MPT International 5/2016 (Oct)

Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

Steelmaking | Single bucket charging practice with telescopic EAF roof closure

October 2016

Modernization | Performance modules KPETGCUG GHÆ‚EKGPE[ QH NQPI RTQFWEV OKNNU

We transform … the world of tube and pipe production.

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

Quality unites – a fact that our customers and we discover time and again with every new project. Together we develop production concepts that give our partners the competitive edge in their business.

SMS GROUP GMBH

Ohlerkirchweg 66 41069 Mönchengladbach, Germany

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

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

EDITORIAL

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Advances in minimill technologies In the evolution of minimill technologies, i.e. metallurgical equipment for electrical steel plants, the target of achieving ever higher levels of efficiency has brought about unique solutions, some of which are highlighted in this issue. First, there is a feature article about a modernized telescopic EAF roof closure (invented by Fuchs many years ago). The main target in developing the telescopic roof design had been to allow for single bucket charging even when low density scrap is charged. In markets characterized by a lack of scrap supply and decreasing scrap quality, this technology has been moving back into the spotlight.

Baątug Metallurgy in Turkey has optimized their telescopic roof EAF and is now sharing the experience from that project with the readers of MPT. A more general concept for future minimills has been drawn up in the UK this year.

Liberty House Group has set out an ambitious “Greensteel” vision, which involves minimills recycling scrap powered by renewable energy. Actually, it is a new version of the historic concept already realized for the early electrical steel plants in the 20th century, when some of the first minimills were powered by hydropower stations close by. However, the new English “Greensteel” vision has been motivated by the combination of steel business (Liberty Steel) and sustainable power assets (SIMEC) within the Gupta Family Group Alliance – an association between the business interests of Parduman K Gupta and Sanjeev K Gupta. Against this background, “Greensteel” vision is rather a business concept than an economic philosophy. In this issue, we report about the concrete terms of the project.

Dipl.-Ing. Arnt Hannewald

Other articles in this issue feature sophisticated technical solutions for long steel production. Dedicated upgrading and automation modules are available for long product rolling mills to increase efficiency while providing a fast return on investment. Since quality is always an issue, a newly developed inspection system for long products not only monitors product quality, but also provides specific recommendations for action in real time. Last but not least, heat treatment of individual (single) steel bars provides better reproducibility of the mechanical attributes required compared to batch processing. All in all, there are always new opportunities to add value to steel products.

MPT International 5 / 2016

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››› CONTENTS

Steelmaking 24 ) TGGPĆ‚GNF OGVCNNWTIKECN YQTMU UWEEGUUHWNN[ EQOOKUUKQPGF CV 6CVC 5VGGN -CNKPICPCICT In the first phase of the ambitious investment programme at the Kalinganagar location in the district of Odisha in India, the converter shop, secondary metallurgy facilities and a continuous slab caster were put successfully into operation in March 2016

26 5 KPING DWEMGV EJCTIKPI RTCEVKEG YKVJ VGNGUEQRKE '#( TQQH ENQUWTG In a market characterized by constantly decreasing scrap quality, BaÄ…tug Metallurgy looked for ways to further increase EAF productivity. In 2015, the EAF was modernized and equipped with a new larger shell and bigger transformer

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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

Company profile

Modernization

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Liberty House Group has a Greensteel vision for the UK, using renewable energy to melt the readily available supply of scrap in Britain. It intends to change the steel industry in the UK enabling it to be more competitive, flexible and sustainable

Dedicated upgrade and automation packages for long product rolling mills provide a very fast return of investment. “Performance modules� added to plants as an upgrade improve mill operation and make processes more efficient

Hot rolling

Heat treatment

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A newly developed system from LAP inspects the entire contour with no shadowing effects and supplies specific recommendations for action

The secret of reproducing steel bars that have exactly the required mechanical attributes is a combination of profound understanding of the steelmaking process and using of modern heat treatment technology

Special equipment 54 % JCPIG KP ITGCUG HQT CRRNKECVKQPU KP GZVTGOG EQPFKVKQPU OC[ NGCF VQ C OQTG RTQFWEVKXG YQTM GPXKTQPOGPV 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 as well as high temperatures and high loads

