¡ Technology ¡ Applications

Manfred Sachse

DAMASCUS STEEL 3rd Edition

Myth History Technology Applications

ISBN 978-3-514-00751-2

79.00 â‚Ź For personal members of Steel Institute VDEh:

71.10 ₏ Verlag Stahleisen GmbH Postfach 105164 ¡ 40042 Dßsseldorf www.stahleisen.de

MPT International 3 / 2016

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Bar inspection unit using eddy current VGEJPQNQI[ URGEKĆ‚ECNN[ FGUKIPGF VQ test thin bars

Deutsche Edelstahlwerke starts innovative bright steel production Deutsche Edelstahlwerke has modernized the bright steel production facilities at their +DJHQ *HUPDQ\ ZRUNV )RU WKH ƂUVW WLPH D KLJK SHUIRUPDQFH FKDLQ WUDFN GUDZLQJ machine is now in use in stainless steel bar production. The modernization also involved WKH LQVWDOODWLRQ RI WZR QHZ JULQGLQJ PDFKLQHV DQG D EDU LQVSHFWLRQ V\VWHP Deutsche Edelstahlwerke GmbH is one of the world’s leading producers of special steel long products. Being a subsidiary of international Schmolz + Bickenbach Group, the company operates four production sites in Germany.

Deutsche Edelstahlwerke has reinforced their quality leadership in the long specialty steel products segment by investing approximately 4.5 million euros in an additional, innovative bright steel production facility at their location in Hagen (Germany). The company has been setting new standards with regard to process reliability and flexibility in the production of premium bar.

Deutsche Edelstahlwerke GmbH, a company of Schmolz + Bickenbach Group, Hagen, Germany Contact: www.dew-stahl.com E-mail: melanie.biskup@dew-stahl.com

MPT International 3 / 2016

The facilities, which began operations in February 2016, consist of â–Ş a bar drawing line, â–Ş two grinding machines and â–Ş a bar inspection system.

State-of-the-art technologies guarantee consistent quality that is reproducible at any time for a total bar length between 2 and 6.2 m and diameters of 5 to 16 mm.

Most of the bright steel bars made in Hagen are used in the automotive industry and in engineering applications.

Clients of Deutsche Edelstahlwerke use the bar to manufacture, for example, high-quality valves that are built into highly efficient car engines. In keeping with the automotive industry’s efforts to reduce the overall weight of the automobile, Deutsche Edelstahlwerke sees great potential for valve steel in the future since not only more, but above all thinner valves are needed to reduce vehicle weight sustainably. The technical customer support team of Deutsche

Edelstahlwerke can find the right special steel solution for the specific application in cooperation with the sub-suppliers and car manufacturers. With the new bar drawing line, the semi-finished product is manufactured as efficiently as possible in terms of time and still fully meets the customers’ high quality requirements. This allows to improve delivery performance and make another contribution to process reliability and material efficiency at the customers’ facilities.

High-productive chain track drawing machine Quality and process reliability along the entire supply chain is the declared objective of Deutsche Edelstahlwerke. To meet this goal, an innovative approach was taken in the design of the new bar drawing line, specifically with respect to the selection of the right drawing tech-

SPECIAL EQUIPMENT nology. Whereas in the past conventional cam-driven drawing machines were used, Deutsche Edelstahlwerke is now using a Danieli chain track drawing machine. “With the chain track drawing system we achieve a drawing force of up to 7 t and, with up to 100 m/min, a much higher drawing speed than with the previous process. At the same time, this chain track drawing technology allows us to produce uniformly thinner and top-quality bar despite these high speeds.

And we still achieve greater process reliability,â€? explains Thomas MĂśller, technical manager at the Hagen site. Deutsche Edelstahlwerke generally uses 5.5 to 30 mm diameter wire rod made of stainless steel, tool steel or engineering steel. “We use high-alloy stainless steel grades for over 50% of our bars, including the valve steel for the automotive industry. One example is PyrodurÂŽ 4718, our most popular steel for intake valves in the dimensional range between 4.8 and 24.0 mm diameter. The steel’s surface hardness of over 60 HRC in the finished valve is extremely impressive,â€? says Thomas MĂśller. “We are the first steel producer in Europe to use a chain drawing line to produce high-alloyed stainless steel bar. And it has been obvious since the plant started operations that we made the right decision. Before investing, our specialists ran extensive pilot tests and held technical discussions whether the use of the chain track drawing technology would actually be appropriate for the intended use and have additional positive effects. Our test runs and the products manufactured since operations began have definitely confirmed their studies.â€?

/QTG ĆƒGZKDKNKV[ CPF RTQFWEV URGEKĆ‚E SWCNKV[ CUUWTCPEG Yet only assured quality is top quality. This was the motivation behind Deutsche Edelstahlwerke’s decision to complete the investment in the drawing line and the two new grinding machines with single-bar feeding with a state-of-the-art crack detection system.

Based on eddy current testing, the system detects surface flaws in a most reliable manner, has a bar separator and was designed specifically to test thin bar.

Drawing, straightening, grinding, testing – not only the plants and machines are new but also the plant layout.

Time-consuming transports between

‚‚‚

47

the bar drawing line and the machining and testing machines have been eliminated and transport has become more efficient and economical. Moreover, Deutsche Edelstahlwerke has designed the manufacturing areas in the production hall in such a way that also material not coming from the bar drawing line can at any time be ground, inspected and tested. This makes the company more flexible when processing customer orders and makes process sequences faster and smoother. “Today, in-process inspection and testing of the material are possible at every stage of production along the entire bright steel line,â€? says Thomas MĂśller.

The new line operates with a drawing force of up to 7 t and, with up to 100 m/min, a much higher drawing speed than before

Deutsche Edelstahlwerke now uses a Danieli chain track drawing machine for specialty bar production

MPT International 3 / 2016

The over 26-m-high building for the batch-annealing plant is the most visible alteration to the Krefeld site

1WVQMWORW Ć‚PCNK\GU OCLQT KPXGUVOGPV RTQITCOOG CV EQNF TQNNKPI EQORNGZ KP -TGHGNF )GTOCP[ “Nirosta Ferrite Optimizationâ€? is the name of a widescale modernization and restructuring project by Outokumpu in Germany. The project will ensure the company’s future position within a highly competitive market environment. It proves Outokumpu’s response to the increasingly high quality demands set by its industrial customers.

