MPT International 4/2016 (Sep)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

Ingot optimization in terms of shape, head and insulation

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September 2016

Lubricating the steel mill for RQVGPVKCN GPGTI[ GHÆ‚EKGP[ EQUV UCXKPIU

We transform … the world of environment–friendly steelworks.

All plants from one source.

Big River Steel located in Osceola, Arkansas, USA on approximately 1,300 acres is one of the country’s most modern and environment-friendly steelworks. Applying innovative, clean, and effective processes, the company will produce high-quality steels for the energy, automotive, oil and gas industry from recycled steel scrap.

The plant has an annual capacity of 1.5 million tons of high-grade steel products and specialty steels including: Deep Drawing and Extra Deep Drawing Grades (DS, DDS, EDDS, IF) Commercial Steel (CQ), Medium and High Carbon Grades

Structural Steel and COR-TEN Grades High Strength Low Alloy Steel (HSLA) Advanced High Strength Steel (DP, CP, MS, FB) Quenched and Tempered, Abrasion Resistant and Pressure Vessel Grades Pipe Grades (API, Sour Gas Resistant (HIC), OCTG) As a provider of integrated systems, SMS group will supply all units – from the melting plant to the finished steel strip, including all drive and hydraulic components, the entire electrical equipment, the complex automation systems as well as the environmental technologies.

SMS GROUP GMBH

Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany

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

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

EDITORIAL

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New requirements of security for automation systems Global cyber security company Kaspersky Lab is not only highly renowned for their consumer security products, but also for the solutions they offer for corporate applications. In spring this year, Kaspersky Lab joined forces with industrial IT specialists BM Automation to develop an industrial cyber security initiative, which we present in this issue of MPT International. Cyber threats have been growing and today the competitiveness of business operations is closely related to cyber security. Hence, cyber security is no longer an issue reserved to IT specialists. Cyber attacks exploit not only vulnerable Internet activities or weak points of the IT network. More than that, digital unconsciousness of users, employees and operators put the companies’ security at risk. Cyber criminals use social engineering to gather information about the industrial network and how to skirt or penetrate protective means. Advanced persistent threats (APT) are used to attack the IT infrastructure of big operations. The joint action of Kaspersky Lab and BM Automation addresses the urgent need to manage industrial cyber risks and protect the continuity and integrity of technological processes in industrial environments. It’s the right means at the right time, with know-how about metallurgical plants included in the BM group’s area of expertise.

Dipl.-Ing. Arnt Hannewald

In this issue, MPT also features metallurgical aspects of process automation and IT solutions, as for instance the optimization of an ingot casting line at the biggest steel producer in the Czech Republic. Engineers have achieved a significant improvement in the performance of the casting plant, which now meets highest quality requirements and saves production time and resources. It goes without saying that the editorial scope of this issue of MPT is completed by various other reports about new and modernized plants and technologies.

MPT International 4 / 2016

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››› CONTENTS

International industry news 26

EU steel sector still paying the price for sustained global overcapacity The EU market for steel products is only modestly growing, yet imports continue to increase as EU trade defence is still not responsive enough

Company profile 28

SMS group adapts to slack demand for metallurgical plants worldwide

Coverphoto: Kocks RSBÂŽ 500++/4 currently operating in China.

With a nominal roll diameter of 500 mm this heavy-duty reducing & sizing block is so far the biggest 3-roll RSBÂŽ that Kocks has designed.

Friedrich Kocks GmbH & Co KG, Hilden, Germany www.kocks.de

Order intake of SMS group has declined again in 2015.

Sales were close to previous year’s level. The cost-cutting program initiated by the group starts to deliver. Moderate growth is expected in the medium term

Automation

Steelmaking – Automation

30

34

Industrial cyber security initiative Kaspersky Lab and BM Automation have jointly developed KICS – a new platform for industrial cyber security. BM Automation has been selected as system integrator to realize KICS

Two steel works successfully modernized at JSW Steel Vijayanagar works in India New process models have been implemented to improve product quality. Subsystems are harmonized and production sequence is optimized

Ingot casting

Continuous casting

36

40

Ingot optimization in terms of shape, head and insulation Czech steel producer Trinec Iron and Steel Works recently decided to modify their entire ingot casting line to optimize the overall process

Dillinger starts production of 500-mm-thick slabs for high-grade heavy plates With the new continuous slab casting machine No. 6 Dillinger presents one of the biggest single investment projects at the site

Material flow logistics

Special equipment

42

44

Hyundai Steel installs new crane positioning system in the rolling mill complex Even in the harsh environment of the rolling mill, Hyundai Steel is able to accurately track the crane and steel positions in real time to avoid downtimes

Lubricating the steel mill for potential GPGTI[ GHĆ‚EKGPE[ EQUV UCXKPIU Advanced lubricants have the potential to enhance equipment functionality and lifespan, reduce energy consumption, and deliver cost benefits

Strip processing

Tube making

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48

Chinese Baotou Steel modernizes cold strip production facilities The new cold rolling mill manufactures refined cold strip products for automotive application after successful commissioning of an annealing plant

MPT International 4 / 2016

World’s most modern large-diameter pipe mill to be expanded Corinth Pipeworks has expanded its product range to satisfy the growing global demand for high-strength pipes for the production and transit of oil and gas

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40

48

47

Columns 8

International industry news

56

Literature service

50

Technical innovations

57

In the next issue

55

Cartoon

57

Imprint

Advertisers’ index ABB AB 22 Almamet GmbH 18 Aumund Fördertechnik GmbH 13 Automazioni Industriali Capitano srl 23 Behringer GmbH Maschinenfabrik u. Eisengiesserei 41 Braun Maschinenfabrik Gesellschaft m.b.H. 45 BWG Bergwerk- und WalzwerkMaschinenbau GmbH 43 CMI INDUSTRY SA Metals 53 Danieli S.P.A. 6, 7 DMT GmbH & Co. KG 51

Eredin Scabini Srl 27 Getriebebau NORD GmbH & Co. KG DRIVESYSTEMS 17 GLAMA Maschinenbau GmbH 39 Guild International Inc. 33 Houghton Deutschland GmbH 45 IMS Messsysteme GmbH 19, 20 JATO-Düsenbau AG 21 Kiro-Nathaus GmbH 38 Friedrich Kocks GmbH & Co. KG 11 MEFKON GmbH & Co. KG 31 Messe Düsseldorf GmbH 12

MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Primetals Technologies Austria GmbH R+W Antriebselemente GmbH Reed Exhibitions (Deutschland) GmbH SMS group GmbH Symeo GmbH ThyssenKrupp Industrial Solutions AG VELCO GmbH Ges. f. Förder-, Spritz- und Silo-Anlagen mbH PAUL WURTH S. A. Zumbach Electronic AG

15 9 25 29 2 16 35 14 58 45

MPT International 4 / 2016

Efficient and competitive fume treatment plants (FTP) based on reverse-air baghouse and pulse-jet technology, quenching tower and hairpin cooler systems, as well as trouble-free slag recovery plants.

Four main references out of total 293 DONGBU STEEL KOREA FTP for a 2.6 Mtpy meltshop.

2x1.6 Mm3/h reverse-air baghouse technology, quenching tower cooling system.

Dioxin < 0.5 I-TEQ/Nm3.

Dust content at stack < 1 mg/Nm3.

Ecological and recovery systems

TOKYO STEEL JAPAN FTP for a 2.6 Mtpy meltshop.

2x1.6 Mm3/h reverse-air baghouse technology, hairpin cooling system.

Dioxin < 0.5 I-TEQ/Nm3.

Dust content at stack < 1 mg/Nm3.

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

DANIELI ENVIRONMENT GREEN STEEL TECHNOLOGY FOR A SUSTAINABLE STEEL INDUSTRY > Fume, dust and noise emission control systems > Water treatment plants > Ecogravel® EAF-BOF slag recovery system > Indutec® EAF dust Zinc Oxide recovery system > CHRTM Clean Heat Recovery from EAF hot fumes

MMK METALURJI TURKEY FTP for a 2.4 Mtpy meltshop.

2x1.9 Mm3/h pulse-jet technology, hairpin cooling system.

Dust content at stack < 10 mg/Nm3.

Noise level < 85 dbA at stack outlet.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

ABS GLOBAL BLUE ITALY Ecogravel: how to turn EAF slag disposal into an added-value industrial aggregate.

2-4% scrap recovery from processed slag.

Return on investment after just one year.

www.danieli.com

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››› INTERNATIONAL INDUSTRY NEWS

Africa Algeria Algerian Qatari Steel to build DRI plant. Algerian Qatari Steel (AQS) has awarded Midrex Technologies and its consortium partner Paul Wurth a contract to supply equipment, engineering and technical services for a new natural gas-based Midrex NG™ DRI plant to be built in Bellara, 375 km east of Algiers.

AQS is a joint venture between Sider Co. and National Investment Fund (51%) and Qatar Steel International (49%). The Midrex® plant will be part of a steel complex that will produce 2.0 million t/year of rebar and wire rod as finished products. The DRI plant will be designed to produce 2.5 million t/year of DRI with the capability to vary between hot and cold direct reduced iron without having to stop production. Hot direct reduced iron (HDRI) will be fed via an Aumund hot transport conveyor to a new EAF meltshop located adjacent to the DRI plant allowing for greater EAF productivity and energy savings.

The Americas

Voestalpine direct reduction plant in Corpus Christi, Texas, Big River Steel has signed an offtake agreement to run for the next four years. From 2017 onwards Big River Steel will take annual delivery of up to 240,000 t of hot-briquetted iron (HBI) from Voestalpine.

Over the past few months Voestalpine has signed long-term supply contracts for high-quality HBI with several customers. In total, 60% of the planned production volume will be supplied to third parties, primarily steelmaking companies within the NAFTA zone.

The remaining 40% will be shipped to the Austrian Voestalpine sites at Linz and Donawitz for processing.

News in brief JSW Steel, India, has granted the FAC for the last of four new BOF converters supplied and commissioned by Primetals Technologies. The shut-down lasted only 33 days, nine days less than agreed.

Tenova, Italy, is moving its headquarters to Castellanza (Varese) to a new, modern corporate campus.

AHMSA, Mexico, has started operation of a new normalizing line supplied by Primetals Technologies. The line has a capacity of 300,000 t/year.

USA Nucor Yamato Steel invests in remote taphole closing system.

Nucor Yamato Steel has placed an order with Danieli for the supply of a remote closing system for the EBT hole of the electric arc furnace. Danieli will supply the Q-EBT SAND system, designed to remotely perform the filling of the EBT hole with refractory sand material (generally Olivine) by means of a dedicated pneumatic system. The EAF operators will execute the closing operation safely from the furnace control room.

Xining Special Steel, China, has issued to SMS group the FAC for the successful commissioning of the new semi-finished products mill. The rolling mill comprises a reversing roughing stand and an eight-stand finishing mill. It features hydraulic roll gap adjustment.

Valin ArcelorMittal Automotive Steel, China, has issued to PSI the FAC for the successful implementation of the PSImetals product management solution.

USA ArcelorMittal USA enters into long-term iron ore supply agreement. Cliffs Natural has entered into a new long-term commercial agreement with ArcelorMittal USA to supply tailor-made iron ore pellets for the next ten years through 2026. The new agreement will replace two existing agreements expiring in December 2016 and January 2017, respectively, and fill the entirety of ArcelorMittal’s pellet purchase requirements from the previous contracts. The new commercial agreement preserves Cliffs’ current position as ArcelorMittal USA’s sole outside supplier of pellets.

USA Big River Steel signs offtake agreement for HBI. Just a few months prior to completion of the new MPT International 4 / 2016

Asia

Axis Pipe and Tube, USA, has successfully commissioned the heat treatment facility and pipe threading line supplied by SMS group.

China STAL Precision Stainless Steel to built new cold rolling mill.

Fives and Shanghai STAL Precision Stainless Steel, a joint venture between USA’s Allegheny Ludlum and China’s Baosteel group, signed a contract for the design, manufacturing and supply of a 20-high cold rolling mill. The new mill will be installed in STAL’s new stainless steel facilities built in Shanghai’s Xin-Zhuang industrial zone. The new 20-high mill will be designed for a production capacity of just over 80,000 t/year. It will be able to roll strip down to 0.040 mm and up to 1.2 mm thick from 1.5 mm thick input strip. Maximum strip width will be 1,250 mm.

Wempco, Nigeria, has issued the FAC to Danieli for the installation and successful commissioning of the 0.3 million t/year wire rod mill.

PAO Severstal, Russia, has successfully commissioned rolling mill “2100” after a comprehensive mill revamp by SMS group.

Seven Refractories, Slovenia, has completed the expansion of their main plant in DivaËa, doubling the capacity.

AS ONE We are stronger

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

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››› INTERNATIONAL INDUSTRY NEWS

Terminal equipment for the mill will be produced locally by Fives’ subsidiary in China.

50 t/h. The contract also includes the supply of a mill fan, dampers, expansion joints, a magnetic separator and a metal detector.

China

and installation supervision. Installation is scheduled for May 2017, with start-up the following month.

Vietnam Philippines

Shougang Jingtang orders casting-rolling plant for strip production. Danieli has received an order from Shougang Jingtang United Iron & Steel for a dual-use plant made up of a caster plus a rolling mill. The mill will be designed for the production of 2.1 million t/year of hot-rolled high-quality strip, running in both endless (continuous) and coil-to-coil modes (discontinuous). The Danieli Universal Endless (DUE®) plant, which is made up of a thin slab caster and a rolling mill, will be capable of producing strips in thicknesses from 0.8 to 12.7 mm in a wide range of steels.

Danieli will supply the equipment in consortium with TMEIC, who will provide the electrics and automation system for the rolling mill.