MPT International 5 / 2016

58 ' HĆ‚EKGPV CPF EQOOC HTGG ITKPFKPI QH JCTF TQNNU HQT EQNF TQNNKPI OKNNU The new HSS rolls for use in cold rolling mills are 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

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Advertisers’ index ABB AB AMOVA GmbH ASMET Research GmbH

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Association for Iron & Steel Technology 60 Aumund Fördertechnik GmbH

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BEDA-Oxygentechnik Armaturen GmbH 31 Boldrocchi srl

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Braun Maschinenfabrik Gesellschaft m.b.H.

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Bürkert Werke GmbH

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Combilift Ltd Co Danieli S.P.A.

62 6, 7

Deutsche Edelstahlwerke GmbH

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Endress + Hauser Mestra AG

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framag Industrieanlagenbau GmbH

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Hannover Milano Fairs Shanghai Ltd. 10 iba AG 52 IMS Messsysteme GmbH 11, 12 INTECO melting and casting technologies GmbH Kaigo Co., Ltd. Maschinenfabrik Köppern GmbH & Co. KG KSK Kuhlmann-SystemKühltechnik GmbH Küttner GmbH & Co. KG LAP GmbH Laser Applikationen Morgardshammar AB NOHMA GbR Primetals Technologies Austria GmbH R+W Antriebselemente GmbH

16 66 43 69 43 23 45 66 61 19

Reed Exhibitions (Deutschland) GmbH Rheinbraun Brennstoff GmbH Ross Europa GmbH Saar-Metallwerke GmbH SGL CARBON GmbH

68 67 18 15 74

Siempelkamp Maschinen -und Anlagenbau GmbH & Co. KG SMS GROUP GMBH Steel Authority of India Ltd TML Technik GmbH

53 2 64 70

ThyssenKrupp Uhde Engineering Services GmbH Ventilatorenfabrik Oelde GmbH Vereinigte Filzfabriken AG PAUL WURTH S. A. Zumbach Electronic AG

55, 56 65 37 21, 22 35

MPT International 5 / 2016

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››› INTERNATIONAL INDUSTRY NEWS

Africa Egypt Ezz Steel signs mill services contract. The Metals & Minerals division of Harsco Corporation has signed a new, multiyear contract with Ezz Steel.

The new contract calls for the provision of mill services at Ezz Steel’s Sadat City plant. Under the terms of the agreement, Harsco will provide slag and scrap management services, with future plans to design and deliver metal recovery and briquetting plants.

As of 2017, customers will be offered three different finishing processes from a single source at Finkl Steel – drilling, milling and heat treatment. Tool and die makers thus avoid material losses and gain production time for manufacturing dies and tools. Finkl Steel customers will no longer have to work with external subcontractors in future for stress-relief heat treatment – an interim step that frequently leads to delays in manufacturing. Technical components of the new Finkl Steel production line include an overhead crane with a capacity of up to 30 t, a horizontal CNC-controlled boring mill and a new furnace for heat treatment.

Peru South Africa Northam Platinum’s furnace project on track. Tenova Pyromet has completed 50% of Northam Platinum Limited’s new platinum group metals (PGM) furnace at the Zondereinde smelter operation in Thabazimbi, having met all major project milestones to date. The contract, which was awarded to Tenova Pyromet in 2015, will support Northam Platinum’s planned growth in PGM production, which requires the flexibility to process high chromite, low base metal and high sulphur contained concentrates. Tenova Pyromet’s scope of the project covers the PGM smelting furnace, the feeding system and off-gas handling plant, as well as the furnace building and all associated civil works, infrastructure and services. Handover of the fully operational 20 MW furnace is scheduled for August 2017.

The Americas Canada Finkl Steel invests in production line for semi-finished products.

Finkl Steel, a subsidiary of Schmolz + Bickenbach, is investing in a new production line at their location in Québec.

With this new production line, Finkl Steel will continue to diversify their product portfolio and extend the range of services in fine and precision machining.