The German plants of Outukumpu are an integral part of the group’s global supply network, and Outokumpu is perfectly positioned in one of the most important European markets for stainless steel. Outokumpu Germany satisOutokumpu Holding Germany GmbH, Krefeld, Germany Contact: www.outokumpu.com E-mail: sven.vanzoest@outokumpu.com

MPT International 3 / 2016

fies about half of the German demand for stainless steel from its four plants and three service centres.

After Outokumpu took over the stainless steel business from Thyssenkrupp a few years ago, two stainless steel meltshops – at the Krefeld and Bochum sites – were closed down. However, Outokumpu decided to considerably modernize the Krefeld site. Today the plant is home of the German headquarters of Outokumpu Nirosta GmbH as well

as a state-of-the-art cold-rolling facility. Ferritic and martensitic stainless steel strip products are manufactured here to thicknesses of 0.2 to to 6 mm, up to 1,530 mm wide. On a total area of around 200,000 square metres, Outokumpu Nirosta in Krefeld produces high-quality stainless steel grades with unparalleled surface quality for applications such as home appliances, pots, cutlery, general tubing and sheet and tubing for automotive exhaust systems.

COLD ROLLING Enormous investment programme for the Krefeld site The “NiFOâ€? project – Nirosta Ferrite Optimization – is the centrepiece of the restructuring and modernization of Outokumpu Nirosta in Germany. The company initiated a 108-million-euro investment programme to optimize production of ferritic cold rolled strip at the Krefeld site. The aim is to expand the cold rolling capacities at the Krefeld plant to take over production from another production site close by in DĂźsseldorf-Benrath that is closing down. For that to happen, Outokumpu has built four major plants at the Krefeld site as following: â–Ş a batch-annealing plant, â–Ş another continuous bright-annealing line, â–Ş another continuous pickling line, â–Ş another cold rolling mill.

While the batch-annealing facilities are installed in a completely new building, the other strip processing lines were installed in existing factory halls.

The dismantling of previous (old) machines began back in December 2014. And, following extensive construction work, new equipment has been assembled in Krefeld.

On 26 January 2016 Outokumpu held the official roofing ceremony for the new building of the batch-annealing plant. On 1 April 2016 the first coil was annealed just 10 months after groundbreaking. These dates marked important milestones in the investment programme that enhances the production capabilities of ferritic materials with new facilities for batch-annealing, pickling, cold rolling, bright-annealing and temper rolling processes. The investment initiated two years ago strengthens the company’s long-term competitiveness in one of its most important markets. “It is Outokumpu’s biggest ongoing investment,� says Oliver Picht, senior vice president for Outokumpu’s business line Nirosta. “This modernization will ensure we continue to meet the highest demands of our customers for top-quality stainless steel.�

Commissioning of the new equipment is scheduled for completion in July 2016. The expanded production of ferritic materials will then encompass the whole process chain for high-quality stainless steel strip with

high-gloss surfaces. With the state-ofthe-art process and equipment technology, Outokumpu is able to reduce energy consumption and emissions in the production of stainless-steel products.

Ferrite manufacturing is closely linked to the research and development (R&D) department in Krefeld.

The constant dialogue between production and the development department guarantees that Outokumpu al-

‚‚‚

49

out in cooperation with Tenova LOI, a leading provider of HPH high-performance hydrogen bell-type annealing technology.

The optimized floor plan facilitates coil logistics and the thermal treatment. Three new tilting tables are installed to turn the coils up before annealing and turn them down afterwards. The crane can be operated remotely from the surrounding, elevated platform.

#RRTGPVKEGU JCPFETCHVGF VJG VQRRKPI QWV YTGCVJ HTQO UVCKPNGUU UVGGN HQT VJG TQQĆ‚PI ceremony of the new batch-annealing facility

ways provides its customers with the best-quality products and innovative ideas.

Bell-type batch-annealing facility Outokumpu erected a completely new building for the batch-annealing plant. The over 26-metre-high building (86 m long, 34 m wide) is the most visible alteration to the Krefeld site.

Following the roofing ceremony in January, installation of the batch-annealing equipment has been going on, with production ramp-up planned for mid-2016.

Equipment and components have been transferred from the DĂźsseldorf-Benrath site. The new bell-type annealing facility comprises 21 bases. The whole project is being carried

Initially, production started using the hoods from the old plant in DĂźsseldorf. These hoods cover only three coils. However, all the equipment, i.e. building, crane, bases etc., is prepared to handle batches of four coils.

“BGL1600� continuous brightannealing line At the place of a previous cold annealing and pickling line, a new continuous bright-annealing line “BGL 1600� was built for processing cold rolled stainless strip within a thickness range from 0.2 – 3.2 mm. Designed for a maximum strip width of 1,570 mm, the line has a total length of around 250 m.

CMI had been awarded the order to supply the equipment for the advanced degreasing section – a multi-stage sysMPT International 3 / 2016

50

››› COLD ROLLING 1P #RTKN VJG ƂTUV EQKN YCU CPPGCNGF at the new batch-annealing plant

phere with lowest possible dewpoint (-60°C). The result is a clean, damage-free surface as well as perfect mechanical values in the annealed strips.

A particular challenge was the re-use of mechanical components from the previous strip-processing line, i.e. the entry and exit section. Several specialist firms were involved in this project: Heckmann Engineering, Simpex Hydraulik, IMEA Automation and others.

According to the project schedule, commissioning of the continuous bright-annealing line will have started in May 2016, with commercial production beginning in July 2016.

“BL1600” continuous pickling line tem combining alkaline spray cleaning, brush cleaning, and a final rinse section including a brush machine and dryer.

The heart of the line is the 30-metre-high annealing furnace.

Ebner – the Austrian specialists in heat treatment furnace facilities – had

been awarded the order for the Hicon/ H2® furnace section comprising a muffle tube type heating section with regenerative natural gas burners to reduce energy costs and achieve low NOx emissions. The proven muffle concept makes use of the pure hydrogen atmos-

Exit section of the continuous bright-annealing line MPT International 3 / 2016

A new pickling line was built at the place of the former hot annealing and pickling line in order to accommodate the special requirements associated with the descaling of hot rolled and batch-annealed strip. The line measures a total length of around 250 m.