China Baosteel Shanghai to upgrade slitting line. As part of a general upgrade programme covering the entire cold processing facilities in Shanghai, Danieli will supply a new side trimmer for a medium gauge slitting line.

The new trimmer, capable of processing grades up to 1,200 MPa, will operate over a thickness range from 1.2 to 12.7 mm. The new heavy-duty machine will be equipped with massive discs of 650 mm in diameter and a powerful scrap chopper. The machine will feature automatic knife gap adjustment and automatic alignment of the main trimming heads.

India Sri Balaha Chemicals to build slag grinding mill. Sri Balaha Chemicals has placed an order with Loesche for the supply of a vertical roller mill.

The mill will be designed to grind granulated blast furnace slag to a fineness of 4,000 cm²/g Blaine at a rate of MPT International 4 / 2016

Capitol Steel orders bar rolling mill. Primetals Technologies, in cooperation with Automazioni Industriali Capitanio S.r.l. (AIC), has received an order from Capitol Steel to supply a new bar rolling mill for the plant in Quezon City. The rolling mill will produce around 500,000 t/year of rebar with diameters ranging from 8 to 50 mm. Diameters up to 12 millimetres will be rolled in multi-slit mode.

Primetals Technologies is responsible for the design of the mechanical equipment supplied and for the entire process planning of the bar rolling mill and will provide specific engineering support for auxiliary systems, such as water treatment plant, workshop and laboratory, fire protection, cranes and civil works. AIC is responsible for the design and supply of the electrical equipment and the Level 2 automation system. Commissioning is scheduled to start in the second half of 2017.

Fuco Steel to install rolling mill.

Danieli will supply a new 0.6 million t/ year rolling mill for rebar, wire rod and small sections to Fuco Steel. The mill will be installed in the Phu My industrial zone and use as input stock 150 mm square billets coming from an existing five-strand casting machine. The rolling mill features latest Danieli Morgårdshammar equipment, including 18 SHS+ stands, fast finishing blocks fitted with M2 multiple drive technology and modular block configuration, space for future upgrading with in-line QTB system for quenching and self-tempering, etc. as well as Sund Birsta equipment for bars with tying/strapping machines and vertical pallet conveyor for wire rod production. Start-up of the plant is scheduled for the end of summer 2017.

Europe Finland

South Korea Posco to revamp hot rolling mill.

ABB has won a contract to replace twin DC motors and associated drives with newer AC motor and drive technology on a hot rolling mill at Posco’s Pohang works. ABB synchronous motors, combined with the ACS6000 multidrive, meet torque requirements over the entire operating range of the rolling mill, from zero to maximum process speed.

This ensures a smooth start, acceleration and operation. The contract also includes the replacement of three AC motors and gate-turn off thyristor (GTO) drives with AMZ synchronous motors and ACS6000 multidrives. In addition, ABB is supplying low voltage motors and drives, for use on the down coilers. ABB will also deliver ancillary equipment including motor control centres and local operation panels for motor cooling fans together with training, commissioning

Outokumpu to upgrade electric arc furnace. Outokumpu Stainless has placed an order with Danieli Centro Met to upgrade its stainless steel EAF in Tornio with the objective to reduce heat loss and increase safety. Danieli will implement its QPanels technological package. The double-layer panels entrap the slag, which acts as a heat insulator, thus reducing the cooled surface exposed to heat radiation from the steel bath. Two independent cooling circuits will ensure higher reliability and operating safety.

Germany ThyssenKrupp Rothe Erde orders upsetting and piercing press.

ThyssenKrupp Rothe Erde, manufacturer of slewing bearings and producer of seamless rolled rings, placed an or-

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worldwide

Welcome.

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

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

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

der with Siempelkamp for the supply of a new 6,000 t upsetting and piercing press to be installed at their Dortmund works for the manufacture of ring blanks.

The new upsetting and piercing press will be a replacement for an older 4,000 t press. The new press will produce ring blanks with weights between 400 kg and 25 t, in diameters of up to 2,500 mm and heights of up to 830 mm. Siempelkamp will supply the complete press solution including all peripheral components. The order scope also includes the supply of service cranes for changing the press punch and the integration of a robotic manipulator into the control system. The press is scheduled to be operational by January 2018.

Germany BGH to modernize electric arc furnace. Primetals Technologies has received an order from steel producer BGH Edelstahlwerke to modernize the electric arc furnace at its Freital site in order to optimize the furnace movements and convert its tapping system. The furnace will be modernized in two conversion stages.

Primetals Technologies will modernize the furnace rocker, as well as the roof raising and tilting systems of the electric arc furnace to speed up furnace movements and enable longer electrode segments to be used.

The tapping system that empties the furnace will be converted in the second phase of the project. Primetals Technologies will be responsible for engineering and supplying the equipment, and will supervise its installation and commissioning. The work is scheduled for completion during the summer shutdown in 2017.

Germany International Metal & Steel Trade Fair for Southeast Asia

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

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

5–8 JUNE 2017

ESF Elbe Stahlwerke Riesa to modernize rolling mill. ESF Elbe Stahlwerke Riesa are going to revamp their rolling mill by installing a new wire rod outlet. The order for the project was placed with Danieli. The project will include the installation of a three-stand compact sizing block, with multiple drive technology. After the modernization the plant will roll 5.5 to 16 mm dia. plain and deformed wire rod into 2,400 kg coils at rolling speeds of up to 115 m/s. The product mix includes low and medium carbon grades for reinforcing and cold drawing applications. The supply also includes a loop laying head with oil film bearing, associated auxiliaries and a controlled cooling line for wire rod. Plant start-up is scheduled for the beginning of 2017.

EXPOCENTRE Krasnaya Presnya Moscow, Russia www.metallurgy-tube-russia.com

Italy

www.tbwom.com

Ilva orders hot-metal desulphurization plants.

Ilva has awarded SMS group an order for the supply of Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Tel. + 49 (0)2 11/45 60-01 _ Fax + 49 (0)2 11/45 60-6 68

www.messe-duesseldorf.de

W E two hot-metal desulphurization plants for steelworks No. 1 and No. 2 at its Taranto site. The new plants will be designed according to the latest emission control standards. A special feature of the equipment will be the high flexibility of the desulphurization plantsâ&#x20AC;&#x2122; injection system. Desulphurization agents can be injected in two configurations: lime only (mono-injection) or both lime and magnesium together (co-injection). For each plant, SMS group will supply the hoppers for the desulphurization agents, the pneumatic conveying system, the injection system with automatic lance changing equipment, the hot-metal treatment station with dog house and a slag skimming device. The project will be handled by SMS INNSE and SMS Mevac. Commissioning of the plants is planned to take place in the early 2017.

C O N V E Y

Q U A L I T Y

Hot Sinter Transport

Italy Arvedi to install new heat recovery unit. Turboden, a group company of Mitsubishi Heavy Industries (MHI), has signed an order with Acciaieria Arvedi for a new waste heat recovery ORC unit to be installed at the steel plant in Cremona. The Turboden ORC unit will convert the off-gas heat from the EAF to electricity.

The system will include a saturated steam heat carrier circuit to convey the heat from the furnace exhaust gas to the ORC unit. This new system will be coupled to the existing Tenova ConsteelÂŽ system, which preheats the metallic charge and feeds it to the 250 t EAF. The waste heat boiler, to be supplied by Tenova, will be installed on the primary EAF off-gas line in parallel to the existing quenching tower and will produce saturated steam.

AUMUND Pan Conveyors The Netherlands Tata Steel scales up HIsarna pilot plant.

Oschatz has been commissioned by Tata Steel Europe to supply a new exhaust gas cooling section for the HIsarna pilot plant in IJmuiden. The HIsarna process is intended to enable pig iron to be extracted in a single step from iron ore and carbon without having to prepare these beforehand to sinter and coke. Oschatz delivered the first cooling stack for the HIsarna process in 2010. Now the tests are being continued on a larger scale. For this purpose the Oschatz exhaust gas cooling system is being expanded and fundamentally optimized. Besides the actual cooling stack, steel construction and assembly are also a constituent part of Oschatzâ&#x20AC;&#x2122;s scope of delivery. Commissioning of the expanded pilot plant is scheduled for the end of 2016.

s #APACITY UP TO T H s 0AN WIDTH UP TO MM s -ATERIAL TEMPERATURE UP TO ²# s &INES AND LUMPS s -INIMIZED HEAT LOSS s .O GENERATION OF lNES

10 Nov. 2016, D uesseldorf/Ger many Pls. visit our stand no. F20

Sintered and agglomerated Materials

Russia Severstal to install new side trimming unit in pickling line. Severstal has placed an order with SMS

AUMUND Foerdertechnik GmbH 3AALHOFFER 3TR s 2HEINBERG s 'ERMANY METALLURGY AUMUND DE q WWW AUMUND COM

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››› INTERNATIONAL INDUSTRY NEWS

group for the supply of a new ASC (automatic setting control) double-head side trimming unit for the No. 3 continuous pickling line in Cherepovets.

SMS group will supply the side trimming unit pre-assembled and complete with its own electrical and automation systems. As the side trimming unit will be delivered in a function-tested state, the new unit will be fully functional right after the installation. Arranged at both sides of the line, the circular knives of the ASC unit will side trim the strip in the exit section of the pickling line. The cutting takes place at speeds of up to 360 metres per minute. An integrated scrap chopper will cut the trimmings into small pieces.

The double-head design provides the advantage that the knives in the maintenance position can be replaced without impacting on production.

Russia TMK orders heat treatment line for tubes. TMK’s subsidiary Seversky Tube Works, located in Polevskoy, has placed an order with SMS group for the supply of a heat treatment line for tubes and pipes. Seversky produces seamless and welded pipe and tube mainly for oil and gas. The design capacity of the line will be 265,000 t/year of heat treated tubes and pipes. It will carry out various process steps, such as quenching, tempering and normalizing. Its main components will include an austenizing furnace with walking beam transport system, a quenching head with inside lance, a walking beam tempering furnace and a cooling bed.

SMS will also supply the complete water treatment system for the line. The recuperative burners to be installed in the new line use up to 30% less fuel than conventional burners. The line is scheduled to commence operation in the first quarter of 2018.

atives were completed in 2015. Another 14 initiatives continued into 2016.

Key environmental initiatives completed in 2015 included reconstruction of sulphur capture system No. 4 at the sintering plant, reconstruction of sludge depository No. 2, and reconstruction of coke gas refrigeration cycle unit No. 1. A large-scale reconstruction of sulphur capture system No. 2 is currently underway. As a result of those measures, total emissions of air pollutants decreased by 6.3% year-onyear and waste reused in sinter burden amounted to 2.25 million t.

Spain ArcelorMittal Avilés to revamp slab casters. ArcelorMittal Avilés has awarded SMS group a revamping order for two slab casters supplied by SMS group in 1987. The two-strand bow-type slab caster No. 1 will be rebuilt into a vertical bending machine.

The plant will be equipped with SMS group’s remote-adjustable mould (Delta speed adjustment). With this technology, any width adjustment and automatic setting of the mould taper can be performed during running production without having to reduce the casting speed. The mechanical oscillation system will be replaced by a hydraulic one. SMS group will also implement a new secondary cooling concept based on a width-dependent spray cooling unit (single-component system) installed in the machine head. All cooling circuits for the mold, machine and spray cooling system will be completely renewed. The slab caster will be prepared for hydraulic soft reduction.

ArcelorMittal Avilés will also receive new workshops equipped with the HD LASr alignment assistant developed by SMS group. This system no longer uses rulers to measure the mold and the segments but a laser tracker and the dedicated SMS-developed measuring software. Caster No. 2 will be revamped in a second phase.

Russia MMK implements environmental protection measures. In the context of the Environmental Programme initiated by Magnitogorsk Iron and Steel Works (MMK), 54 initiMPT International 4 / 2016

Sweden Sandvik to build tube pickling plant. Sandvik has broken ground for

a new tube pickling plant. Construction of the plant is set to begin immediately and the new pickling line will be up and running by the end of 2017. The facility will cover approx.

6,000 square metres. The plant will be equipped with state of the art technology which will make for a safer working environment and environmentally friendly processes.

Turkey Yildiz orders cold mill complex. Yildiz Demir Celik selected Danieli for the supply of the technological equipment for a cold mill complex to be built in Kocaeli. The plant will produce 1,500,000 t/year of pickled, cold-rolled, galvanized, annealed and skin-passed coils. The main plant units will include a continuous pickling line coupled with a five-stand 6-high tandem mill, a vertical hot-dip galvanizing line, bell annealing furnaces and a temper mill. The plant will gradually come on stream in 2017, starting with the bell annealing furnaces and ending with the continuous pickling line.

Turkey Cemtas to build new heat treatment line. Cemtas Celik has signed a contract with Danieli Centro Combustion for the supply of a new heat treatment line for bars to be installed at the company’s Bursa location. The contract comprises engineering, supply of equipment as well as supervision of erection, commissioning and startup. The line will be designed for hardening, normalizing, tempering and annealing high-grade bars.

Companies CMC signs definitive agreement for sale of G.A.M. Steel.

Through its wholly owned Australian subsidiary G.A.M. Steel Pty. Ltd., Commercial Metals Company signed a definitive asset sale agreement to sell its

remaining steel distribution assets located in Australia. The facility, located in Melbourne, Victoria, distributes and processes primarily long steel products.

Voestalpine presents 2015/16 business results. Voestalpine Group was largely able to maintain its revenue at the previous year’s level, namely, roughly EUR 11.1 billion versus EUR 11.2 billion (-1.1%). First-time full consolidation of companies belonging to the Metal Engineering division, which had previously been consolidated at equity, and increasing revenue contributions from companies acquired by the same division in 2014/15 resulted in positive non-recurring effects. The divestments undertaken in the previous year in the Metal Forming division had a slight negative effect on revenue.