MPT International 5 / 2016

Ferrobamba signs agreement for iron ore development project. Ferrobamba has selected Tenova HYL Micro Module to develop its iron ore deposit in the Aymaraes region.

Tenova will oversee the technological design and provide the equipment to develop and build a 500,000 t/year pelletization plant and a 250,000 t/ year DRI plant. The Tenova HYL Micro Module will produce high-carbon DRI using the zero reformer technology. The DRI produced will have a high carbon content of around 4%.

Asia China XiWang Special Steel to build bloom caster. XiWang Special Steel has awarded Danieli the order to supply a new jumbo bloom caster for an annual production of 450,000 t. The new caster will be equipped with two casting strands and have a nominal radius of 16.5 m. It will cast low and medium-carbon quality structural steel into 600, 700 and 800 mm diameter blooms. The plant will feature hydraulic bloom oscillators with dynamic parameter control, soft mould and secondary cooling as well as mould and final stirring. The caster will be designed for the future installation of a strand stirrer. Danieli Automation will supply the level 1 and level 2 automation system as well as the first Q-pulpit installed in a long product caster in China. This will enable XiWang Special Steel to manage the plant in a safe and autonomous way, with one operator taking control of the whole machine. Plant start-up is scheduled to take place in the summer of 2017.

China USA AM/NS Calvert to revamp galvanizing furnace. Drever International, a company of SMS group, has received an order to provide additional equipment for a galvanizing furnace installed in the Calvert plant of AM/NS in Alabama. The equipment will be retrofitted to the hot-dip galvanizing line No. 3 erected by SMS group. The modification will enable the furnace to process 3rd generation advanced high strength steels (AHSS). The supply scope consists of additional seal roll assemblies, new deflector roll boxes, induction heaters, a partitioning section, a final cooling section and an exit section with a hot bridle.

The installation will give AM/NS Calvert the possibility to apply the quench and partitioning process, which allows a twostep thermal treatment. The equipment will be installed and commissioned at the end of 2016.

Shandong to build waste gas recirculation system for sinter plant.

Shandong Iron & Steel has ordered a selective waste gas recirculation system from Primetals Technologies for its new sinter plant in Rizhao, Shandong province. With a waste gas recirculation rate of up to 40%, the system will reduce waste gas emissions to the atmosphere by 770,000 m3/h. In addition, coke consumption for the sintering process will be reduced. Due to the lower waste gas flow rate, downstream gas cleaning facilities can be designed 30% smaller. The new sinter plant will consist of two 550 m² sinter strands which will be installed in two construction phases. The startup of phase 1 is scheduled for September 2017. The strategic target of constructing this new steelmaking facility is to be able to shut down several older production facilities in the Shandong province which do not meet the required environmental standards anymore.

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››› INTERNATIONAL INDUSTRY NEWS

China Jiansu Shagang completes revamp of shaft EAF. In December 2015, Inteco had received an order from Jiansu Shagang for the revamping of the existing 100 t Fuchs shaft EAF with oval bottom tapping (OBT) to an eccentric bottom tapping (EBT) shaft EAF with a capacity of 120 t. The change in tapping mode improves meltdown operations of the EAF by increasing the hot heel. The new design allows full utilization of the transformer and of the chemical energy package. The first heat was produced in June 2016, with the furnace being in continuous operation ever since.

plant, billet storage and billet heating machine and provide the buildings including equipment, infrastructure, water management and transformer station.

Niles-Simmons-Hegenscheidt (NSH) will supply the quenching and tempering system for the wheels and the contour machining units. The new plant will fully automatically produce 100,000 wheels in diameters from 720 to 1,200 mm. The plant will be designed for a capacity increase to 200,000 wheels per year. Production start is scheduled for the autumn of 2018. This greenfield project will contribute to the expansion of India’s transport infrastructure and decrease the country’s dependence on imported railroad wheels.