COLD ROLLING

‹‹‹

51

Rinsing section of the continuous pickling line

Around 2,500 cubic metres of concrete were used for the complex underwater construction work. Approximately 30,000 man hours went into installing the equipment.

International technology group Andritz was awarded the order to supply the whole continuous pickling line.

The scope of supply included the laser welding machine, the automation and electrical equipment, as well as the instrumentation systems. One special feature of the facility is a scale breaker which can stretch the strip by up to 6%.

The pickling line is designed for processing ferritic and martensitic stainless steel strip with gauges from 1.5 to 8.0 mm and tensile strength between 300 and 800 MPa. At the exit section an intermediate paper layer is inserted into the coils, which have a maximum outer diameter of 2,100 mm and weigh up to 25 t. Strip speed in the pickling section is 14 to 24 m/min, while the strip speed in the entry and exit section may attain 22 to 36 m/min.

According to the project schedule, commissioning of the pickling line will have started in June 2016.

Revamped cold rolling and ƂPKUJKPI RNCPVU Already in 2014, Outokumpu awarded to SMS group the order to revamp the cold rolling mill “SG3” of type MB 21BB-61“, with the aim of technically updating the cold rolling stand previously modernized in 1991. The “SG3” 20-roll cold mill designed for a maximum strip width of 1,570 mm and strip gauges of max. 10 mm and min.

0.5 mm will continue to be used for the production of high-grade special-steel strips made of austenitic, ferritic and martensitic materials. The range of products includes, in particular, thingauge ferritic strips in high-gloss quality (2R bright-annealed).

The cold rolling mill was modified in order to be able to manufacture mirror-finish material. The existing squeezer system was converted to a dual-cassette wiper system, including a changing device and designed to operate with different types of coated wiper rolls. One of the aims of the

conversion work was to roll the entire thickness range at maximum rolling speed. Commissioning of the modernized mill took place already in 2015.

SMS group was also awarded the order for the revamp of the existing rolling-oil treatment plant. Key equipment included a new dirty-oil tank with automatic pre-separation and the ultra-fine filter system Supafine® developed by SMS. Outokumpu Nirosta has already started producing the desired grades on the upgraded 20-roll cold mill.

CMI Metals division was awarded the order to modernize a skin-pass mill. Specifically, the order included the design, supply and assembly of a new anti-crimping roll and all necessary adaptations (hydraulics, electrical etc.). After modernization, the skinpass mill re-started production as early as in late 2014.

Outokumpu worldwide Outokumpu is a leading stainless steel producer with a global presence.

Headquartered in Espoo, Finland, Outokumpu employs 11,000 people in 30 countries. The company runs 15 plants and 16 service centres in China, Finland, Germany, Mexico, Sweden, Great Britain and the U.S. Outokumpu’s global customer base benefits from its extensive sales network supplying all major markets, resulting in shorter delivery times and first-class service.

Outokumpu’s new streamlined business area structure was announced in connection with the launch of Outokumpu’s new vision and measures to improve competitiveness and financial performance of the company. Outokumpu’s new structure has three business areas: Europe, Americas and Long Products.

Europe and Americas will cover Outokumpu’s entire flat products offering in these two markets, including all coil and plate business. The previous European Quarto Plate operations and sales network in APAC have become part of Europe, and the US Quarto Plate business part of Americas.

Europe is Outokumpu’s largest business area and accounts for more than half of the group’s revenue. It manufactures large quantities of customized standard stainless steel grades, which are used primarily in the auto industry, the heavy-goods transport sector, white goods and construction, as well as in the chemical and petrochemical industries, the energy sector and other processing industries.

The Asia-Pacific region is one of the fastest growing regions overall, currently accounting for 60% of global demand for stainless steel. Outokumpu presently operates a service centre and an extensive network of sales offices in the region.

Americas. Outokumpu has a strong presence in the North, Central and MPT International 3 / 2016

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››› COLD ROLLING

South American markets and works closely with its customers in various market sectors – automotive industry and transport, home appliance, oil, gas, chemical and petrochemical, in food and drink production as well as in construction. The two plants in this region are located in Mexico and the US. Long products. Outokumpu is a leading manufacturer of rolled wire, rods, reinforced steel, billets, welded tubes and other long products made of stainless steel. It operates production facilities in Sweden, Great Britain and the US. Furthermore, the smelting plant in Sheffield is a global supplier of semi-finished products, serving facilities with long products like slabs, billets, blocks and bars.

Modernized cold rolling mill

COMMA-FREE ROLL SURFACES CBN grinding tools for roll grinding The GENIS Roll Star product line is the cost-effective grinding solution for machining ultra-hard rolls in cold rolling mills. With these new CBN grinding tools from TYROLIT you achieve the best quality with a practically comma-free roll surface. In addition, the smooth running core enables operating speeds of up to 80 m/s.

Find out more about the GENIS Roll Star at www.tyrolit.com

A Company of the SWAROVSKI Group www.tyrolit.com

MPT International 3 / 2016

Fives, innovative solutions for cold rolling process: DMS 20Hi Eco-Mill and DMS Skin-Pass Mill Fives designs and manufactures cold rolling mills for stainless, silicon and carbon steels, as well as for nonferrous materials like copper and titanium.

DMS 20HI ECO-MILL ADVANTAGES — Enhanced flatness performance — New design of strip wipers, strip and work roll spraying — Wide range of thicknesses 0.03-12 mm; width - up to 1,880 mm — Operator friendly and faster maintenance — Improved fume exhaust The new features allow for optimum strip wiping for high-speed production of the thin strip with a top-rated strip surface, optimum lubrication of roll bite and an advanced flatness control in order to produce stainless steel strips at high productivity level with very tight thickness and flatness tolerances.

DMS 20Hi Eco-Mill leads to energy savings, improved performance of mechanical parts, faster maintenance, friendly operation and minimized environmental footprint.

Fives designs and supplies a full range of skin-pass mills (2Hi - 4Hi – 6Hi), either in-line, off-line or stand alone for stainless, carbon, tin-plate and galvanized steels for any applications.

DMS SKIN-PASS MILLS ADVANTAGES — Ideal for materials with high surface and flatness requirements — High range of strip grade, from very low to very high strengths — Best solution for in-line installations with an ultra-fast roll change — Available in a tandem version with two or more stands 2Hi skin-pass mills are designed for demanding stainless steel production applications that require a high level of brightness.