Despite record investment of more than EUR 1.3 billion in the business year 2015/16, the net financial debt in percent of equity was reduced. The most significant factor was stable and solid development of earnings that made a 10.5% increase of the equity base possible. The workforce of the Voestalpine Group has again reached a new record.

After undertaking strategic acquisitions in the USA and China as well as expanding numerous locations worldwide, particularly in the automotive sector, the construction of the direct reduction plant in Corpus Christi, Texas, USA is now nearing its completion.

Essar Steel Algoma moves for purchase offer approval. Essar Steel Algoma has entered into an asset purchase agreement for the sale of substantially all of the company’s assets to a consortium of bidders formed by KPS Capital Partners and the company’s prepetition term lenders. The consortium bid includes cash consideration, a credit bid equivalent to the term loan, and the assumption of certain liabilities.

Nucor and JFE Steel form JV. Nucor Corporation is forming a 50-

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››› INTERNATIONAL INDUSTRY NEWS

50 joint venture with JFE Steel Corporation of Japan to build and operate a plant in central Mexico to supply that country’s automotive market. The plant is expected to have capacity of 400,000 t/year of galvanized sheet steel. Operations are expected to begin in the second half of 2019.

SMS group and Mettop establish JV company. In May 2016, SMS group and Austrian Mettop GmbH founded the joint venture PolyMet Solutions GmbH, with each company holding 50% of the shares. PolyMet Solutions is an independent company with headquarters in Leoben, Austria. Managing director is Andreas Filzwieser. The JV company will offer innovative processes and solutions for primary concentrate melters, converters (such as Peirce Smith converters) and anode furnaces. Thus it will be possible in future to supply complete process routes, extending as far as electrolysis and the subsequent processing of semi-finished products.

This will expand the SMS group’s portfolio in production and processing equipment for copper, lead, zinc, tin and other non-ferrous metals.

Schmolz + Bickenbach expands international sales and services network. Schmolz + Bickenbach International is expanding their sales network as well as warehouse and processing capacities in the American, Asian and Scandinavian markets. In December 2015, a subsidiary was set up in in Tokyo, Japan, and a new sales office was opened in Bangkok, Thailand. A new warehouse for tool steel, including state-of-the-art sawing and milling technologies, was opened in Chongqing, China. At the sales and services location in Valkeakoski, Finland, sawing capacities have been extended. By establishing a presence in Queretaro, Mexico, Schmolz + Bickenbach International is responding to developments in the Mexican automotive industry.

SSAB concludes negotiations to reduce workforce. Negotiations

by SSAB to reduce the workforce in its Nordic operations have been concluded. They will result in the loss of 98 permanent front-line jobs in Oxelösund.

The number of temporary employees will be reduced by 85 persons. As communicated earlier, the workforce will

also be reduced by a total of around 50 office jobs in Finland and around 260 in Sweden.

VDM Metals restructures organization. VDM Metals has restructured its organization, increasing transparency of internal processes.

VDM Metals Holding GmbH, VDM Metals International GmbH and VDM Metals GmbH now form the VDM Metals Group, together with the foreign VDM subsidiaries. The three companies remain headquartered in Werdohl, Germany.

Low investments impact on metallurgical plants and rolling mill producers. As a result of the sustained pressure on commodity prices and continuing geopolitical risks, investments in metal production remained at a low level. The German metallurgical plants and rolling mills association VDMA again expects a double-digit fall in sales in the current year. However, the main potential is seen in the NAFTA region and in certain South-East Asian

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INTERNATIONAL INDUSTRY NEWS markets. In line with overall developments, annual average production fell to a value of slightly more than €1.5 billion in 2015, 22% below the figure for the previous year. In April this year, capacity utilization was 75 percent. On the basis of the export data of the five largest supplier countries (China, Italy, Germany, Japan and the USA), VDMA estimates that there was a further slight fall of about 2 percent in world trade. Germany remained the third-largest exporter, after China and Italy. Commenting on the situation in the industry, VDMA officials see good prospects for German manufacturers of metallurgical plant and rolling equipment to maintain their strong position. German metallurgical equipment producers are also in demand for modernization projects and environmentally compatible plant modifications.

However, there will only be very few major projects in the metal production sectors in 2016.

SGL Group completes carve-out of business unit. SGL Group has successfully completed the legal carve-out of its Performance Products (PP) busi-

ness unit earlier than planned. With this step SGL Group takes account of the changed fundamentals in the market for graphite electrodes. The overcapacities in the steel industry have exposed it to substantial price erosion.

By means of the legal carve-out, SGL Group has created the necessary prerequisites for participating in a potential market consolidation. The cornerstone of the strategic realignment initiated by SGL Group last year is the focus on the two business units Composites – Fibers & Materials (CFM) and Graphite Materials & Systems (GMS).

SKW Metallurgie reaches agreement on loan contract. Specialty chemicals group SKW Metallurgie and its lending banks have agreed to amend the existing syndicated loan contract to the effect that the waiver of extraordinary bank rights to terminate the contract be extended until 29 September 2016. The termination rights in question result from the global steel crisis, due to which contractual financial figures were no longer met.

The company remains optimistic to reach during the further course of the year a solution for the continued fi-

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News in brief Outokumpu, Germany, has processed the first coil in the new bright annealing line in Krefeld, marking an important milestone in the implementation of the NIFO (Nirosta Ferritic Optimization) project.

Outokumpu, Sweden, has installed and commissioned a Shapeline flatness gauge on its plate levelling line in Degerfors.

Atakaą, Turkey, processed the first coil on the new continuous pickling line built by Danieli.

Companhia Siderúrgica de Pecèm, Brazil, successfully put into operation the second of two coke oven batteries supplied by Paul Wurth.

Angang, China, has started up its new continuous galvanizing plant supplied by SMS group. The line will be able to process 450,000 t/ year of galvanized or galvannealed steel strip.

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››› INTERNATIONAL INDUSTRY NEWS

nancing of SKW Stahl-Metallurgie Holding AG and the SKW Metallurgie Group.

Ovako broadens restructuring programme. The restructuring programme that Ovako launched in November 2015 is being broadened. Several initiatives from the initial plan are progressing according to plan: closures of the Forsbacka production and distribution and of the distribution centre in Turenki are planned to be finalized during 2016. Workforce reductions in the steel and rolling mill in Hofors were achieved ahead of schedule in December 2015 by transitioning from 4 to 3 shifts. The restructuring plan is being reinforced in the following areas: the new organization that was launched in March enables reduced structural site costs in Hofors and Hällefors and in the commercial organization; reduced site costs in business unit Imatra and SmeBox through increased productivity, increased energy savings and reduced purchasing costs. The focus will be on implementing the above savings rather than the previously announced complex process of closing the Hällefors rolling mill. The Hällefors rolling mill will therefore remain in operation.

Danieli selects global trade management solution to enhance compliance. Seeking more comprehensive coverage to support current operations and future growth, Danieli decided to further enhance its compliance controls by implementing a state-of-theart global trade management solution.

The company chose Amber Road’s Restricted Party Screening solution. Amber Road will implement the solution in several phases, aiming to eventually cover Danieli’s entire worldwide operations. The solution will be hosted in Amber Road’s high-security facilities in Frankfurt, a new facility opened in September 2015, to meet the specific needs of European companies for compliance with EU data protection and privacy regulations.

MPT International 4 / 2016

Gerdau to divest operation in Spain. Gerdau will sell its specialty steel operations in Spain to Clerbil SL, an investment group with international experience formed by local executives of the company and led by the current CEO of the operation, José Jainaga.

The sale in Spain will allow Gerdau to focus on its more profitable businesses.

The company, which will again operate under the brand Sidenor, has factories in the Basque Country, Cantabria and Cataluña and commercial offices in Germany, France, Italy and the United Kingdom. In addition, the company owns one of the largest centres of research and development in Europe.

Sidenor and Gerdau will continue collaborating on the development of new products, particularly steel applications for the automotive industry.

Outotec introduces electrochemical water treatment. Outotec has combined its unique understanding of water treatment, process design, electrolysis and hydrometallurgy into a cost-effective electrochemical water treatment product – the modular Outotec® EWT40 system. One module can treat 5 to 40 m3/h of waste water depending on the application. The operation can easily be scaled up as needed simply by adding more modules. Outotec’s EWT solutions can handle everything from the removal of arsenic, selenium and antimony, to trace metals and organic removal.

MMK adopts new environmental policy. The new policy adopted by MMK has been driven by the update of the company’s environmental management system to a new version of the international standard ISO 14001:2015 and the strategic development plan. The strategy includes measures to markedly improve the air quality index in Magnitogorsk. By 2025 MMK also plans to meet technological requirements for environmental impact in line with the best available technologies recommended in Russia, as well as to completely eliminate discharge of contaminated waste water produced during technological processes into water facilities.

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INTERNATIONAL INDUSTRY NEWS NSSMC sells part of Posco shares.

Over 15 years, Nippon Steel & Sumitomo Metal Corporation (NSSMC) has developed an alliance relationship with Posco. Based on the strategic alliance, NSSMC and Posco have steadily been achieving various results in many fields, such as research and development, technology exchange, raw materials procurement, and mutual supply of steel slabs. In accordance with various measures being taken to strengthen NSSMC’s competitiveness and taking into account proposed asset reductions and other programmes designed to improve the financial structure, NSSMC has decided to sell the 1,500,000 Posco shares that NSSMC additionally purchased pursuant to an agreement signed in October 2006. NSSMC will decide the timing of the sale after taking into consideration market conditions and other factors.

IMI Z&J Düren moves to new office complex. IMI Z&J Düren has built a new modern office complex.

The previous office building, built in 1877, had undergone multiple extensions and upgrades. While the old building was 300 metres away from the workshops, the new one, covering a floor area of 2,000 square metres, was set up next to the workshops.

Construction had begun in August 2015.

Primetals Technologies and PSI cooperate on production management solutions. Primetals Technologies and PSI Metals have signed a cooperation agreement on the sale and implementation of Industry 4.0 production management solutions for the steel and aluminium industries.

Customers will receive complete solutions from a single source consisting of equipment, basic automation (level 1) and process automation (level 2) from Primetals Technologies, and the PSImetals production management solution (level 3) from PSI. The exclusive global cooperation agreement covers plants with equipment and automation from Primetals Technologies, as well as complete turnkey solutions for

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21

modernization projects and new plants throughout the entire supply chain.

Thyssenkrupp strengthens steel service centre business. Thyssenkrupp’s Steel-Service-Center group has been renamed Thyssenkrupp Materials Processing Europe. Thyssenkrupp Materials Processing Europe serves customers from the automotive, electrical, construction and furniture industries from its numerous locations. Business activities have been expanded to further strengthen the company’s customer focus. Alongside the steel service centre in Györ, Hungary, the stainless steel specialist Edelstahl-Service-Center in Willich, Germany, was added. Additionally it is planned to complete the organizational integration of Metallcenter Wörth by the end of this fiscal year, supplementing the company’s offering with tailored aluminium products.

Tenth anniversary film of ArcelorMittal. On 1 August 2006, Arcelor and Mittal Steel merged to create the world’s leading steel company.

On the occasion of its ten-year anniversary the company released a new film – “ArcelorMittal – Our Ten Year Journey”. Shot in multiple countries, high-

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lighting the company’s size and scale, the film reminds viewers of the logic of the 2006 merger between Arcelor and Mittal Steel, and looks at how the company has adapted and strengthened itself in response to the decade’s major economic challenges and is now positioning itself for the future. This 15-minute film features news footage and interviews with ArcelorMittal’s chairman and CEO Lakshmi Mittal, CFO and CEO of Europe Aditya Mittal, many of the group’s senior executives as well as employees from across the global company’s steel and mining.

MPT International 4 / 2016

22

››› INTERNATIONAL INDUSTRY NEWS

Personalities

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Severstal appoints CEO of Russian steel division. PAO Severstal has appointed Vadim Germanov as

CEO of Severstal’s Russian steel division and the Cherepovets steel mill.

Vadim Germanov was previously repair and maintenance director of Severstal’s Russian steel division.

Magnetic Analysis appoints president and CEO. Non-destructive testing specialists Magnetic Analysis Corp. (MAC) have promoted Dudley M. Boden to president and chief executive officer. Having spent 15 years as MAC’s vice president – sales & marketing, Boden brings an in-depth understanding of the com-

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pany’s test systems and customer inspection needs.

Thyssenkrupp appoints chief information officer. Martin Hölz has taken over as head of Group Processes & Information Technology (GPI) at Thyssenkrupp. He will also assume the position of chief information officer for the Thyssenkrupp group. GPI is responsible for implementing group-wide standards and optimizing and harmonizing business processes and the IT infrastructure.

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MPT International 4 / 2016

Outokumpu leadership team. The new organizational set-up connected to Outokumpu’s new vision and strategy entered into force on 1 June 2016. Roeland Baan heads the leadership team as president and CEO. He is also head of the Europe business area. Christoph de la Camp is chief financial officer.

ISSF elects new office bearers. The International Stainless Steel Forum (ISSF) has elected new officials during its 20th Annual Conference in Helsinki. Roeland Baan, CEO of Outokumpu, has been elected chairman.

Bernardo Velázquez, CEO of Acerinox Group, Tim Di Maulo, CEO of Aperam Group, Oh In Hwan, head of POSCO’s steel division and Hitoshi Ito, representative

INTERNATIONAL INDUSTRY NEWS director and president of NSSC, have been elected as vice chairmen.

Changes on managing board of DEW. Oliver Bell, chairman of the managing board and head of sales of Deutsche Edelstahlwerke (DEW), left the company at his own request, due to differences in strategic opinion. The two board members Jürgen Alex and Mathias Rist have taken over Oliver Bell’s posts on an interim basis.