India

India

RINL to build plant for railroad wheel production. Rashtriya Ispat Nigam Limited (RINL) has placed an order with SMS group as consortium leader to supply a plant for the manufacture of railroad wheels. SMS group will supply the wheel rolling line with billet saw

Jindal places order for processing lines. Jindal (India) Ltd. has awarded CMI a contract for the supply of two new processing lines, a continuous galvanizing line and a colour coating line to be built at the Kolkata site. The galvanizing line will be designed to attain a pro-

MPT International 5 / 2016

News in brief CSP, Brazil, has brought on stream the new two-strand continuous slab caster supplied by Primetals Technologies. The caster has a capacity of 3 million t/year.

Vallourec & Sumitomo Tubos do Brazil (VSB), Brazil, has issued the FAC to SMS group for the new PQF® roll dressing machine used in the 16” PQF® seamless tube plant.

Baosteel Zhanjiang, China, has started up the new continuous galvanizing line supplied by Primetals Technologies. The new CGL No. 2 is designed to galvanize 465,000 t/year of steel grades for the automotive and home appliances industries.

Surface Inspection: Nothing stays hidden!

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IMS – World Market Leader in Measuring Systems

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INTERNATIONAL INDUSTRY NEWS cessing speed of 150 m/min and produce close to 0.15 million t/year. Essential components of the new line will be the special chemical roll coater for passivation after metal coating, and the latest generation gas-jet-based cooling and drying system. The line will also be equipped with a 4-high skin pass mill. The new colour coating line will be designed to process strip thicknesses from 0.15 mm to 1 mm and widths from 750 mm to 1,450 mm at a processing speed of 90 m/min, with a total capacity of 0.135 million t/year. Installation of the two lines is scheduled to take place by mid-2017.

material. The new line will comprise a vertical cleaning section and a radiant tube annealing section. It will be designed to reliably process very thin strips down to 0.14 mm at 400 m/min.

Entry and exit speeds are to reach 500 m/min. The supply scope includes two pay-off reels, a roller seam welding machine, the multi-stage cleaning section, a vertical entry accumulator, the low-energy annealing furnace including CMI’s patented Blowstab® cooling system, an exit accumulator and inspection stand, a rotary shear and two tension reels. The line is scheduled to start production in the first half of 2018.

India Indonesia JSW to build new continuous annealing line. JSW Steel Coated Products has placed an order with CMI Industry Metals for the supply of a continuous annealing line to be erected in the JSW works in Tarapur. This new line will produce 208,000 t/year of steel substrate for tinplate, which will then be electroplated and used as packaging

PT Krakatau Steel places order for hot strip mill. PT Krakatau Steel has placed a turnkey order with SMS group for the supply of a high-performance hot strip mill to be built in Cilegon on the island of Java. The order comprises the entire process equipment ranging from the slab yard to the coil yard, the electrical and

3rd ESTAD

ECCC

¬%UROPEAN¬#ONTINUOUS#ASTING¬#ONFERENCE

Aperam has signed a financing contract with the European Investment Bank under the Investment Plan for Europe. The 50 million euro contract is intended to finance a research and development programme and upgrade plants in Isbergues, France, and Châtelet, Belgium.

Voestalpine Stahl, Austria, has granted Primetals Technologies the FAC for the new secondary dedusting system in the Linz plant. The new system cleans up to 700,000 m3/h of off-gas from the secondary metallurgy facilities.

Vizag Steel, India, has successfully completed all performance guarantee tests for the No.3 blast furnace supplied by a consortium of Paul Wurth and Larsen & Toubro.

2017

EUROPEAN STEEL TECHNOLOGY AND APPLICATION DAYS

VIENNA, AUSTRIA

26 – 29 JUNE 2017

Contact: ASMET

EUROPEAN CONTINUOUS CASTING CONFERENCE VIENNA, AUSTRIA

26 – 29 JUNE 2017

13

News in brief

Franz-Josef-Str. 18 8700 Leoben, Austria Tel. +43 (0) 3842 402 2290 Fax : +43 (0) 3842 402 2202 E-mail : estad2017@asmet.at Website: www.estad2017.org E-mail : eccc2017@asmet.at Website: www.eccc2017.org

© IAKW AG, Marius Hoefinger

TH

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››› INTERNATIONAL INDUSTRY NEWS

automation systems, the auxiliary facilities such as water management, roll shop and crane systems, and the construction of the pertaining infrastructure and bays.