4Hi and 6Hi skin-pass mills are suitable for a wide variety of galvanized, continuous annealed and steel products, from very low to very high strengths.

A complete range of skin-pass mills optimized for your final product application and CAPEX expectations is available worldwide.

60 years of experience in cold rolling mill design and supply 1 200 fastest 20Hi mill 100 rolling mills in operation mpm

in operation worldwide CONTACT US:

Fives DMS 1 rue du Mont-de-Templemars - B.P. 30219 - 59472 Seclin Cedex - FRANCE Tel.: +33 3 20 49 35 00 - Fax: +33 3 20 49 35 01 E-mail: fivesdms@fivesgroup.com – website: www.fivesgroup.com

Copyright © 2016 - Fives - All rights reserved.

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››› STRIP PROCESSING

New colour coating and printing line at Lysva, Russia Hot commissioning of the new colour coating and printing line for the production of varnished, painted and printed strip was started at the Lysva Metallurgical Plant in February 2016.

Located in the Perm region of Russia, Lysva Metallurgical Plant (LMZ) is one of the oldest production plants in the Urals, founded in 1785 by the family of prince Boris Grigorievich Shuhovskoi.

Today, LMZ is Russia’s only producer of electrolytically galvanized and colour-coated strip products.

Ten years ago LMZ began to modernize the production facilities and develop new technological processes, which expanded the product line and improved the quality of products. In 2013, the first stage of a large-scale modernization project commenced. During that first stage, a new colour coating line with printing technology and a capacity of up to 110,000 t/year was to be installed. In February 2014 the contract for the supply of the new strip processing line was signed with Danieli. Construction was completed in late 2015.

Technical milestones of the project The colour coating and printing line was designed to produce 110,000 t/year of thin strip from 0.3 to 1.5 mm thickness, in widths up to 1,500 mm. Since the line had to be installed in the existing building at LMZ, a customized layout and compact design were needed so that the entire line would fit into the available space of 160 m length.

The line has three coaters (prime, finish and clear) and one printing section with three printing heads. Convection ovens, supplied by Danieli Centro Combustion, are located after each coater; here the paint coats are cured by hot air.

The first coater (prime coater) applies the primer on both sides of the

&CPKGNK % 1HĆ‚EKPG /GEECPKEJG 5 R # $WVVTKQ +VCN[ Contact: www.danieli.com

MPT International 3 / 2016

6JG Ć‚TUV RTKPVGF UVTKR YKVJ RCVVGTP V[RG 1/ RTQFWEGF QP /CTEJ

strip, while the second one (finish coater) applies the top finish coat and the backing coat. If printed products are required, the first coater applies the primer on both sides of the strip, while the second coater applies only a top coat called “base coating�. After the curing oven for the base coating, there is a printing section with three printing heads, which apply the ink to the painted strip using pattern rolls. After each printing section a hot air dryer dries the ink applied to the strip surface. After the printing section, the third coater (clear coater) applies a transparent or “clear� paint to the strip surface as a protection and to enhance its resistance to corrosion.

In order to purify the solvent-containing air coming from the ovens and coating rooms, two purification systems have been installed. A rotoconcentrator has been arranged downstream the coating rooms. This is an auto-regenerative zeolitic wheel which reduces the solvent concentration from 100 mg/ mÂł down to 20 mg/mÂł (s.t.p.). The wheel

directly adsorbs the solvents, which are regenerated with a hot air flow.

A regenerative thermal oxidizer (RTO) has been installed downstream the ovens in order to oxidize the solvents. The concentrated flow coming from the wheel is also sent to the RTO. Oxidation reduces the solvent concentration from 8 g/mÂł to 20 mg/mÂł (s.t.p.).

During normal operation, oxidation is performed without gas consumption.

The entire electrical and automation systems, including motors, drives, MCS, level 1 and level 2 process controls, were designed and supplied by Danieli Automation. Coating layer thickness control, accurate strip temperature control and efficient drive systems are the key technological components of Danieli Automation’s 3Q technology package. To ensure smooth and fast ramp-up, supervision of installation, start-up and commissioning is also provided by Danieli.

Hot commissioning has already begun. On 16 February 2016, the first coil was painted with both prime and fin-

STRIP PROCESSING ish coating in the presence of the Minister of Industry of the Russian Federation. On 2 March 2016, the first strip was printed, attaining an impressive quality right from the very first day of the printing trials.

The inauguration ceremony for the LMZ colour coating and printing line took place in Lysva on 30 March 2016.

Russian Prime Minister Mr. Medvedev

praised these results in a video conference accompanying the event.

Outlook The highly satisfactory preliminary results provided by the line will enable LMZ to position itself as the only supplier in Europe of this special high-value-added product. The new technology allows to

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coat decorative patterns imitating various materials (wood, brick, stone, etc.).

Next, construction of the cold rolling shop with a hot-dip galvanizing line and of another colour coating line with the total capacity of 820,000 t/year of products will be completed. In the second phase of the modernization project it is planned to construct another rolling shop, scheduled for completion by 2020.

Millmate Roll Force Load Cells. More than 60 years of knowledge and experience.

For more than 60 years we have built up knowledge and experience leading to longterm solutions for all types of roll force measurement installations in hot and cold rolling mills worldwide. We provide reliable and user-friendly measurement systems based on the unique Pressductor technology in combination with our installation design and maintenance know-how.

Our leading position as a reliable partner is well summarized by one of our customers: “Millmate Roll Force load cells combined with precision-machined pressure plates certainly contributes to better control of the rolling process, safe stable rolling, improved strip/plate quality and reduced scrap. MRF load cells and Millmate Controller MC400 is an unbeatable combination”. www.abb.com/rollforce

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

MPT International 3 / 2016

A DeVeTec thermal power plant uses the waste heat of batch-type annealing furnaces at Bilstein GmbH & Co. KG in Hagen-Hohenlimburg (Germany)

ORC power plants recover waste heat and help to improve energy GHƂEKGPE[ QH UVGGN OKNNU ,Q PDQ\ SURFHVVHV RI VWHHO SURGXFWLRQ JHQHUDWHG ZDVWH KHDW LV RIWHQ QRW HIƂFLHQWO\ recovered and hence lost. In contrast, Organic Rankine Cycle – ORC – waste heat power plants convert valuable waste heat into electricity. Waste heat power plants, ZKLFK DOVR RSHUDWH KLJKO\ HIƂFLHQWO\ XQGHU SDUWLDO ORDG FRQGLWLRQV KDYH SURYHQ WKHLU UHOLDELOLW\ LQ H[WHQVLYH ƂHOG WHVWV LQ YDULRXV LQGXVWULHV DOVR LQ WKH VWHHO LQGXVWU\ 6XFK D plant has been implemented at a bell-type annealing plant of a German steel mill. In a fundamentally new approach, the technology extracts all excess energy from coils previously heated to up to 700°C and makes it available to other uses in the mill in the form of electricity or thermal energy.