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GFG Alliance, has appointed former Tata senior steel executive Michael Horan as managing director of Liberty Performance Steels, as Liberty House Group continues its growth plans with a series of high ranking appointments across its expanding UK oper-

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23

ations. Liberty Performance Steels is a manufacturer of high-quality precision steel strip, supplying industries including automotive, construction and general manufacturing, among others.

Outotec appoints CEO. Outotec’s board of directors and Pertti Korhonen have agreed that Pertti Korhonen will leave the duties of chief executive officer with immediate effect. The board has appointed Markku Teräsvasara as Outotec’s new chief executive officer.

Markku Teräsvasara is currently presi-

New member appointed to SKW Metallurgie supervisory board.

Alexander Kirsch has been appointed by court as the sixth member on the supervisory board of SKW Stahl-Metallurgie Holding.

The appointment was based on a motion by the executive board of the company, after no candidate had obtained a sufficient shareholder majority at the annual general meeting held last May. Alexander Kirsch’s appointment will last until the next annual general meeting.

Additional member on management board of NLMK International.

NLMK Group has extended the management board of NLMK International B.V., a holding company for NLMK’s international assets. By appointing Cornelius Louwrens to the newly introduced position of director of operational efficiency, the number of board members has been increased to five.

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Liberty recruits former Tata steel chief.

Global steel and engineering business, Liberty Industries Group, part of the

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››› INTERNATIONAL INDUSTRY NEWS

24

dent of Atlas Copco’s mining and rock excavation service division.

British Steel appoints executive chairman. British Steel has appointed Roland Junck as the company’s new executive chairman. He has been working with the senior management team at British Steel in an advisory capacity since the middle of June.

The search for a permanent CEO is ongoing and once completed, Roland Junck will continue as non-executive chairman of British Steel.

New appointments to board of Thyssenkrupp Industrial Solutions. Jörg Schönewolf, chief financial officer, and Martin Hilbig stepped down from the board of Industrial Solutions for personal reasons. The new CFO of Industrial Solutions is Stefan Gesing, formerly head of controlling, accounting & risk at Thyssenkrupp AG. Additionally, Michael Höllermann and Johan P. Cnossen are to join the board. Michael Höllermann, since

2012 CEO of the regional headquarters South America, will be the new chief human resources officer.

Johan P. Cnossen, who joined Industrial Solutions in May 2016 as head of the transformation office for the implementation of the “planets” reorganization programme, will hold the new position of chief operating officer.

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28 – 29 September 2016 Aachen, Germany Organizers: Steel Institute VDEh, TEMA Technologie Marketing www.sis-world.com

SIS.Europe 2016. The Surface Inspection Summit is the industry event for the surface inspection community.

Speakers from steel mills and R&D will discuss surface inspection for flat and long products.

Events ›

12 – 14 September 2016 Linz, Austria Organizers: Austrian Society for Metallurgy and Materials (Asmet) www.ecic2016.org

ECIC 2016. The 7th European Coke and Ironmaking Congress will provide information on the complete process chain from coke making, iron ore production and handling, sintering, pelletizing, blast furnace ironmaking, direct and smelting reduction through to energy saving and recycling.

›

24 – 26 October 2016 Rio de Janeiro, Brazil Organizers: Asociación Latinoamericana del Acero (Alacero) rio57.alacero.org

Alacero-57. As in previous years, the annual conference of Alacero will bring together representatives of companies active along the entire value chain of steel. Conference papers will address issues such as competitiveness and innovation for growth, the economic future of China and its steel industry, world and regional markets, etc.

STAHL 2016 – Orientation in uncertain times 10 November 2016 Düsseldorf, Germany Organizers: Steel Institute VDEh and the German Steel Federation www.stahl-online.de · www.stahl2016.de The motto of STAHL 2016 – Orientation in uncertain times – examines the challenges for the steel industry and points out potential courses of action. Discussing steel as a mature material offering potentials that are nowhere near exhausted, the event focuses on the sector’s prospects, considering the upheavals on global markets as well as European climate policy. Developments in energy efficiency during steel production, the latest research collaborations, material innovations and the topics of industry acceptance and digitalization will be discussed as well.

The following papers will be presented during the “Talks about steel” conference sessions:

Distortions on the global steel market – options for decision makers and industry Industry 4.0 – digitization as stimulus for growth and business change Limits and paths of flexibility in iron and steel production Material-based lightweight construction – solutions with steel Innovation in process modelling changes the world of flat steel products – virtuality becomes reality Technical aspects of digitalization in the steel industry Setting the course after Paris: Ways to a sustainable climate policy Industrial acceptability – indispensable for competitiveness and prosperity

The event traditionally closes with the “Steel get-together”.

MPT International 4 / 2016

INTERNATIONAL INDUSTRY NEWS

›

25 – 29 October 2016 Hanover, Germany Organizers: Mack Brooks Exhibitions www.euroblech.com

EuroBLECH 2016. The exhibition will, once again, be the meeting place for sheet metal working professionals from all over the world looking to find enhanced machinery and innovative production solutions. This year, the exhibition will reflect the trend towards digitalization and smart manufacturing in modern sheet metal processing.

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

TMP 2016. The ThermoMechanical Processing Conference will examine the key aspects of TMP, namely phase transformations, complex microstructures, in-line heat treatments, measurement techniques and forming processes.

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20 – 22 April 2017 Mumbai, India Organizers: Ministry of Steel Government of India, FICCI www.indiasteelexpo.in

India Steel 2017. The third edition of this international exhibition and conference will provide latest information and networking opportunities for steel industry stakeholders. Areas covered will include machinery and technology for steel and metal manufacturing as well as buying, sourcing and processing of raw materials.

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18 – 22 June 2017 Amsterdam, The Netherlands Organizers: Steel Institute VDEh, TEMA Technologie Marketing www.sct2017.com

SCT 2017. This conference on “Steels, Cars and Trucks” will cover topics such as body structure, forged and stamped parts, engines, axles, shafts, etc, which are of interest to all involved in the automotive industry. Papers will also feature intelligent forming processes, heat treatment techniques, joining techniques, modelling and simulation processes.

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10 – 14 September 1017 Düsseldorf, Germany Organizers: Steel Institute VDEh,

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25

TEMA Technologie Marketing www.eccc2017.com ECCC Creep & Fracture 2017.

This event will bring together engineers and scientists from around the world to present and discuss the latest research and developments in all aspects of creep behaviour of high-temperature materials and components.

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››› INTERNATIONAL INDUSTRY NEWS

EU steel sector still paying the price for sustained global overcapacity The EU market for steel products is only modestly growing, yet imports continue to increase as EU trade defence is still not responsive enough, says the European Steel Association (Eurofer).

Axel Eggert, Eurofer director general: “Once again third country suppliers continued to capture a larger portion of the EU steel market.”

Jeroen Vermeij, European Steel Association (Eurofer), Brussels, Belgium Contact: www.eurofer.be E-mail: j.vermeij@eurofer.be

MPT International 4 / 2016

EU apparent steel consumption grew 3.1% year-on-year in the first quarter of 2016. Improving business activity at the end-user level and inventory replenishment in the downstream steel supply chain fuelled steel demand.

Improving international steel pricing conditions since mid-February and lengthening lead times also explain the increase in buying interest and related stockpiling over the quarter.

Eurofer director general Axel Eggert said: “Imports rose by 24% year-on-year in the first quarter of 2016, but EU domestic deliveries fell by 1%. This shows that once again third country suppliers gained most from the modest growth in demand and continued to capture a larger portion of the EU steel market.

While deliveries from China into the EU remain at an elevated level, suppliers from other third countries such as Japan, South Kora, Iran, Belarus, Russia and Ukraine are increasingly targeting the still relatively open EU market.”

Similar conditions appear to have shaped the market in the second quarter of 2016. EU pricing and supply conditions remained supportive to the purchasing behaviour of EU steel buyers. Demand remained close to the level of the previous quarter, while imports continued to increase.

The outlook for the second half of this year is for apparent consumption to stabilize at around the level of the same period of 2015. The seasonal stock cycle suggests that inventories will be reduced gradually over this period. Steel demand is forecast to rise by around 1% in 2016.

Demand-side fundamentals in 2017 are seen as moderately positive, supported by a steady rise in real consumption and an overall neutral stock cycle.

Axel Eggert added: “So long as global overcapacity persists and authorities

elsewhere are more responsive to unfair trade, supply-side distortions will pose a risk to steel market stability in the EU”.

EU steel consuming sectors EU steel consuming sectors began 2016 on a positive tone: output increased by 1.8% year-on-year. The mild winter resulted in work on construction projects continuing or starting earlier than anticipated. Automotive activity again grew vigorously. The only sector that continued to act as a drag on total growth of output in the steel using sectors was the steel tube sector. First estimates for the second quarter of 2016 are relatively positive and signal the likelihood of a mild acceleration in the production growth of the key steel using sectors in the EU. The outlook for the second half of this year is relatively healthy, with also somewhat better support for growth from investment-led sectors such as the mechanical engineering and steel tube sectors. In 2017, investment is forecast to continue to moderately strengthen; this will broaden the basis for activity growth in steel using sectors. Also international trade is seen becoming more supportive to growth.

EU economic context Moderately positive economic fundamentals underpin the continuation of the economic recovery in the EU. Domestic demand prospects are relatively healthy, owing to the expected strength of consumer spending. Less clear is the outlook for investment and exports, reflecting heightened uncertainty given business conditions following Britain’s vote to exit the EU, as well as other global headwinds. For 2017, international trade activity is expected to pick up, supported by an anticipated moderate improvement in global economic conditions.

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş COMPANY PROFILE

SMS group adapts to slack demand for metallurgical plants worldwide Order intake of SMS group has declined again in 2015. Sales were close to previous yearâ&#x20AC;&#x2122;s level. The cost-cutting programme initiated by the group starts to deliver.

Moderate growth is expected in the medium term.

Facing a generally weak market for metallurgical plant and machinery equipment worldwide, Germanybased SMS group has exposed itself to a moderate restructuring initiative. Order intake by SMS group in business year 2015 dropped to EUR 2.758 billion (-13%). Meanwhile sales, at EUR 3.310 billion, approached almost the level of the previous year (-2.1%). The net operating result of SMS group contracted to EUR 7 million (2014: EUR 31 million).

Costs for restructuring means also depressed the result for 2015.

Due to the lower order intake, the order backlog of the group, at EUR 4.018 billion, was also down on the previous year (2014: EUR 4.613 billion). The SMS groupâ&#x20AC;&#x2122;s companies generated orders for metallurgical plant and machinery construction totaling EUR 2.476 billion (2014: EUR 2.921 billion). While plant business decreased to EUR 1.882 billion (2014: EUR 2.406 billion), service business grew to EUR 594 million (2014: EUR 515 million).

In 2015, the average number of employees including apprentices in SMS group totaled 14,342 (2014: 14,003).

Primarily, the increase results from the expansion of service business and more jobs abroad. This is in contrast to the declining number of employees in Germany. To retain the expertise of retiring employees, SMS group has organized a transition process. It ensures know-how transfer to younger employees so that the company remains strong for the future.

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MPT International 4 / 2016

Sales Operating result Order intake Order backlog Employees

2015

2014

change

3,310

3,406

-2.8%

7

31

-77.4%

2,758

3,167

-12.9%

4,018

4,613

-12.9%

14,342

14,003

+2.42%

(million euros) (KIWTGU QH VJG 5/5 ITQWR HQT VJG Ć&#x201A;PCPEKCN [GCT

There are two effects. First, SMS group GmbH adjusts its HR capacities to declining order intake in its core field of plant construction. Second, it retains its status as a globally and efficiently operating supplier covering all products and services over the entire metallurgical process chain.

Entry into new business Ć&#x201A;GNFU SMS group successfully started business in the field of direct reduction technologies. Just one year after signing a licensing contract with Kobe Steel, Ltd., Japan, for the construction of Midrex plants, Paul Wurth landed two initial orders for reference plants in Algeria.

The two logistics subsidiaries CTI Systems S.A. in Luxembourg and SMS Logistiksysteme GmbH in Germany merged to form one larger business unit, operating under the company name Amova. The objective here is to expand business on the growing market of cargo logistics â&#x20AC;&#x201C; for instance in the air cargo industry.

SMS group GmbH, Germany, and Mettop GmbH, Austria, founded the joint venture PolyMet Solutions GmbH. This expands the SMS group product and service portfolio to include the planning and supply of equipment and plants for copper, lead,

zinc, tin, and other nonferrous metals.

That gives it the scope to supply entire process chains right up to electrolysis and semi-finished products processing.

Recently, the subsidiary SMS digital GmbH was established. This startup company will build on the work already done to develop and market further digital products in direct contact with customers.

Furthermore, SMS group has acquired the majority share in QuinLogic GmbH in Aachen, Germany.

This young company creates software solutions for perfect quality management in the steel, aluminium, and paper industries. Included here are quality assurance systems for flat steel, stainless steel, special steel, and nonferrous metals.

Job cuts in Germany â&#x20AC;&#x201C; NCTIGN[ KP NKPG YKVJ UQEKCN TGURQPUKDKNKV[ Faced with a sustained global crisis in the steel, copper, and aluminum industries plus an associated decline in orders, the management of SMS group in 2014 announced plans for a two-stage capacity reduction in its core business of plant and machinery construction in Germany. Compared to 5,250 jobs in Germany at the beginning of 2014, the workforce here will

COMPANY PROFILE be cut by 1,200 jobs to some 4,050 employees by 2017.

Cooperating constructively and in a spirit of partnership, the managing board and the works council have agreed on a plan to implement most of the job cuts as painlessly as possible.

This involves part-time work for older employees, retirement at 63 for longterm contributors to the insurance system, a recruitment stop, and transfers to the continually growing service business. That will in most cases avoid forced redundancies.