Planning and execution of building construction and civil engineering is carried out by the Indonesian consortium member, PT Krakatau Engineering. The mill will be designed to produce strips with a maximum width of 1,650 m. In its first construction stage it will have a capacity of 1.5 million t/year. Key components will be a reheating furnace, a four-high reversing roughing stand with edger, a six-stand finishing mill, a laminar strip cooling section, a universal coiler and the coil transfer system. The mill is scheduled for commissioning in early 2019. At a later stage, annual production may be increased to up to 4.0 million t/year.

Iran IDRO commissions new ESR plant. IDRO Heavy Foundry & Forging has successfully produced the first melt in the new 50 t ESR plant built

by Inteco. The ESR project had been halted in 2011 due to the political situation in Iran. In late 2015 it was resumed. Production is now possible in short collar as well as in the static mould mode. Before the construction halt, four bogie hearth furnaces with a capacity ranging between 80 t and 100 t respectively had been supplied along with extensive laboratory equipment.

Iran Process equipment for Sangan iron project. Outotec has been awarded a contract by Shangdong Province Metallurgical Engineering (SDM) for the supply of dewatering process equipment to the second phase of the Sangan iron concentrate project in northeast Iran. The Iranian Mines and Mining Industries Development & Renovation Organization owns the Sangan mines and SDM is their engineering partner.

Outotec’s scope of work includes the design and delivery of thickeners and filter presses as well as related installation

News in brief Huta ŁabÙdy, Poland, has granted SMS group the FAC for the new 12 ¾-inch ERW welded tube line installed at the Gliwice works.

Štore Steel, Slovenia, has placed an order with Zumbach Electronics to supply an inline profile measuring system for the hot rolling mill.

The Profilemaster® system is scheduled to be commissioned before the end of 2016.

Baosteel, China, has commissioned the new inspection and grinding plant supplied by Danieli. The new plant combines grinding technology with automatic defect detection.

“Is the metallurgic industry able to keep pace with innovation pressure?”

It can. Because Bürkert helps to creatively counter the pressure of innovation in metallurgy – and to respond to new material requests with fast, market-driven adjustments to the product portfolio. Type 874x is the name of our MFC family for contemporary gas flow control. Easy to use and with a state of the art communication concept. Bürkert now introduces a well-coordinated, flexible system that redefines precision, achieves the highest repeatability and manages up to 16 devices through a single Ethernet interface. This results in more transparent processes and utilizes resources efficiently. Thus, processes can be simplified and managed in an intelligent way: a perfect combination of centralized and decentralized control.

Slim, precise, future-proof – mass flow controllers that meet the needs of tomorrow.

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INTERNATIONAL INDUSTRY NEWS supervision and commissioning services including spare parts. The new plant will process 5 million t/year of ore.

Pakistan Agha Steel to upgrade meltshop. Agha Steel Industries and Danieli have signed a contract for a meltshop enhancement project. The project includes the complete reconstruction of the electric arc furnace as well as the supply of a new fume treatment plant. Agha Steel Industries is the only private steelmaker running a minimill in Pakistan. The targets of the project are to reduce electrical consumption and tap-to-tap time.

Danieli will install its Q-Reg+ electrode regulator integrating a slag foaming management system and an integrated system for automatic scrap charging. The latter will allow Agha Steel to reduce the number of buckets charged from three to one.

A new chemical package will allow more efficient utilization of the chemical energy in the furnace. Agha Steel will also receive a new fume dedusting system.

Thailand Kobelco Millcon Steel to modernize wire rod mill. To increase their local supply of special steel products, Kobelco Millcon Steel is modernizing a wire rod mill in Rayong with equipment supplied by Primetals Technologies. Upgrades to the mill include new mill stand gear drives, water boxes, pinch rolls and laying heads. In addition, Primetals Technologies will install a Morgan reducing sizing mill (RSM) with a quick change feature to produce thermomechanically rolled products and improve tolerances, mechanical properties and coil packages.