MPT International 3 / 2016

ENVIRONMENTAL PROTECTION

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57

The centrepiece of each thermal power plant from DeVeTec: the ORC steam expansion engine

Excess process heat is generated during many steps in the energy-intensive production and processing of steel. Two heat power plants of German-based engineering company DeVeTec demonstrate that huge amounts of this energy can be efficiently recovered. One plant is part of a comprehensive energy efficiency scheme of German cold-rolled steel manufacturer Bilstein. In a fundamentally new approach, any excess energy from the coils, heated to up to 700°C, is extracted during the cooling and made available to other consumers in the plant as electricity or thermal energy. This plant is an example of high efficiency with a widely fluctuating heat supply: Once the cooling process starts, the hydrogen used as inert gas is cooled down from 700 to 350°C. The energy extracted then heats thermal oil up to 270°C in a special bypass cooler.

This oil is used to evaporate the ethanol that the Organic Rankine Cycle (ORC) module uses to generate electricity with its steam expansion engine.

The heat derived from the condensation of ethanol is used for hall heating and for heating up an emulsion bath.

For every annealing heating cycle, the ORC plant generates about 350 kWh of electric power which don´t have to be purchased from external providers.

The waste heat power plant has been part of the annealing line at Bilstein since 2014. As an industrial-scale pilot project that helps to improve resource efficiency it was funded by the German Federal Ministry of Environment as part of its Environmental Innovation Programme.

The other waste heat power plant of DeVeTec has been in operation on the plant grounds of the Badische Stahlwerke in Southern Germany since the beginning of 2014. Badische Stahlwerke uses waste heat from a natural

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gas-fired pusher furnace to generate electricity. Due to limited space, the waste heat power plant was erected at a height of 8 m and distance of 80 m to the ORC heat exchanger. Badische Stahlwerke now plans to take the waste heat from the ORC process to operate an absorption chiller. By using an induced draft blower in the flue gas line of the ORC heat exchanger, the influence of the waste heat power plant on the existing pressure regulation of the pusher furnace could be ruled out.

Ecological and economic DGPGƂVU DeVeTec’s waste heat power plants recover the maximum amount of energy from industrial processes by simultaneously generating electricity and using the remaining energy at different temperature levels. They are also a model example of CO2-neutral and zero emission power generation because a DeVeTec waste heat power plant with a nominal output of 200 kWel can save up to 3,000 t/CO2 per year.

Industrial users confirm that DeVeTec’s plants pay for themselves in less than four to five years, and even

in less than three years, depending on the configuration, while they simultaneously generate electricity and utilize heat. Using waste heat generation power plants reduces the costs of externally procured fuels and electrical energy. To German companies also applies that, depending on the case, this self-produced electricity is partly or sometimes even completely free from levies or other charges of the Renewable Energy Law. Here, operators can raise additional revenue with the CHP (combined heat and power) bonus, because DeVeTec’s waste heat power plants are CHP plants in compliance with Germany’s Combined Heat and Power Act. Since these operate automatically and do not require on-site monitoring, no costs are incurred for personnel.

# RKUVQP GPIKPG CU DCUKE principle Waste heat power plants by DeVeTec operate on the same basic principle as large power plants do: they evaporate a liquid, which is then expanded in a piston expansion engine (heat engine) developed by DeVeTec, and thus generMPT International 3 / 2016

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››› ENVIRONMENTAL PROTECTION

ate power. Instead of water, an organic fluid (bioethanol) is used here, which exhibits efficient thermodynamic behaviour even at low temperatures.

Waste heat flows can be exploited efficiently and economically starting at 230°C. However, when you take a look at industrial waste heat, the heat engine must depend on the generated heat such as from the production process for example. This is what the piston expansion engine was developed for.

It is the basis of the DeVeTec waste heat power plant. Here, it can respond very quickly to changing waste heat condi-

constant efficiency. Should other heat sources with lower temperatures be exploited, then the same engine can also be operated with other organic fluids without having to be modified. The engines also provide heat to other users at a temperature level of about 80°C. More than 90% overall efficiency can thus be achieved. The recovered energy can be used to heat plants, dry material or temper processes for example.

The waste heat power plants are suitable for all processes where temperatures exceed 230°C. More recently, fluids that already achieve significant efficiency at 170°C are also available.

door plants. Bioethanol is also distinguished by its low price.

Right from the beginning of the development, DeVeTec designed the plants in cooperation with German TÜV (Technischer Überwachungsverein/Technical Supervisory Association) in order to avoid any potential hazard. Special emphasis was drawn to the subject of fire and explosion protection.

%NCUUKƂECVKQP QH RNCPVU Following an intense developmental and testing period with industrial ap-

The thermal power plant is installed in a container

tions and thus exploit an exceptionally high proportion of the valuable waste heat. The piston expansion engine itself is highly efficient; these engines achieve a very high pressure differential in a single stage so that the enthalpy gradient increases significantly to thus generate much more electricity than is possible using related technologies. This high pressure differential results in high temperature differences (> 150°C) and a large enthalpy difference and thus in a high energy yield.

Waste heat power plants by DeVeTec generate electricity efficiently even under partial load conditions. Depending on the amount of waste heat available, one can choose between three versions of the steam expansion engine: the V8 engine operates in the 0 – 130 kW range, the V12 engine in the 0 – 200 kW range, and the V16 engine in the 0 – 266 kW range at nearly MPT International 3 / 2016

'NGEVTKEKV[ HTQO RTGXKQWUN[ WPWUGF YCUVG JGCV DeVeTec’s machines use a method known as organic rankine cycle (ORC). The method is a traditional steam cycle: the waste heat flow of a process is used to vaporize an organic medium – in this case ethanol – which is then expanded in a steam expansion engine. The depressurized vapour is fed into a condenser to be liquefied there. The liquid ethanol is then fed back to the evaporator with a pump and evaporated again. The process is thus complete and the cycle starts all over again.