Despite its cost-cutting programmes, SMS group will maintain its unusually high commitment to training young talents. This is how the company is responding to demographic change and

ensuring it can draw on a pool of adequately qualified personnel in the future.

Future prospects Burkhard Dahmen, chairman of the managing board: “Due to worldwide overcapacities, metal companies hardly invest in new plants. What’s more, ongoing political uncertainty in our important sales markets Russia and Ukraine is also damaging business. Looking on the brighter side, the gradual opening up of Iran offers opportunities for us to support the modernization and rebuilding of the country’s steel industry in the near future.

In fact, we’ve already signed letters of

‹‹‹

29

intent for projects collectively worth more than EUR 1 billion. Plus, we’ve just founded a joint venture with an Iranian company in the field of technical service and repairs.

We’re confident there’s unbroken potential in modernizations to make plants greener and more energy efficient. Other growth areas are digitization and the whole spectrum of services. However, overall the market situation demands that we consolidate and reduce our capacities. That’s why we’re expecting order intake in 2016 to remain at the same level as last year. Because of declining orders in hand, sales will be lower. We anticipate a moderate improvement in our net result due to lower restructuring costs.”

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30

››› AUTOMATION

Industrial cyber security initiative Kaspersky Lab and BM Automation have jointly developed KICS – a new platform for industrial cyber security. The solution addresses the urgent need to manage industrial cyber risks and protect the continuity and integrity of technological processes in industrial environments from cyber attacks. BM Automation has been selected by Kaspersky Lab as system integrator to realize KICS.

Panel of experts introducing the KICS platform to the public, London, 14 April 2016 (2nd from left: Eugene Kaspersky, 2nd from right: Andrea Tonini)

The constant evolution of informatics applied to industrial processes bears a new challenge for the industry: cyber security. Ethernet connections are constantly extending to all levels and this offers many advantages for plant automation. At the same time, however, production processes that were secure in the past are now open to attacks, violations and unauthorized accesses.

BM Automation – a division of BM S.p.A., Cimego, Italy Contact: www.bmgroup.com E-mail: cybersecurity@bmgroup.com

MPT International 4 / 2016

Threat environment Breach incidents affecting industrial control system (ICS) environments have increased significantly.

Although air gaps between industrial floors and the outside world used to be sufficient to offer a good level of protection, that’s no longer the case. Recent research found that cyber attacks caused 35% of industrial network malfunction incidents. There are many ways that air gaps can be bridged so that an isolated ICS becomes infected – such as via a USB memory stick. In addition, systems that aren’t directly attached to the Internet may be indirectly connected – via interaction with the company’s business IT systems.

Andrea Tonini, sales director of BM Group and representative of BM Au-

tomation, the division specialized in automation systems for the steelmaking process, explains: “Cyber attacks are already numerous in the steel sector, too. Unfortunately, often they are not recognized and are still generically called ‘failures’, because current systems are not able to analyze them. If damages in terms of production stops and maintenance costs can be immediately quantified, it is more difficult to estimate the seriousness of a data theft. An attack on production departments at high rate of human risk would be disastrously. That’s why our group has accepted the request of Kaspersky, investing heavily in internal technical training, so that BM teams are ready to respond to this growing need, in the interests of our customers’ protection.”

32

››› AUTOMATION

KICS – a new platform for industrial cyber security Process availability, integrity and confidentiality – this is what distinguishes industrial cyber security needs; even the highest quality security solution is effectively useless if it puts the continuity (in some cases integrity) of process at risk. Operational processes are automated and managed by PLC and ICS/SCADA. Because of this reliance on automation, information security is critical. A random virus attack or internal security breach may present a threat not only to the business itself but also to employees and to the environment.

Andrea Tonini: “To guarantee secure plant operations or machine functionalities, it is necessary to combine automation with industrial security.”

To ensure comprehensive protection of industrial plants from internal and external cyber attacks, all levels must be protected, from the plant management level to the field level.

The role of system integrator has changed and evolved to meet the needs of safety and security of manufacturing. BM Automation has been the first system integrator that accepted the challenge of working at three levels.

First, a new method to design and develop the future’s automation systems.

The project is focused on the quality of components, industrial plant performance, cost reduction and production efficiency. Cyber security enhances all those elements in order to supply protected automation systems.

Second, a new approach to modernization and revamping projects. By assisting customers in upgrading their existing – complex and multibrand – systems, plant availability is related to new technologies in order to make existing factories both innovative and secure.

Third, a specific training dedicated to internal staff and technicians to learn the correct use and maintenance of computer-based systems, from the simple access mode to the network management.

BM Automation plays a leading role as consultant for assessment and supplier for the platform KICS in the steel sector because of its deep and complete knowledge of all PLC brands (Siemens, Rockwell, …), new as well old ones.

MPT International 4 / 2016

The solution developed together with Kaspersky Lab is based on an ongoing process involving education, risk identification, recommendation, configuration changes and process improvement, created specifically for industrial environments. “Today, information security of industrial and

network segmentation, and encrypted communication to protect automation networks against unauthorized access…). It allows to increase plant availability and to avoid losses and unexpected costs as well as damage to people and machines, protecting confidential data against manipu-

Typology

Vulnerability

Effects and impact

PLC

extremely high

disastrous

DCS

extremely high

disastrous

SCADA

high

great

others

low

average

Typologies of control systems, their vulnerability and possible effects

critical infrastructure systems is essential. More and more such systems use devices and channels which interact with the outside world. Sometimes, they use machines that were never designed for access from the outside, not to mention the software that was created decades ago and has not been updated ever since. This is a very serious problem because not only the continuity of the production process is at stake, but also the environment and the health of humans. Our solution is able to ensure information security of the technological cycle at every level of automated process control. We also work closely with the manufacturers of automation systems to develop equipment that meets new requirements and standards of cyber security,” said Morten Lehn, general manager of Kaspersky Lab Italy. Kaspersky Industrial Cyber Security has been tested and successfully integrated in many projects, including the petrochemical terminal VARS and the Taneco oil refineries, who have chosen Kaspersky Lab to protect their industrial networks.

lation and ensuring compliance with legal requirements.

About Kaspersky Lab Kaspersky Lab is a global cyber security company founded in 1997. Kaspersky Lab’s deep threat intelligence and security expertise is constantly transforming into security solutions and services to protect businesses, critical infrastructure, governments and consumers around the globe.

The company’s comprehensive security portfolio includes leading endpoint protection and a number of specialized security solutions and services to fight sophisticated and evolving digital threats. Over 400 million users are protected by Kaspersky Lab technologies and 270,000 corporate clients are helped to protect what matters most to them.

About BM Automation BM Automation is a provider of process automation, turnkey industrial plants, motors & drives, power centres, motor control centres, energy automation & electrical substations, industrial IT and special instrumentation packages as well as cyber security. BM Automation offers tailor-made advanced control systems and packages

Conclusion Cyber threats are increasing. Competitiveness is closely related to cyber security. The above described platform specifically developed for critical infrastructures is in fact a coordinated defence strategy covering all levels and consisting of specific security measures working together within the plant network (as access controls, network access protection,

for: ironmaking and steelmaking, continuous casting machines, hot rolling mills for long and flat products, cold rolling mills, non-ferrous rolling mills, processing lines and auxiliary plants as well as systems like water treatment, dedusting and filtration plants. With over 20 million euros of consolidated turnover, BM Automation is the main company of BM Group, ranking among the top suppliers of automation systems.

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34

››› STEELMAKING – AUTOMATION

Two steel works successfully modernized at JSW Steel Vijayanagar works in India Primetals Technologies has successfully commissioned the new process optimization in two steel works in Vijayanagar. New process models have been implemented to improve product quality. Subsystems are harmonized and production sequence is optimized.

Example of operator displays installed at two steel works, SMS-1 and SMS-2, at JSW Steel in Vijayanagar, India

JSW Steel has issued Primetals Technologies the final acceptance certificates for the new process automation system in a total of 25 subsystems in the two steel works at the Vijayanagar site, in the Indian state of Karnataka.

At the steel works SMS-1, new process automation systems were installed for the following plants: ▪ two hot metal pre-treatment stations, each with a capacity of 100 metric tons, ▪ three 100 metric tons hot metal desulphurization stations, ▪ two ladle furnaces, each with a tapping weight of 135 metric tons, and ▪ four single-strand continuous slab casters.

The existing basic automation system was also modernized in one of the cast-

Primetals Technologies, Ltd., a joint venture of Siemens, Mitsubishi Heavy Industries and Partners; London, UK Contact: www.primetals.com E-mail: rainer.schulze@primetals.com MPT International 4 / 2016

ing machines. At the steel works SMS2, the process optimization systems of ▪ seven hot metal desulphurization stations and ▪ four ladle furnaces were modernized.

Both steel works have been equipped with a ladle tracking system and central production monitoring. The scope of services also included the engineering and the supply of all the hardware and standard software, as well as the computer networks for both steel works. A user-friendly HMI system simplifies the operation of all plants.

Some parts of the new process automation are web-based and allow selective data access via the company intranet or the Internet. All the production and process data are archived for later evaluation, and can be analyzed in an extensive reporting system.

The integrated automation solution enables production and process data to be exchanged seamlessly between different units, and all subsystems to run with consistently optimized coordina-

tion. JSW Steel can now increase production and further improve product quality with the aid of optimized process sequences. The individual units were commissioned in stages within a tight schedule less than twelve months after the contract was signed.

JSW Steel is India’s leading private steel producer, and has an installed annual production capacity of 14.3 million metric tons. Of this total, ten million metric tons are produced alone by the Vijayanagar steel works in Toranagallu, in the state of Karnataka. The company currently has six plants in India: Vijayanagar in the state of Karnataka, Salem in Tamil Nadu, Tarapur in Vasind, and Kalmeshwar and Dolvi in Maharahstra. JSW Steel is part of the JSW Group, which also runs a plate and pipe plant in the USA.

Reference [1] BOF plant started operation at JSW Steel Vijayanagar works in India. In: MPT International, 1/2016, p. 28

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36

››› INGOT CASTING

Ingot optimization in terms of shape, head and insulation In order to be able to meet the constantly increasing demands on both product quality and cost reduction, Czech steel producer Trinec Iron and Steel Works recently decided to modify their entire ingot casting line to optimize the overall process. The engineers KDYH DFKLHYHG D VLJQLƂFDQWO\ LPSURYHG LQJRW FDVWLQJ SURFHVV WKDW PHHWV FXUUHQW TXDOLW\ requirements and saves production time and resources.

Trinec Iron and Steel Works (Czech: Tāinecké železárny/TŽ) is the biggest steel producer in the Czech Republic – an integrated iron and steel works with a history dating back to the early 19th century. At present, their products are exported to more than 60 countries all over the world, covering the production of rail, wire rods, SBQ long products and semi-finished products. TŽ is also well known for their cast ingots.

Reliable and stable production processes and high quality and cleanness of all ingot products are constant requirements. In order to optimize production, TŽ recently decided to revise its entire ingot casting line. Wanting to manage the revision of the complex production processes most effectively, TŽ chose the latest release of MAGMA5, a software which offers autonomous optimization and tools for effective evaluation and assessment.

For the investigation of the impact of possible variations of the ingot body, head and insulation, a combination of design of experiments and genetic algorithms was used. Also, the layout of the steel die was open to modification in order to achieve optimal robustness of the casting process and meet the newly defined quality demands.

ing approximately 5 t, cast in a cluster of four. For stripping purposes, the original shape of the ingot resembled the letter “A”, providing inverse conicity. With this shape, TŽ had produced good quality ingots thus far, but to meet new specifications, the centreline macro shrinkage had to be reduced.

The target was to develop an improved casting shape by autonomously simulating a number of possible solutions.

As a first step to identify the causes for the macro shrinkage, the engineers from TŽ analyzed the current production process. They sectioned the ingots and examined the porosity. Then TŽ subsequently modified the steel die

Approach to reducing macro shrinkage TŽ first made examinations with a slim, tall, cylindrical steel ingot weigh-

Petr Kotas, MAGMA Gießereitechnologie GmbH, Pardubice, Czech Republic; Bohuslav Chmiel, Trinec Iron and Steel, Czech Republic Contact: www.magmasoft.de, www.trz.cz E-mail: info@magmasoft.de

MPT International 4 / 2016

Original casting design

and positioned five thermocouples along the height of one of the four ingots, allowing for precise temperature measurements during the casting process. These temperature recordings were then used to obtain optimal height-dependent heat transfer coefficients for MAGMASOFT®, matching the measured and calculated temperature curves.

Based on this agreement between simulation and reality, the next step was to set up an autonomous optimization following multiple objectives.

To identify the best set of process parameters and geometrical features, two objectives were defined:

INGOT CASTING ▪ minimum shrinkage porosity and ▪ minimum centreline micro porosity.

Since a casting free of macroscopic shrinkage was required according to the new specifications, the allowed porosity in each of the evaluation areas of the ingot body was set to 0%. In total, eleven independent casting and geometric design variables were used in the optimization procedure, covering the flow profile during teeming, the dimensions of the ingot, its head, the insulating sleeve as well as the steel die and the pouring temperature. MAGMA5 was then able to autonomously generate a first set of designs and eight following generations.

The variations created and tested were comprehensive, and they covered options that had not been exploited by the engineers by practical trials in the past.

‹‹‹

37

Empty

5.000 4.643 4.286 3.929 3.571 3.214 2.857 2.500 2.143 1.786 1.429 1.071 0.714

+PVGTOGFKCT[ ƂPFKPIU The engineers evaluated the analyzed designs in the assessment perspective. According to the ranking, the top five designs led to similar values regarding the objectives, offering the engineers the chance to select the best design out of those five in terms of costs of production.

The evaluation of the main effect diagrams revealed a strong correlation between the height of the ingot head with the centreline and macro porosity. Below a critical height, considerable macroscopic shrinkage porosity and centreline shrinkage are formed in the ingot body. These designs were unacceptable for TŽ and therefore excluded from further assessment.