Speed guarantees for the 480,000 t/year mill will be 110 m/s, with a maximum rolling rate of up to 120 t/h. When completed in May 2017, the mill will supply steel rods for automotive parts.

Vietnam Hoa Phat Steel Sheet orders new cold mill complex. Hoa Phat Steel Sheet has awarded Danieli the order to

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15

News in brief Hyundai, South Korea, has granted SMS group the FAC for the successful installation and commissioning of the 3-roll PSM® (precision sizing mill) into the existing bar mill in Pohang.

The International Stainless Steel Forum (ISSF) has released figures for the first three months of 2016 showing that stainless steel melt shop production increased by 0.4% year-on-year to 10.3 t. Production increased in Central and Eastern Europe, Asia without China and in China.

Saarstahl, Germany, has successfully put into operation the high-speed wire rod mill modernized by SMS group.

Technological Innovations for iron, steel, ferro alloy and non-ferrous metal manufacturers

High quality water cooled copper products Forged and machined

Saar-Metallwerke GmbH Am Römerkastell 6 · 66121 Saarbrücken · Germany info@saarmetall.de www.saarmetall.de

MPT International 5 / 2016

WE ARE ...

ELECTRIC ARC FURNACE

design and supply all equipment for a new cold strip complex to produce 600,000 t/year of pickled/ cold-rolled/galvanized coils with final thicknesses down to 0.14 mm. The new plant to be built in the region of Hanoi will include a push-pickling line for 600,000 t/year, two cold reversing mills for 200,000 t/year each and two hot-dip galvanizing lines for 150,000 and 350,000 t/year respectively. Conceived for eco-friendly production, the cold complex will incorporate Danieli technological packages, such as automatic flatness control for the cold rolling, X-Jet for the air wiping system, Save-Cut for all cutting and trimming processes, Q-Surface for improving the shape and elongation of material. Commissioning of the complex is scheduled to take place by the end of 2017.

Vietnam

INTECO’s design solutions for its EAF units are focused on the development of heavy-duty equipment capable of with standing both high electrical and chemical melting power density without impairing quality of produced steel, reliability of equipment, environment and overall safety of all the furnace operations. Tailor made design and development activities are the starting basis to follow the path marked by the future EAF technology requirements and trends. Thanks to the acquisition of the worldwide known FUCHS Technology, INTECO enhances its capabilities reaching the excellence in the designing technique and operation technology of Electric Arc Furnaces and Ladle Furnaces, providing the market with the most advanced and innovative equipment for meltshops.

USP‘s of INTECO Design

Ton Dong A to install new hot-dip galvanizing line. Danieli will supply a new hot-dip galvanizing line for the new facility of Ton Dong A in Binh Dong. HDGL No. 6 will have a total annual production capacity of 0.35 million t/year at maximum process speeds of 180 m/min for GI and up to 200 m/ min for GL coated strip. The incoming strip will be in the thickness range from 0.25 to 2.5 mm and up to 1,250 mm in width. The line will be designed for a possible future upgrade to enable the production of home appliances. The project teams of Ton Dong A and Danieli aim to produce the first galvanized coil by the end of November 2017.

Europe

› INTECO as unique supplier of all technical packages › Patented Telescope EAF (with a 165t tap EAF reference) › Advanced and patented integrated Scrap Preheating › Ultra High Chemical Power input (UHChP) furnaces › INTECO PTI solutions for fuel and oxygen Injection › INTECO PTI solutions for injection of solid materials › INTECO PTI SwingDoorTM system for EAF deslagging control and overall performance improvement › Enhanced design for the water-cooled components for increased safety and service life › Integrated INTECO atec ISEC electrode control system › Integrated melting process control › Integrated INTECO atec IFOB furnace optimization system › Safe operations

INTECO melting and casting technologies GmbH Wienerstraße 25 • 8600 Bruck a.d. Mur • Austria Tel.: +43 (0) 3862 53110-0 • Fax: +43 (0) 3862 53844 inteco.austria@inteco.at • www.inteco.at