Normally, the organic fluid used

by DeVeTec is bioethanol, which has proven itself due to its many advantages. For example, it is not toxic and therefore relatively environmentally friendly. Moreover, it does not freeze – an important argument for out-

plication partners over five years, DeVeTec’s waste heat power plants are now available in a single product family with three performance classes. This allows unused waste heat flows between 800 kW and 2 MW to efficiently generate electricity at a temperature level above 230°C. It is possible to retrofit the waste heat power plants as DeVeTec delivers them as mobile container units together with the expander generator unit, the pump unit and the control unit. The entire heat transfer technology can also be implemented. If higher outputs are required, multiple plants can be connected in parallel.

The plants work fully automatically and are monitored remotely. The specially developed noise & vibration guard monitors signs of wear, protects the engine from potential damage and, in the context of preventive maintenance, minimizes the risk of faults.

TECHNICAL INNOVATIONS

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#DRTKOGTQHY@SHNM RXRSDLR ENQ GNS LDS@K @MC RSDDK IRON AND STEELMAKING Stein Injection Technology supplies state-of-the-art pneumatic conveying, dosing and injection systems to the steel producing industry worldwide, for applications such as hot metal or steel desulphurization.

Hot metal and liquid steel are desulphurized by injection of one or multiple agents (CaC2, CaSi and/or CaO) with a gasevolving carbonaceous additive at a defined injection rate.

Hot metal desulphurization serves to relieve downstream metallurgical processes from desulphurization work. For example for CSN (Companhia Siderúrgica Nacional), Stein Injection Technology supplied two new units for the injection of lime into two torpedo cars. At a rate of 14,000 t of hot metal per day, a sulphur content reduction in the hot metal from 0.050% down to 0.005% has been achieved.

Further, calcium carbide use has been reduced by 60%.

Hot metal desulphurization in a ladle upstream of the BOF and downstream ladle metallurgy of steel are generally applied to achieve the required steel grades. In EAF steelmaking, desulphurization of steel takes place in the ladle or the ladle furnace. CaC2, CaSi and CaO are most commonly used to desulphurize steel in combination with immersion lances and a stirring method. In hot metal desulphurization, magnesium is additionally added in powdered form with a carrier gas via an immersed lance.

The smart combination of products, equipment and ser-

Display of the injection process for desulphurization in a ladle furnace

vices solves complicated metallurgical requirements at numerous stages of the steel production process. For this, Stein Injection Technology maintains close customer relations which among others involve the development of products and solutions directly with the customer.

Contact: www.sit-gmbh.net

Award for energy DEÖBHDMBX HM BQTCD RSDDK OQNCTBSHNM ENVIRONMENTAL PROTECTION Salzgitter Flachstahl GmbH (SZFG) has been awarded the Energy Efficiency Best Practice Label for its energy-efficient crude steel production. The label, conferred by the German Energy Agency, specifically acknowledges the optimized extraction of converter gas in the steelworks achieved by renewal of the converter A vessels and an optimized control concept, coupled with more intensive internal monitoring. The implemented measures enable approximately 15 GWh of additional energy to be recovered, enough for heating 7,500 households. Process gases from other SZFG operations are used in the company’s own power plant to produce electricity and process steam for its integrated steelworks.

In 2013, SZFG had already won the first prize of the Energy Efficiency Awards and in 2014, the Label for Energy Efficient Crude Steel Production. The most recent award confirms the success of SZFG’s activities as part of the Energy Efficiency project conducted by the Germany Energy Agency.

Contact: www.salzgitter-ag.com

Measure Your Products with the Highest Accuracy and Reliability Introducing NDC’s Metals Gauging Systems for: Ź Flatness Ź Width Ź Thickness

Ź Coating Weight Ź Length and Speed

™

®

™

AccuRay® TDi-700 X-Ray Thickness Measurement System

Rometer™ Optical Flatness System

LaserSpeed® Length & Speed Gauge

Contact us today! www.ndc.com/metals AMERICAS: +1 626 960 3300

www.laserspeed.eu

BELGIUM: +32 4239 9010

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CHINA: +86 10 5993 5830

MPT International 3 / 2016

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››› TECHNICAL INNOVATIONS

,D@RTQDLDMS RXRSDLR ENQ @TSNLNSHUD FQ@CD @KTLHMHTL RGDDS QUALITY ASSURANCE NDC Technologies provides aluminium producers with accurate, reliable measurement systems to produce automotive-grade sheet. NDC’s non-contact thickness and profile measurement systems measure a range of dimensional properties critical to the production of automotive-grade aluminium sheet. For thickness measurement, NDC’s AccuRay® TDi-700 X-ray measurement system provides highly accurate and reliable thickness gauging of aluminium sheet and other flat rolled products in all typical rolling mill and processing applications. The AccuRay TDi-700 can be configured with one of

several sensors to cover the complete thickness range required in rolling mills and process lines regardless of mill size, metal type and existing conditions. The X-ray sensors and C-frames require minimal space for installation.

All TDi-700 systems feature a distributed intelligence architecture that creates a more powerful, yet simpler system which not only provides excellent measurement performance, but better uptime, maintainability and lower cost of ownership. NDC Technologies also delivers a profile characterization method that eliminates reproducibility errors common among sensor arrays by normalizing the profile measurement to critical centreline thickness in real time.

NDC’s Beta LaserMike LaserSpeed® non-contact gauge directly measures the length and speed of aluminium sheet with better than +/-0.05% accuracy, and +/-0.02% repeatability. It is an ideal solution for replacing mechanical contact tachometers/ encoders that are prone to a variety of measurement errors and high maintenance costs. The LaserSpeed gauge uses advanced, laser-based technology to perform these measurements. It projects a unique pattern on the product’s surface. As the product moves, light is scattered back to the gauge. This information is translated into product speed and pulses are produced to determine the product length. The LaserSpeed gauge has no moving parts and is factory calibrated.