0.357 0.000

Centreline macro porosity as calculated [%] and visually analyzed

Further proceeding and results For a final conclusion, the engineers evaluated the effects of the remaining geometrical parameters. The best de-

Height of the ingot head

Height of the ingot head 100.00

Centreline shrinkage

100.00

Macroshrinkage

sign features a “V”-shape instead of the formerly used “A”-shape, significantly improving directional solidification. In addition, the new shape of the ingot head is conical and no

50.00

0.0 150.00

250.00

350.00

50.00

0.0

150.00

250.00

350.00

/CKP GHHGEV FKCITCOU KPƃWGPEG QH VJG JGKIJV QH VJG KPIQV JGCF QP OCETQ CPF EGPVTGNKPG UJTKPMCIG MPT International 4 / 2016

38

››› INGOT CASTING Porosity %

longer straight. Together with a modified insulating sleeve, this design provides the best overall results in terms of feeding efficiency. The macro porosity results of this new design are in compliance with TŽ’s requirements. A remaining amount of micro porosity is also within the specification, as previous research had proven that subsequent forging will close this porosity entirely.

At the end of the optimization process, the TŽ engineers had successfully used the means of autonomous optimization to significantly improve the ingot casting process and meet new requirements while saving time and resources.

Microporosity %

Empty

Empty

100.0

0.9403

92.9

0.8731

85.7

0.8059

78.6

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0.4701

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0.2686

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0.2015

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0.0

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5KOWNCVKQP TGUWNVU QH VJG optimal ingot design

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40

››› CONTINUOUS CASTING

The thick-slab caster was inaugurated on 5 July 2016

Dillinger starts production of 500-mm-thick slabs for highgrade heavy plates With the new continuous slab casting machine No. 6 Dillinger presents one of the biggest single investment projects at the site. The new plant commissioned by SMS JURXS ZDV RIƂFLDOO\ LQDXJXUDWHG RQ -XO\ For Dillinger, this project is without parallel. With an investment volume of more than EUR 400 million, the company built the new vertical continuous casting machine No. 6. The biggest single investment at the Dillingen steel works will allow production of the world’s thickest slabs (500 mm).

“With the new continuous casting machine, which has now successfully been put into trial operation, we want to diversify into new dimensions and quality grades and to cover an increas-

AG der Dillinger Hüttenwerke, Dillingen, Germany Contact: www.dillinger.de E-mail: pressestelle.shs@stahlholding-saar.de

MPT International 4 / 2016

ingly advanced product mix. This will further strengthen our position as the leading European heavy plate producer,” said Fred Metzken, spokesman for the management board and chief financial officer of AG der Dillinger Hüttenwerke (Dillinger) during his welcoming address. He added: “This extraordinary machine is a key element of our innovation strategy and a demonstration of our commitment to steel production in the Saar region of Germany.”

Dillinger, founded in 1685, is one of the world’s leading producers of high-grade steel for heavy plates. Dillinger Group employs a total of about 7,400 people and has annual sales of around two billion euros. High-tech plate from Dillinger is used to realize extraordinary and technically sophis-

ticated projects all over the globe, including steel construction, engineering, offshore, and line pipe and boiler construction.

Double-strand vertical casting of extremely large slab dimensions Incidentally, the slab size that can be cast with CC 6 is not the first world record for Dillinger continuous casting technology: the company put itself at the forefront of advanced technology back in 1961 when it launched operation of the world’s first double-strand casting machine for the continuous casting of heavy slabs. The Dillinger continuous casting machine (CCM) No. 5, which started operation in 1998 and underwent modernization

CONTINUOUS CASTING in 2010, is likewise among the most capable machines of its kind holding the current world record in slab thickness with 450 mm.

The design of the new CCM No. 6 essentially corresponds to that of the CCM No. 5. As early as in 2011, Dillinger placed the order for the supply of this plant with SMS group. The contract comprised the casting platform, mould, hydraulic oscillator, strand guide system, edge-controlled secondary cooling and position-controlled segment adjustment as well as the pinch-roll units for the dummy bar and hot strand.

Also included in the supply scope was the complete X-Pact® electrical and automation package including commissioning. In cooperation with the R&D departments of Dillinger, SMS group developed a customized hydraulic adjustment system for the pinch rolls.

In order to produce slabs with optimized internal quality, the continuous caster is equipped with dynamic soft reduction and load compensation control. The adjustment mechanisms otherwise customary in continuous casters have been extended and sophisticated on the basis of experience from rolling technology. This results in high soft reduction rates, as successfully implemented earlier in the Dillingen CCM No. 5.

Dr. Bernd Münnich, chief technical officer concludes: “The continuous

41

Cut-to-length slab taken off from the new vertical slab caster

caster No. 6 takes our continuous casting technology to a new level. With its unique combination of state-of-the-art system and process technology, we will be able to produce the world’s largest

slab dimensions – up to 2,200 mm x 500 mm. This input material of unsurpassed quality will be processed in both of Dillinger’s heavy-plate hot rolling mills.”

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş MATERIAL FLOW LOGISTICS

Hyundai Steel installs new crane positioning system in the rolling mill complex Even in the harsh environment of the rolling mill, Hyundai Steel is able to accurately track the crane and steel positions in real time to avoid downtimes and make logistics DQG SURGXFWLRQ SURFHVVHV PRUH HIĆ&#x201A;FLHQW PRUH FRVW HIIHFWLYH DQG VDIHU To precisely track the positions of the raw materials to the finished products. overhead cranes, as well as of the raw Overhead cranes transport the steel durmaterials and steel coils, Hyundai Steel ing the various stages of production. implemented a robust, fail-safe and accurate positioning and telemetry solution. The Korean steelmaker commisCrane tracking with robust sioned Symeo GmbH to localize 28 24 GHz wireless sensors The robust, fail-safe and highly-accucranes at the companyâ&#x20AC;&#x2122;s special steel rolling mill in Dangjin, South Korea. rate positioning and telemetry solution In an environment where dirt, dust, implemented by radar and GNSS expert vibrations and heat complicate reliable crane positioning by means of common technologies such as laser systems, Hyundai Steel now uses Symeo´s robust radar positioning systems, which work independently of such environmental conditions. The tracking solution, already implemented at Dangjin, is not only the first joint project of Hyundai Steel and Symeo, but also the first major project involving the new LPRÂŽ-1D24 wireless system from Symeo, which was launched in 2015.

As a part of the Hyundai-Kia Motor Group, Hyundai Steel is heavily engaged in the development of next generation steel for future automotive applications as well as for the ship building industry. In the special steel rolling mill in Dangjin, South Korea, prodSymeo´s robust LPRŽ -1D24 radar sensor ucts such as hot rolled, cold rolled and galvanized steel sheets are manufactured by the one-stop production system, which Symeo GmbH precisely tracks the pointegrates all production processes, from sitions of the overhead cranes, the raw materials and the steel products. It is essential for the operations at Hyundai Steel to accurately track the crane Symeo GmbH, Neubiberg, Germany and steel positions on a continuous baContact: www.symeo.com sis and in real time, even in the harsh E-mail: sabrina.kaspar@symeo.com environment of the rolling mill. This MPT International 4 / 2016

makes logistics and production processes more efficient and safer, and avoids downtimes, which has a very positive effect on cost effectiveness.

Symeoâ&#x20AC;&#x2122;s LPRÂŽ-1D24 wireless sensors use the 24 GHz radio band without interference from WiFi networks. The robust system reliably detects the X and Y crane positions even in an environment where dust, dirt, extreme temperatures and vibrations are common. Thanks to the integrated diversity antenna into the sensor and the use of several parallel measuring channels, multipath effects are eliminated, which may cause inaccurate measurements. A user-friendly web interface simplifies installation of the individual sensors.

Symeo positioning solutions are deployed worldwide in the steel industry. More than 80 steel companies worldwide have already equipped over 800 cranes and vehicles with indoor and outdoor radar- and satellite-based Symeo positioning solutions. The real-time locating systems (RTLS) are used for applications such as coal handling, hot slab handling and rolling operations in order to improve the quality of production, logistics and automation processes.

With its LPRÂŽ products, Symeo offers a wireless-based, real-time-capable measurement system that is ideally suited for industrial applications. Symeo has several years of experience in the development of cost-effective, customer-specific industrial solutions on the basis of LPRÂŽ and GNSS positioning technology (GNSS = global navigation satellite systems GPS, Glonass and Galileo).

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş SPECIAL EQUIPMENT

Lubricating the steel mill for RQVGPVKCN GPGTI[ GHĆ&#x201A;EKGPE[ EQUV savings Advanced lubricants have the potential to enhance equipment functionality and lifespan, UHGXFH HQHUJ\ FRQVXPSWLRQ DQG GHOLYHU FRVW EHQHĆ&#x201A;WV %\ VHOHFWLQJ WKRVH ZLWK SURYHQ HQHUJ\ VDYLQJV EHQHĆ&#x201A;WV VWHHO PLOO RSHUDWRUV FDQ UHDOL]H FRVW VDYLQJV The steel industry is under growing pressure to increase energy efficiency in its operations and there is a growing body of evidence showing its positive impact on a companyâ&#x20AC;&#x2122;s bottom line.

In the steel industry, with its enormous, high-temperature operations and roundthe-clock production, energy consumption plays such an important role that even small reductions can have a significant impact on overall energy costs.

Advanced lubricants, despite accounting for just 1 or 2% of operational costs, have the potential to enhance equipment functionality and lifespan, reduce energy consumption, and deliver cost benefits. Advancements in lubricant technology have seen significant breakthroughs in extending equipment life compared to conventional mineral oils, lengthening oil drain intervals and improving the energy efficiency of equipment [1].

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To ensure efficient operations and help equipment continue working long-term, steel mill operators rely on a number of lubricants, so it is important to identify the most effective oils that can be applied to the correct areas of the mill. By selecting those with proven energy savings benefits steel mill operators can realize cost savings.

Gear oils Ensuring lubrication of gears, allowing equipment to operate effectively in a range of conditions, is an important contributor to energy efficiency in the steel plant. Lubricants that protect gear-driven equipment and allow it to perform for extended periods must withstand increasingly harsh environments.

While offering protection against these conditions, the low traction and high viscosity index in the Mobil SHCâ&#x201E;˘ 600 series of synthetic gear oils reduce power consumption and energy costs compared with conventional mineral oils. The technology used allows up to 3.6% efficiency compared with the ref-

erence when tested in a worm gearbox under controlled conditions [2].

An example of the energy efficiency benefits of synthetic gear oils is Xinyu Iron & Steel Co, which switched from a mineral oil to a synthetic, Mobil SHC 630. The goal was to improve energy efficiency, as well as extending oil drain intervals and reducing wear. After switching to the new oil, the company was able to lower the average working temperature of the gearboxes by 6.7° Celsius and decrease the electric motor current by 3.2%. This resulted in total annual savings of US$1,800 for one gearbox [3].

In the paper industry â&#x20AC;&#x201C; which uses similar gearboxes to the steel industry â&#x20AC;&#x201C; another company, Smurfit Kappa in the UK, was able to improve its energy efficiency through the temperature reduction benefits of Mobil SHC 632.

ExxonMobil engineers recorded temperature and power usage data from the gearbox with both the mineral and synthetic grades over a six-month period.

The gearbox was operated at a constant load throughout this reference period.

Mobil SHC 632 greatly improved the

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46

››› SPECIAL EQUIPMENT

energy efficiency of Smurfit Kappa’s gearbox operation. The lower traction coefficient and superior viscometrics of the fluid meant that an average of 6.5% less energy was required to power the gearbox, representing a significant reduction in energy usage over the previous mineral grade. The improvement in operation generated an annual saving for Smurfit Kappa of US$4,000 from just one gearbox [4].

Lubricating hydraulic systems Hydraulic systems, which are used throughout the steel manufacturing process, amount to roughly 25% of all oil used in the steel mill. It is clear then that there is a huge opportunity to make energy savings through the choice of lubricant. In addition to this, by protecting components and minimizing unscheduled downtime, steel mill operators can improve productivity.

To help reduce unscheduled downtime, contamination control is a key component of a hydraulic oil. Contamination may be generated in the system or externally, meaning a hydraulic oil must demonstrate excellent oxidation resistance and filterability to avoid lubrication and component failures, frequent oil changes and sub-optimal functionality leading to inefficient energy usage.

Alongside its exceptional oxidation resistance and filterability, the Mobil DTE 10 Excel™ series of hydraulic oil can help to reduce hydraulic system energy consumption by up to 6% compared to standard mineral hydraulic oils [5].

Improved hydraulic efficiency benefits can translate to increased machine productivity and/or reduced energy consumption. The increased hydraulic efficiency, system cleanliness and durability can help manufacturers extend oil drain intervals and optimize equipment protection decreasing both machine maintenance and product disposal costs.

longevity in such conditions, and allow for cost-effective energy usage.

In extreme temperature steel applications, poor grease performance is possible due to degradation resulting from thickener and base oil oxidation, or the loss of base oil from grease bleed and evaporation. A factor that can improve the ability of a grease to provide lubrication at higher temperatures is oxidative resistance. Oxidation is a chemical reaction that occurs between oxygen and the in-service lubricant, and is accelerated in high temperatures.

A grease’s oxidation rate generally doubles with every 15°C rise in temperature above 60°C, causing the lifetime of the grease to halve and increasing the re-lubrication interval. Typically, greases with synthetic base oils can provide a wider operating temperature range than conventional, mineral oil-based greases. For example, the Mobil SHC Polyrex™ series is a range of high performance, synthetic bearing greases that uses advanced poly urea thickener technology in order to achieve excellent high-temperature performance up to 170°C. Even at these extreme temperatures, the polyurea thickener technology resists oxidation and loss of structural stability allowing re-lubrication intervals to be extended while maintaining equipment protection when compared to mineral oil-based greases. This carefully balanced combination of thickener, base oils, and additives yields a

grease with excellent load carrying capabilities and rust protection.