Czech Republic Tāinecké Železárny to install new billet stand and combination saw. Tāinecké Železárny has awarded Primetals Technologies an order to supply a new billet stand and a combination saw for its plant in Tāinec. Primetals Technologies will be responsible for designing the process equipment such as an entry-side manipulator unit, the billet stand and the combination sawing machine. The scope of supply also comprises the process equipment, the fluid systems and the electrical equipment – including converters and motor controllers, the automation system and mechatronic packages. The combination saw can be operated with either abrasive or metal cutting disks of up to 1,800 mm diameter. The saw system will include a device for crop collecting and a dust extraction unit. Primetals Technologies will also supervise installation and commissioning, which is scheduled for November 2017.

W E Germany ArcelorMittal Ruhrort to replace converter. Primetals Technologies has won an order from ArcelorMittal Ruhrort to replace the LD (BOF) converter “K2�. The new turnkey converter will have a tapping weight of 150 t. Primetals Technologies will be supplying the converter vessel, trunnion ring, maintenance-free Vaicon Link 2.0 suspension system, slag protection and dog house gates.

The scope of supply also includes the measuring and sampling device, control desks and control stations.

The project will be implemented by a consortium led by Primetals Technologies in partnership with Buchinger Anlagen-Stahl-Rohrbau, Austria. Primetals Technologies will be responsible for engineering and supplying the new plant components, assembly engineering, supervision of the dismantling and assembly work, the cold test as well as commissioning and training of the operating and maintenance personnel. Buchinger will handle the disassembly of those old plant components for which there is no further use, and assemble the new plant components. The new converter is scheduled to come into operation in October 2017.

C O N V E Y

Q U A L I T Y

Hot Sinter Transport

Germany Lech-Stahlwerke places order for bar mill expansion. SMS group will supply a precision sizing block including the associated roll workshop, a rake-type cooling bed, abrasive cut-off machines and a finishing section to expand bar mill 2 at the Meitingen site of Lech-Stahlwerke. In addition to the mechanical equipment, SMS group will supply the electrical equipment and the automation system and be responsible for erection and commissioning. The project is scheduled to be completed by the autumn of 2017. With this project Lech-Stahlwerke is reacting to the demands of the automotive industry. In future, bar steel in the diameter range from 30 to 80 mm will be rolled from a single-pass family on the new 380/4 PSMÂŽ sizing block. The 3-roll block will be equipped with a MEERgaugeÂŽ diameter measuring device.

Germany BGH Freital operates with new EAF manipulator. BGH Freital has successfully commissioned the new automatic EAF temperature and sampling manipulator supplied by MORE. The CATFIS 2.1 operates through the EAF slag door with four axis and four degrees of freedom. This design allows the manipulator to operate in very confined areas and to be easily reconfigured in case the plant situation changes. BGH Freital produces specialty steel and

AUMUND Pan Conveyors s !PPLICATIONS UPSTREAM OR DOWNSTREAM OF THE SINTER COOLER s #APACITY UP TO T H AND PAN WIDTH UP TO MM s 7ITHSTANDS MATERIAL TEMPERATURES OF UP TO ²# s #OMBINED CONVEYING AND COOLING n INCREASE OF COOLING CAPACITY s 2EPLACEMENT FOR VIBRATORY FEEDERS OR BELT CONVEYORS 10th Nov. 2016, Dßsseldor f, Ge rmany Please visit ou r stand no. F2 0

New build. Upgrade. Conversion.

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

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››› INTERNATIONAL INDUSTRY NEWS

specialty alloys for most demanding applications via a 42 t EAF, LF, VD/VOD and AOD route.

Luxembourg AM Differdange to receive new straightening machine. ArcelorMittal has placed an order with Danieli for the supply of new finishing equipment for its jumbo beam mill in Differdange.

The core of the project will consist of the installation of a new nine-roll straightener to replace the manual straightening operations by two gag presses. The double-support design of the new ma-

chine will allow both web and flange-tip straightening. Automatic roll adjustment and automatic roll change will be fully hydraulic. Changing all nine straightening rolls will take less than 25 minutes.