Thickness gauge

Contact: www.ndc.com

-DV L@MTE@BSTQHMF OQNBDRR ENQ GHFG OQDRRTQD STAHMF

High-pressure tubing for petrochemical producer

SPECIAL TUBING PRODUCTS Over the last decade, high-pressure tubing (HPT) for low-density polyethylene (LDPE) environments has had extended supply chains that created long lead times for North American customers. SBQ steelmaker TimkenSteel has developed a new production process for HPT that uses the assets and opMPT International 3 / 2016

erations the company has in place. HPT that previously took more than a year to produce now takes a matter of months. Another advantage the process offers is flexibility, allowing customers to buy smaller lot sizes.

TimkenSteel’s process begins in Canton where its special bar quality (SBQ) steel is forged-rolled and heat treated. It is then sent to TimkenSteel Material Services in Houston where it is bored and honed. TimkenSteel recently entered into a supply agreement with A&A Machine & Fabrication, LLC, of La Marque, Texas, to further process, market and sell HPT for LDPE customers. A&A completed reliability testing to ASME code on prototype tubing and processed that material to industry fabrication requirements in order to illustrate material performance.

A&A and TimkenSteel then met with end-users to gain market acceptance of the material. TimkenSteel recently accepted its first order of HPT for a major petrochemical producer.

Contact: www.timkensteel.com

TECHNICAL INNOVATIONS

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"QNRR OK@MS @M@KXRHR NE LDBG@MHB@K UHAQ@SHNMR CONDITION MONITORING The measurement of vibrations is a reliable and tried and tested solution for small plants and individual components. In complex plants, the vibration behaviour may be influenced by factors associated with the process. Therefore damage to machine parts can only be detected in a reliable way by simultaneously monitoring all machine, process, material and quality data. To meet these requirements, Iba AG has refined its well-established ibaInSpectra product range. With ibaInSpectra, mechanical vibrations can be monitored in a time-synchronous and continuous way. Frequency analyses can be displayed in real time. This way, critical machine conditions or exceeded limit values can be signalled. As the ibaInSpectra technology module is integrated into the ibaPDA process data acquisition system, also other relevant data from the plant can be acquired. Thus, the user can identify relations between the vibration effects and the process behaviour.

As refined solutions, Iba now offers ibaCMC and ibaCMU-S for long-term analysis of the machine status. Built in a modular structure, it consists of up to four digital and four analogue input and output modules and vibration inputs according to the IEPE standard. It can process up to 32 vibration signals. The signals are acquired under conditions

Hardware and software for condition monitoring

of chronological synchronism at up to 40 kHz. For special applications, up to 100 kHz are available. This solution is especially suitable for centrally monitoring production systems within complex plants. The system is highly scalable.

Recently, a project with more than 800 vibration sensors has been implemented.

Contact: www.iba-ag.com

"NLO@BS RDMRNQR ENQ GHFG OQDBHRHNM LD@RTQDLDMSR MEASURING EQUIPMENT MicroEpsilon has introduced new, confocal chromatic sensors for its confocalDT measurement system. The non-contact IFS2406 sensors are maintenance-free and have been specially designed for vacuum applications. They stand out due to their compact size, sub-micrometer accuracy and a small measurement spot size. Due to their axial and radial measuring directions, the sensors are extremely versatile in terms of applicability. Their passive design

Confocal sensors

even allows them to be used in Ex areas.

The measurement channel is parameterized via a comfortable web interface which makes it unnecessary to in-

stall a separate measurement software.

As well as for distance measurements on reflecting or transparent surfaces, these sensors are suitable for one-sided thickness measurement of transparent film, plates or layers. The confocalDT measurement system, for which these sensors have been developed, achieves measurement rates of 10 kHz, using an LED light source, and 70 kHz, using a Xenon light source.

Contact: www.micro-epsilon.com

-DV RSQ@OOHMF GD@C ENQ BNHK BNLO@BSNQ WIRE ROD ROLLING Sund Birsta will supply strapping heads of the SBHX5 type to ArcelorMittal Duisburg for installation in the coil compactor of ArcelorMittal’s wire rod mill in Duisburg-Hochfeld. Installation will take place in the middle of this

year. The Sund Birsta SBHX5 head makes a strong and safe joint that will not open even if the coils are frequently handled during shipment.

Maintenance is very simple and access for replacement of wear parts is extremely convenient. As a result

maintenance stops are minimized.

Long-life wear parts and a constant joint strength of 83% of the strap material ensure maximum output of the rolling mill.

Contact: www.danieli.com MPT International 3 / 2016

62

››› TECHNICAL INNOVATIONS

,NAHKD HMENQL@SHNM L@M@FDLDMS INFORMATION TECHNOLOGY With its web-based Comos Mobile Solutions product family, Siemens is supporting globally networked collaboration in the process industry along the entire value chain. The new Comos Mobile Solutions Version 2.0 comes with a number of improvements for mobile information management in globally distributed plant engineering projects, facilitating cooperation between different departments and specialist disciplines. Users are able to access and edit up-to-date plant data, information and documentation at any time on the go, no matter what their current location – for example during a meeting, on business trips or while inspecting a facility. This reduces the work load for project management and so drives down costs.

Version 2.0 offers a new graphical user interface for touch-capable terminals. This simplifies operation for the user by providing context-sensitive support functions. All project stakeholders can now navigate to relevant plant information with the aid of quicklinks, view documents and submit project-related inquiries. The new GUI provides users with fast, simple access to individual projects. Important information can be displayed at a glance, using personalized dashboards. Suitable warnings are issued in the event of deviations from target, and an inte-

Access to plant information using web-based services and mobile terminals

grated task management system provides support to project stakeholders in completing their next work steps. The need for manual data entries is reduced by the availability of editable web attributes. Comos Mobile Solutions 2.0 supports Android, Apple iOS and Microsoft Windows operating systems.

Contact: www.siemens.com

'NS CHO F@KU@MHYHMF KHMD QDU@LODC VHSG MDV @HQ JMHED RXRSDL STRIP PROCESSING LINES In 2008, Danieli supplied a complete hot and cold mill complex for the MMK Metalurji project in Dortyol, Turkey. The supplied hot-dip galvanizing line was equipped with Danieli Kohler S-Jet air knives.