Used oil analysis Proactive maintenance programmes are an essential way to achieve production goals by monitoring the condition of equipment and oil. One maintenance programme being implemented is used oil analysis, a series of tests that determine the condition of equipment components and in-service lubricants.

Alongside the use of high quality lubricants, oil analysis helps maintenance professionals extend equipment component and lubricant life, provide early warning signs of contamination and minimize unscheduled maintenance.

With its SignumSM programme, ExxonMobil provides its customers with detailed oil analysis that offers a report on the trends of equipment, lubricant and contaminants in the industry. Steel operators can monitor oil quality and change oil at the optimal time to ensure efficient operation of their equipment, reduce scheduled downtime and improve productivity.

Leading steel mill operators worldwide are paying close attention to their choice of equipment lubricants.

The good news is that at only a fraction of operational costs, with proper lubrication, the resulting savings from well-functioning machinery can be considerable.

Supplementary notes [1] Energy efficiency relates solely to fluid performance when compared with conventional reference oils of the same viscosity grade in hydraulic applications. For example, Mobil DTE 10 Excel™ is able to achieve up to 6% efficiency compared with the reference when tested in a hydraulic system under controlled conditions. Efficiency improvements vary based on operating conditions and application.

[2] Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in circulating and gear applications under controlled conditions. Efficiency improvements will vary based on operating conditions and applications.

[3] This Proof of Performance is based on the experience of a single customer. Actual re-

Managing high temperatures with grease

sults can vary depending upon the type of equipment used and its maintenance, op-

Steel mills are renowned for their high-temperature operating environments. Alongside an obvious upfront energy cost, this puts even more pressure on components. Accordingly, operators require lubricants including greases that are specifically designed to ensure consistent performance and

[4] This Proof of Performance is based on the experience of a single customer. Actual re-

MPT International 4 / 2016

erating conditions and environment, and any prior lubricant used. sults can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.

[5] Energy efficiency relates solely to fluid performance when compared with conventional reference oils of the same viscosity grade in hydraulic applications. The technology used is able to achieve up to 6% efficiency compared with the reference when tested in a hydraulic system under controlled conditions. Efficiency improvements vary based on operating conditions and application.

STRIP PROCESSING

‹‹‹

47

Chinese Baotou Steel modernizes cold strip production facilities for improved quality of automotive strip products The new cold rolling mill at Baotou Iron & Steel Group (BISG) – Rare Earth Steel Plate &R /WG PDQXIDFWXUHV UHƂQHG FROG VWULS SURGXFWV IRU DXWRPRWLYH DSSOLFDWLRQ DIWHU successful commissioning of an annealing plant supplied by SMS group.

The commissioning team of SMS group in front of the 6-high skin-pass mill

The first of two annealing lines, which SMS group supplied to Baotou Steel (BISG Baotou Iron & Steel Group – Rare Earth Steel Plate Co. Ltd.), has been commissioned according to schedule and has annealed the first coil as planned. In October 2013, Baotou Steel had awarded SMS group

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

the order for the supply of main plants for the new cold rolling mill No. 2, which the company is building in Inner Mongolia, actually: ▪ two continuous annealing lines and ▪ two 6-high inline skin-pass mills.

The second annealing plant will be started up also this year. Both annealing lines will be of almost identical design. Once on stream, the two annealing lines will be able to produce more than 1.5 million tons of refined cold strip per year. The majority of the material will be used in the automotive

industry. The product range includes steel grades for exposed car body parts as well as high-strength steels such as dual phase steel and TRIP steel with tensile strengths of up to 980 MPa. The new lines are designed to process strip with a width range between 830 and 1,580 millimetres and thickness range from 0.25 to 2.5 millimetres. The maximum process speed amounts to 400 m/min. Each line has a designed annual production capacity of 630,000 tons.

In addition to the design of the mechanical equipment and the manufacture of various core components, the SMS group’s supply package also included the supervision of part of the local manufacturing scope and of equipment installation and commissioning. EMG Automation supplied the complete strip control system and the quality assurance systems SORM (for optical roughness measurement) and IMPOC (for non-contact magnetic tensile strength and yield point measurement).

The inline six-high skin-pass mills are technological cornerstones of the strip processing plants. The mill stands feature CVC® plus technology that ensures compliance with the contractual strip flatness requirements. The extended bending system (EBS) for the work rolls provides for the targeted skin-passing of soft IF steels even at low rolling forces.

The two new strip processing plants – annealing lines with inline skin pass mills – form integral parts of the new cold rolling mill No. 2, which Baotou is building in Inner Mongolia. The recent commissioning of the first annealing line is an important milestone of the overall project.

MPT International 4 / 2016

48

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TUBE MAKING

With its new JCOEÂŽ NCTIG FKCOGVGT RKRG OKNN %QTKPVJ 2KRGYQTMU KU PQY EQORNGVKPI KVU RTQFWEVKQP ECRCEKVKGU KP VJG Ć&#x201A;GNF QH welded tubes and pipes

Worldâ&#x20AC;&#x2122;s most modern largediameter pipe mill to be expanded In 2015, Corinth Pipeworks has started up production of 18-m longitudinally seamwelded large-diameter pipes. By investing in a new pipe welding machine, the Greek company has expanded its product range to satisfy the growing global demand for highstrength pipes for the production and transit of oil and gas.

Corinth Pipeworks (CPW) from Athens, Greece, is one of the worldâ&#x20AC;&#x2122;s leading manufacturers of steel pipes, which are used in energy projects, as well as for hollow sections of large dimension applied in the construction sector. With a history of nearly half a century and significant investments in state-of-theart equipment, Corinth Pipeworks is a renowned supplier for oil and gas

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

MPT International 4 / 2016

companies, as well as for international construction companies with extensive know-how in the implementation of demanding projects all over the world.

In 2013, Corinth Pipeworks commissioned SMS group to supply an 18-m JCOEÂŽ pipe mill for longitudinally seam-welded large-diameter pipes. Only two years later, the first pipe was welded on the new mill. The large-diameter pipe mill has been designed for a capacity of 400,000 tons of pipes with outside diameters between 16â&#x20AC;? and 56â&#x20AC;? in wall thicknesses of up to 40 millimetres and lengths of up to 18.3 metres.

With the fully automated JCOEÂŽ pipe forming press from SMS group, Corinth Pipeworks is able to meet

the high quality requirements for high-strength pipes. Pipe dimensions with high wall thicknesses and small pipe diameters can also be produced in economic quantities.

Corinth Pipeworks already successfully operates a high-frequency induction pipe welding machine and a two-step spiral pipe mill from SMS group.

The pipes produced by Corinth Pipeworks are earmarked for future use by the pipline companies for supplying energy to the Mediterranean region, Gulf of Mexico, Latin America, West and East Africa and the North Sea. The new large-diameter pipe mill has immediately started production, since Corinth Pipeworks has been commissioned by Trans Adriatic Pipe-

TUBE MAKING

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line AG (TAP) to supply large-diameter pipes for a total length of approximately 495 km, for the onshore part of the pipeline across Greece. The contract for approximately 270,000 tons of 48â&#x20AC;? diameter line pipes was awarded in a form of cooperation with the Japanese Marubeni-Itochi Steel group. Delivery of the pipeline project will begin in 2016 and is expected to be completed in 2017. The scope of supply comprises both, longitudinally welded pipes and helically welded pipes as well.

First use of ShapeView system worldwide The new state of the art JCOEÂŽ largediameter pipe mill from SMS group enables Corinth Pipeworks to comply with the high technical requirements and to adhere to strictest environmental regulations and challenging applications, as required nowadays by the major oil and gas companies in the offshore industry. The plant is equipped with the new Shape Automation System that precisely controls the forming process using special sensors. Possible negative influenc-

es associated with the starting material or the operator, are thereby minimized.

The system comprises three modular sub-systems, â&#x20AC;&#x153;ShapeBaseâ&#x20AC;?, â&#x20AC;&#x153;ShapeViewâ&#x20AC;? and â&#x20AC;&#x153;ShapeControlâ&#x20AC;?, and is aimed altogether at achieving optimized forming of longitudinally seam-welded largediameter pipes during the JCOÂŽ process. â&#x20AC;&#x153;ShapeViewâ&#x20AC;? has been implemented at Corinth Pipeworks for the first time in the world offering optimized real-time control of the forming process. Thus, the new large-diameter pipe line is the most modern in the world.

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MPT International 4 / 2016

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

Installation of electromagnetic stirrer provides improved EAF operation STEELMAKING In the summer of 2014, an ABB ArcSaveÂŽ electromagnetic stirrer was installed on a 90 t spout tapping furnace for stainless steel production, delivering a wide range of process improvements including the successful elimination of furnace bottom skulls. Outokumpuâ&#x20AC;&#x2122;s stainless steel meltshop in Avesta, Sweden, specializes in the production of steel grades with a high chromium content. The addition of ferro-chromium during the arc furnace process necessary to produce these steel grades has the disadvantage that with a higher melting point than the surrounding melt, the ferro-chromium may settle on the furnace bottom to form skulls. At Outokumpu, this used to lead to variations in the tapping weight, higher electrode and energy consumption and even practical difficulties when charging the scrap baskets.

Outokumpu chose the ArcSaveÂŽ electromagnetic stirrer (EMS) to optimize the performance of their electric arc furnace operation. A specific stirring profile, controlling stir-

ring intensity, duration and direction, was created to focus ArcSaveâ&#x20AC;&#x2122;s improved stirring power on Outokumpuâ&#x20AC;&#x2122;s desired process improvements. A new lower furnace shell made of non-magnetic stainless steel was fitted and, to exploit the full potential of ArcSave, a new temperature robot was installed. The new system provides a more stabilized arc, more homogeneous steel bath, enhanced slag-metal reaction, more consistent EAF tapping conditions and argon oxygen decarburization (AOD) operation. Solving the furnace bottom skull problem has resulted in smoother, more predictable EAF operations at lower costs. The average savings due to the installation of the new system include 3 to 4% less electricity consumption, 8 to 10% less electrode consumption, tapping temperature hit ratio 100%, tapping weight hit ratio 93% (increase of 24%) and 70% less N2 consumption.

Contact: www.abb.com

Production milestone MATERIAL HANDLING Combilift Ltd, specialist manufacturer of multidirectional forklifts, straddle carriers and other handling solutions, recently celebrated a milestone in the companyâ&#x20AC;&#x2122;s history. The 30,000th Combilift to roll off the production lines in Monaghan, Ireland, has been sold to Haslinger Stahlbau. The company processes an annual amount of around 40,000 t of steel to realize projects such as production facilities, logistics centres, aircraft hangars, bridges, sports complexes as well as industrial power plants. The new C14000 is its eighth Combilift. A variety of models from a 4 t capacity Combi-CB counterbalance design truck and 8, 12 and 14 t models from the Combi-C series are in operation across its sites to ensure safe and productive handling and storage of its in part very heavy loads.

Contact: www.combilift.com

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Carbon-dioxide-free ironmaking project ENVIRONMENTAL PROTECTION The Swedish Energy Agency will contribute SEK 6.7 million to support the pre-feasibility study in the joint initiative of SSAB, LKAB and Vattenfall for carbon-dioxide-free ironmaking. The initiative is split into three phases beginning with a pre-feasibility study, which will analyze all the conditions and which will continue until the end of 2017. This will be followed by a more concrete research and development programme in a pilot study, which will last until 2024 before finally progressing to demonstration plant trials, which will continue until 2035.

MPT International 4 / 2016

In early April this year, SSAB, LKAB and Vattenfall announced their joint initiative to solve the carbon dioxide problem in the Swedish steel industry. By using hydrogen in the direct iron ore reduction process instead of blast furnaces using coal and coke, the goal is to create a steel process that releases water instead of carbon dioxide. The success of the project is also an important contribution to the drive to make Sweden fossil free by 2045.

Contact: www.ssab.com

Grinding mill for granulated blast furnace slag IRONMAKING RESIDUES Loesche will supply a vertical roller mill to Yoo Gyeong CM Co. in South Korea. The mill will be used to grind granulated blast furnace slag at a rate of 90 t/h at 4,500 Blaine. The gearbox will have a power output of 2,800 kW. The scope of supply will also include the filter, fan and hot-gas generator.

Yoo Gyeong CM Co. owns gravel works which it has equipped with its own cement mixing and loading terminals. The company has been purchasing ground slag to operate its plants. By using the Loesche vertical roller mill, it will be possible to use the cheaper granulated slag in future.

All the mill equipment will be put into operation as early as in October 2016.

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Liquid level transmitters MEASURING EQUIPMENT MTS Sensors, a division of MTS Systems Corporation, introduces a new series of its Level Plus® liquid level transmitter product line. The new series targets hazardous area applications in the oil and gas, as well as chemical and mining industries. All models in this series feature an integral display and have Intrinsically Safe approval under NEC, CEC, ATEX, and IECEx. This new offering includes Tank Slayer®, RefineME® and chambered models, based on MTS Sensors’ proprietary Temposonics® magnetostrictive sensing technology. Once installed and calibrated there is no requirement for .GXGN VTCPUOKVVGT KP EJCODGTGF XGTUKQP

Single coke oven chamber pressure control Ideal pressure conditions Significant reduction of emissions Retrofit of coke ovens

Coal and Coke Laboratory Raw material evaluation & consultancy Coal blend optimisation Prediction of coke quality through modelling Large scale carbonisation tests Quality control & assurance www.dmt-group.com · INE@dmt-group.com Phone +49 201 172-1563

Earth. Insight. Values.

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

scheduled maintenance or recalibration work to be carried out. As a result running costs can be significantly reduced.

Designed for use in bulk storage aboveground tanks, the Level Plus Tank Slayer features 3-in-1 measurement of the product level, interface level and an average product temperature that is determined from up to 16 different points. It is highly suitable for monitoring inventory levels of refined fuels, crude oil, fuel oil, ethanol and other expensive liquids. It comes with a flexible hose that is available in lengths up to 22 m.

This is complemented by the Level Plus RefineME level transmitter aimed at shorter process tanks. RefineME has the same 3-in-1 measurement capability but offers a wider variety of process connections, such as ANSI and DIN flanges, as well as wetted parts including stainless steel, Hastelloy C and Teflon. An ex-

tensive offering of mechanical packages enables this device to be used in numerous applications from reactors and alkylation tanks to additive storage tanks and sump level monitoring. It is equipped with a rigid pipe that is available in lengths up to 7.6 m.

The Level Plus Chambered is especially optimized for incorporation into magnetic level gauge (MLG) systems, such as those found throughout refineries and chemical plants as well as boilers. The transmitter is mounted externally to the MLG to provide remote feedback in addition to the local visual measurement. The device is compatible with most MLG manufacturersâ&#x20AC;&#x2122; chambers currently on the market. %QPVCEV YYY OVUUGPUQTU EQO

Strip stabilization and air knife integrated in one system STRIP COATING As part of the project for the modernization of hot-dip galvanizing line 2 at Voestalpine Stahl in Linz, Austria, EMG Automation is installing a strip stabilization system fully integrated in a zinc air knife manufactured by Duma-Bandzink. The strip calming results and the increased added value that can be achieved through the use of an electromagnetic strip stabilization system depend significantly on the optimum arrangement of the strip stabilization system in relation to the zinc air knife. In other words, the better the EMG eMASSÂŽ system is integrated into the air knife system and the closer the strip stabilization system is located to the air knife lips, the better the to be expected results will be.

The combination of these technologies offers advantages such as optimum synergy between air knife design and strip stabilization, ability to achieve the highest and most accurate zinc coating results, creation of optimum conditions for a closed control circuit and enhanced control of the overall coating process. It also provides an optimum technical solution in terms of maintenance and air knife lip cleaning, the possibility to integrate the EMG eBACS strip edge sensors for controlling the strip edge masks and, last but not least, a significant noise reduction.

The proximity of the EMG eMASSÂŽ system to the air knives enables direct conclusions to be drawn with regard to the strip

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position and shape between the air knife lips, thereby allowing corrections to be made to the position of the air knife without delay. Furthermore, the integrated inductive edge mask control sensors provide additional information regarding the lateral position of the strip. The combined system is a logical development of the EMG eMASSÂŽ strip stabilization system and will be offered in parallel to separate systems that are either installed on the air knife or on separate supporting structures. %QPVCEV YYY GOI CWVQOCVKQP EQO

Increased casting thickness for austenitic stainless steel slabs CONTINUOUS CASTING AM Industeel Belgium has produced a 355-mm-thick slab, supposedly the thickest austenitic stainless steel slab ever cast, on a caster revamped by Danieli. The renewed plant is designed to process special steel grades, such as carbon-manganese HIC-S355, A387 chrome-molybdenum grades for boilers, HLE grades and stainless steel grades, austenitic grades 304 â&#x20AC;&#x201C; 316 and duMPT International 4 / 2016

plex steels. New equipment mainly comprised a mould for casting 355 mm x 2,200 mm slab sizes and a segment 0. The modification of the existing caster segments included the supply of all related clamping cylinders and three horizontal withdrawal segments. Danieli also supplied the new segment support frames and removal guides for the new segments as well as the whole hydraulic system for segments

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1 to 12. The upgraded plant also features Danieli Automation technological packages, such as Q-CORE and Q-PULSE for dynamic soft reduction hydraulically controlled via position transducer and Q-COOL for high-efficiency strand temperature control. This revamping project increased the production capacity and broadened the product range to include larger sizes. The newly installed soft reduction system also improves the product quality. %QPVCEV YYY FCPKGNK EQO

Absolute encoders VHSG 2(+ "+ BDQSHĂ&#x2013;B@SD MEASURING EQUIPMENT Johannes Huebner Giessen has launched a new series of absolute encoders with SIL CL3 certificate for deployment in applications requiring certified compliance with functional safety requirements. The new encoders have been specially developed for deployment in heavy industry applications of safety integrity level class 3, as found in steel and rolling mills, in mining, in cranes and in port systems. Features such as a thick-walled aluminium casing, large ball bearings with high dynamic load rating and corrosion-resistant material with an additional protective coating make the encoders ideal measuring devices for heavy duty applications in operating temperatures from -25°C to +70°C. All devices are equipped with secure bolted connections to prevent them working loose under vibration loads as well as with feather keys for form-fit shaft connections. The available degree of protection up to IP66 and

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

the quality of the materials used mean the absolute encoders are also suitable for deployment in salt-laden environments.

The encoders come in three versions: with solid shaft of 14 mm diameter as a flange and a flange-foot version to mount the encoder using a coupling, as well as with a continuous hollow shaft of 20 mm diameter to mount the encoder directly onto the drive shaft. The total resolution is 28 bit, 13 bit single-turn

resolution (8,192 steps/revolution) and 15 bit multi-turn resolution (32,768 rotations). An additional incremental output offers 4,096 pulses. As the encoders are certified as functionally safe, the user is no longer required to provide separate verification of the functional safety of the position sensors. %QPVCEV YYY JWGDPGT IKGUUGP EQO

Portable ED-XRF instruments for reliable coat-weight measurement STRIP PROCESSING LINES The consistency of coating thickness â&#x20AC;&#x201C; commonly referred to as â&#x20AC;&#x153;coat weightâ&#x20AC;? â&#x20AC;&#x201C; is vital to successful production quality and requires advanced analytical techniques. Depending on substrate and customer requirements, analytical instruments might be needed to detect and measure the thickness of a wide variety of coating materials. X-ray fluorescence (XRF) spectroscopy is an excellent technology for coat-weight analysis and can be performed with instruments, ranging from handheld systems to laboratory-based wavelength-dispersive

X-ray spectroscopy (WD-XRF) instruments. Laboratory instruments are expensive and can delay process schedules, as samples must be taken from the line to the lab. Handheld XRF systems are popular but have many practical and analytical drawbacks.

Now, a new generation of portable energy dispersive X-ray fluorescence (EDXRF) instruments launched by Spectro Analytical Instruments provides performance comparable to laboratory-based systems and offers the flexibility to be easily moved to various process points to provide high-accuracy quality assurance and quality con-

trol for producers of steel or aluminium sheets. The new instruments such as the Spectroscout portable analyzer have excellent analytical range and precision exhibiting very low limits of detection. Using this instrument at-line has been shown to provide reliable coat-weight measurement for a wide range of coating materials, including iron, zinc, manganese phosphate, zirconium, chromium and titanium. Spectro provides more details about this application in a brief downloadable at http://goo.gl/CwVs4S. %QPVCEV YYY URGEVTQ EQO

Modular, rotating gauges for high-speed dimension measurement LONG PRODUCTS Zumbach Electronics introduces new, modular additions to their line of Steelmaster rotating gauges. The new SMR gauges rotate continuously at 60 or 100 rpm. Up to three ODACÂŽ laser heads take 2,000 measurements per second and head in a fully synchronized process. This results in up to 10 complete profiles per second. Alternatively, the SMR can operate in static, orientable mode with 2,000 diameter or dimension measurements per second in each direction. The mechanical concept of the gauges is extremely simple and robust. There are no wear parts, no collector rings, no brakes, etc. The transmission of power and signals to and from the laser heads is fully contactless.

Many standard and special software features are provided, including EPM function for true section display (also with polygonal and asymmetric shape deviations), special functions for 3-roll mills, and head and tail scrap calculation. The new gauges make for faster start-ups, reduce scrap, ensure tighter tolerances and display true shape. They are suitable for hot and cold processes, products such as rod, bar, rebar, rounds, squares, flats, hexagons and other sections in a diameter range from 4 to approx. 370 mm. %QPVCEV YYY \WODCEJ EQO MPT International 4 / 2016

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TECHNICAL INNOVATIONS

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â&#x20AC;&#x153;With sustainability an increasing focus for steel mills, in what ways can lubricants help contribute to this effort?â&#x20AC;?

In the steel industry, with its huge, high-temperature operations and round-the-clock production, advanced lubricants have the potential to enhance equipment functionality and lifespan, reduce energy consumption, and deliver cost benefits.

Advancements in lubricant technology have seen significant breakthroughs in extending equipment life compared to conventional mineral oils, lengthening oil drain intervals and as a result reducing the amount of oil used â&#x20AC;&#x201C; and wasted â&#x20AC;&#x201C; and in some conditions reducing energy input required.

One of our customers â&#x20AC;&#x201C; an insulation production company in Russia â&#x20AC;&#x201C; was able to reduce oil consumption by 1.5 times. This was achieved by switching to Mobilgrease XHPâ&#x201E;˘ 222 which has better structural stability compared to the previous grease being used. As a result leakages and contamination of the separator by abrasive material stuck to the leaked grease were eliminated.

Response from Jarmo Vihersalo, ExxonMobil Industrial marketing advisor EAME and MPTâ&#x20AC;&#x2122;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.

Š Utz Peter Greis, Dßsseldorf

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş LITERATURE SERVICE Energy saving guide Downloadable, English ExxonMobil and ENER-G have created a free guide to energy measures for the steel industry. The guide provides advice and practical recommendations on how managers can prioritize productivity while also saving energy.

Contact: www.mobilindustrial.com Download: http://chpcontent.energ-group.com/exxonmobil-guide

/GVCNYQTMKPI Ć&#x192;WKFU 6 pages, English A brochure outlining the rolling fluids portfolio offered by Houghton for all stages of casting, rolling and coating processes as well as for roll grinding. Also aspects like health safety, environmental and application considerations are covered.

METALWORKING FLUID SOLUTIONS FOR THE STEEL INDUSTRY HOUGHTON â&#x20AC;&#x201C; YOUR FORMULA TO MOVE FORWARD

Contact: E-mail:

www.houghtonintl.com houghtonde-CSC@houghtonintl.com

Laser sensors 24 pages, English A product catalogue setting out the range of laser-based measuring systems offered by LAP Laser Applications, including systems based on laser triangulation, the shadowing method and the laser light section method. Detailed technical information is provided of each product series.

Contact: E-mail:

Heat protection

4 pages, English, German This brochure presents silicate-based heat protection products made by Lippmann. The product range includes silicate cloths, felt, tapes sleevings, cords, mats, etc., in various designs. The silicate fibers are resistant to temperatures of up to +1,200°C.

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

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Contact: E-mail:

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

Refractory gunning systems 20 pages, English, German A brochure describing refractory gunning systems offered by Velco. Detailed technical information and photos are provided of gunning machine types, moistening systems, pressure vessel systems, gunning manipulators for converters, EAFs, RH snorkels, etc., as well as spraying, conveying and centrifugal machines.

Contact: E-mail:

MPT International 4 / 2016

www.velco.de info@velco.de

IN THE NEXT ISSUE…

‹‹‹

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Steelmaking Eco-friendly steelworks starts production of high-quality slabs at PT. Gunung, Indonesia The new EAF melt shop with ladle furnace is designed for an annual production of 1.2 million t of steel to be cast into slabs on the new single-strand continuous caster. The range of charge materials for the electric arc furnace includes scrap, hot briquetted iron (HBI) and hot metal.

Cold rolling Efficient and comma-free grinding of hard rolls for cold rolling mills The most impressive feature of the new HSS rolls for use in cold rolling mills is their outstanding wear resistance and long lifetime. Such rolls are, however, very hard to grind using conventional grinding wheels. Recently a new generation of grinding wheels has been developed being a truly cost-effective solution for machining ultra-hard rolls, since they enable production of significantly higher quality surfaces without commas.

Quality assurance – Automation Permanent contour measurement and surface inspection of long products during hot rolling “Contour Check Shape” is a new system offered by LAP for the measurement of the contours and surface inspection of long products during hot rolling. The non-contact system performs up to 2,000 measuring cycles per second. It operates based on several thousand measuring points distributed over the entire surface of the rolled product. Thus it is possible to capture the complete profile with a high-resolution measurement and to reliably and automatically detect any rolling defects or surface imperfections. As the system operates in real time, it is able to instantly correct the rolling parameters, if required, and cut start-up times after a product change.

Special equipment Change in grease for applications in extreme conditions may lead to a more productive work environment When selecting a grease in the metallurgical industry it is important that it can stand up to the extreme conditions, including the presence of water contamination and metal particles. Additionally, it is essential that the grease chosen provides adequate performance for the application to reduce the occurrence of component damage.

This preview may be subject to change.

Metallurgical Plant and Technology

Advertising Manager: Sigrid Klinge

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

+49 211 6707-527, Fax +49 211 6707-582 e-mail gabriele.wald@stahleisen.de Production Manager: Burkhard Starkulla e-mail burkhard.starkulla@stahleisen.de

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

+49 211 6707-568 Assistant Editor: Edith Mielke

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© 2016 Verlag Stahleisen GmbH, Düsseldorf This journal and all articles and illustrations contained in it are protected by copyright.

With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems.

Upon acceptance for publication, the author agrees to grant, transfer and assign to the publisher all exclusive rights to publish the work during the lifetime of the copyright.

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Certification of circulation by the German Audit Bureau of Circulation (IVW) Permit number: 011-224, ISSN 0935-7254 Printed by: Kraft Druck GmbH Industriestr. 5–9, 76275 Ettlingen, Germany Printed on paper bleached totally chlorine-free (TCF) using heavy metal-free printing ink.

MPT International 4 / 2016

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