Since then, the production mix of the hot-dip galvanizing line has been progressively expanded to include a higher percentage of thin strips with very thin coatings (including Z70). The initial air knives had become an impediment to an increase in processing speed, creating a bottleneck for higher throughput. The decision to install X-Jets, which had not yet been available in 2008, when the line was originally supplied, followed technical discussions and a thorough analysis of the expected production benefits. Thanks to the modular design of Danieli Kohler’s air knives, the revamping included the re-use of many parts of the existing equipment, minimizing the capital investment. Danieli supplied new X-Jet air knives with lip cleaners, new blowers with special piping, modifications to the existing roll rigs as well as electrical and automation equipment. The new air knives were installed during a scheduled, one-week maintenance shutdown. The performance increase provided by the X-Jets in terms of coating weight and line speed was immediately obvious. After the revamp, the hot-dip galvanizing line is able to produce Z100 at 180 m/min, and tests have shown

MPT International 3 / 2016

First X-Jet installation in 2009

that the X-Jets can produce Z80 with 40 g/m2/side at 180 m/min. Productivity has increased by approximately 10%, with a payback time of less than six months for MMK. In January 2016, Danieli received the FAC for the new air knives.

Contact: www.danieli.com

TECHNICAL INNOVATIONS

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63

“How can lubricants help to reduce our steel mill’s operational costs?”

Price isn’t the only consideration when selecting a lubricant; the overall cost benefit of selecting an advanced lubricant that will perform better over a longer period of time will ultimately enable more cost savings compared to a cheaper, less effective oil. Some advanced lubricants have potential energy efficiency benefits, too.

Despite accounting for just 1% or 2% of operational costs, advanced lubricants actually have the potential to enhance equipment functionality and lifespan, reduce energy consumption, and delivering substantial cost benefits.

cy compared with the reference when tested in a worm gearbox under controlled conditions.

Given the huge amount of energy required to power a steel mill, small reductions in energy such as this can translate into significant cost savings. In the paper industry – which used similar gearboxes to the steel industry – Smurfit Kappa in the UK switched to Mobil SHC™ 632 and was able to save $4,000 annually from just one gearbox.

Response from Jarmo Vihersalo, ExxonMobil Industrial Mar-

One example from our company is the Mobil SHC™ 600 series of synthetic gear oils that allow up to 3.6% efficien-

keting Advisor EAME and MPT’s expert Contact: www.mobilindustrial.com

Disclaimer: This advice is provided for general guidance only and should not be relied on for any specific situation. You should always contact your own lubricants supplier in relation to your specific issues and needs. MPT International and ExxonMobil companies do not accept any liability incurred by you as a result of relying on the advice in this column.

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How times have changed ...

MPT International 3 / 2016

64

››› LITERATURE SERVICE Customised material handling solutions 16 pages, English A brochure setting out the range of handling solutions available from Combilift, such as 4-way side loaders, compact and all-wheel-drive multi-directional forklifts, articulated aisle forklifts, etc., for a wide range of industrial applications.

Contact: E-mail:

www.combilift.com info@combilift.com

Fire protection sleeving 4 pages, English, German A product brochure outlining the features of ProtectorTM fire protection sleeving offered by Lippmann for the protection of cables, lines and hoses against open fire, flying sparks and metal splashes. The material comes as sleevings in different diameters and as tapes in widths up to 200 mm.

Contact: E-mail:

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

Refractory products Various product brochures, English Product brochures providing information about refractory products made by Lungmuß Feuerfest, for example, prefabricated parts for electric arc furnaces and secondary metallurgy, protective plates, castables and brick lining for steel ladles, insulation for heat treatment furnaces, etc.

YOUR SPECIALIST IN INNOVATIVE, REFRACTORY PRODUCTS

Contact: E-mail:

www.lungmuss.de info@lungmuss.de

Flatness measurement 4 pages, English A brochure detailing the technical features and advantages of the VeriFlat flatness sensor developed by Shapeline. The sensor integrates all optical, mechanical and electrical parts in one single robust housing. It measures strips up to 2,000 mm wide.

Contact: E-mail:

www.shapeline.com info@shapeline.com

Industrial safety equipment 48 pages, English, German A comprehensive catalogue detailing the wide range of safety equipment manufactured by Rudolf Uhlen, including face and eye protection such as headgears, hard hat brackets, face shields, wire mesh visors, protective filters, and welding and arc flash protection.

Contact: E-mail:

MPT International 3 / 2016

www.aschua-uhlen.de info@aschua-uhlen.de

IN THE NEXT ISSUE…

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65

Tube making World’s most modern large-diameter pipe mill to be expanded In 2015, Corinth Pipeworks from Athens, Greece, started up production of 18 m longitudinally seam-welded large-diameter pipes. The mill has been designed for a capacity of 400,000 t of pipes with outside diameters between 16” and 56” in wall thicknesses of up to 40 mm and lengths of up to 18.3 m. By investing in a new pipe welding machine, Corinth Pipeworks is now expanding its product range to satisfy the growing global demand for high-strength pipes for the production and transit of oil and gas.

/CVGTKCN ƃQY NQIKUVKEU Hyundai Steel installs new crane positioning system in rolling mill complex To precisely track the position of the overhead cranes as well as of the raw materials and steel coils, Hyundai Steel implemented a robust, fail-safe and highly accurate positioning and telemetry solution. Even in the harsh environment of the rolling mill, Hyundai Steel is now able to accurately detect the crane and steel positions on a continuous basis – in real-time – to avoid downtimes and to make the logistics and production processes more efficient, cost-effective and safer.

5RGEKCN GSWKROGPV Right choice of lubricants may save energy costs Advanced lubricants, despite accounting for just one or two per cent of operational costs, have the potential to enhance equipment functionality and lifespan, reduce energy consumption and deliver cost benefits. Compared to conventional mineral oils, advancements in lubricant technology have provided significant benefits. They have led to extended equipment lives, longer oil drain intervals and improved energy efficiency of the equipment. Steel mill operators rely on a number of lubricants to ensure efficient and long-lasting operation of the equipment. Therefore, it is important to identify the most effective oils for the various areas of a mill. By selecting oils with proven energy-saving potential, steel mill operators may reduce costs.

This preview may be subject to change.

Metallurgical Plant and Technology

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MPT International 3 / 2016

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.

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