Danieli will also extend the existing cooling bed, supply a new cold disc saw and related handling equipment. All electrical and automation systems will be provided by Danieli Automation. Plant startup is scheduled for the beginning of 2018.

its environmental programme, MMK plans to complete approximately 100 environmental initiatives in 2016 aimed at reducing and mitigating the company’s environmental impact. The initiatives will cover all of MMK group’s production facilities and subsidiaries with the focus on reducing emissions of air pollutants at Magnitogorsk.

Spain Russia MMK continues investments in environmental initiatives. Under

ArcelorMittal Asturias to modernize coking plant. ArcelorMittal is going to reconstruct and modernize the coking plant at its Gijon works, which has been out of operation since 2013. Within the context of this project, Paul Wurth has been awarded a contract covering the engineering and supply of key equipment for the rebuild of two coke oven batteries and the modernization of the adjacent by-product plants. Also supervision services during erection and commissioning are included in the contract.

Paul Wurth will supply the refractory material and perform the battery heating-up services.

The coke oven batteries, featuring 45 ovens each, are designed to produce 1.1 million t/year of coke. For the by-product plants, including the coke oven gas desulphurization plant, Paul Wurth will provide the overall engineering and supply key equipment. Paul Wurth will also install a Claus plant for sulphur removal.

Turkey Tat Metal orders hot-dip galvanizing line. After doubling their overall rolling, tempering and pickling capacity since 2011, Tat Metal has chosen CMI to supply their new hot-dip galvanizing line. CMI will supply a line designed to galvanize 400,000 t/year of steel strip to be installed in Tat Metal’s steel works in EreÛli. CMI will be in MPT International 5 / 2016

INTERNATIONAL INDUSTRY NEWS charge of the complete design of the line, the manufacture of some of the core machines, supervision during erection and commissioning as well as coordinating all key subcontractors. Also included in the supply package are the major components of the electrical and automation systems. The line will be designed for strips in thicknesses ranging between 0.25 and 3.00 mm and widths of up to 1,300 mm. The strip will be galvanized at a process speed of 200 m/min, while in the entry and exit sections speeds of up to 270 m/min will be attained. The project is scheduled to be completed by the end of 2017.

United Kingdom SIMEC Power commissions mini-power station in South Wales. Liberty Steel and SIMEC Power have worked together to create the first of an eventual network of 14 ‘peaking’ power plants which will be located across the UK. They will ensure continuation of low-cost, clean power supply during times of peak demand or periods when solar and wind power are not delivering.

The first of these innovative installations – a 9 MW plant driven by biofuel – was inaugurated in July 2016 at Liberty Steel Newport (Gwent). SIMEC owns and operates the adjacent 395 MW power station at Uskmouth. SIMEC’s initial roll out of 14 strategically-located peaking plants could have a combined capacity of 200 MW of biofuel-generated power focused on geographical areas of high industrial demand. The units will have the capability to deliver on demand power to the grid or to the industrial site within eight seconds.

Companies NSMMZ renamed NLMK Ural. NSMMZ, a company in NLMK Group’s long products

division, has been renamed JSC NLMK Ural. The name and corporate identity of the company were brought in line with its production profile, its geographical footprint and its role as part of NLMK Group’s unified technological chain.

S-Tec Sensor Technology joins Berthold Technologies. Norwegian-based Sensor Technology AS (S-Tec) has joined Berthold Technologies, suppliers of radiometric instruments for process control. S-Tec, specialized in nucleonic gauges, is considered as a perfect complement to Berthold’s growth strategy.

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19

Seven Refractories and Dalmia Bharat plan JV. Seven Refractories has entered into an agreement with the refractory business of the Indian Dalmia Bharat group to develop and supply a wide range of monolithic refractories for the Indian market. Dalmia Bharat has over sixty years of experience in refractories. The cooperation agreement between Dalmia and Slovenia-based Seven Refractories is intended to lead to a joint venture between the two companies.

Vallourec starts negotiations with Ascometal on Saint-Saulve steel mill. Vallourec has started ex-

20

››› INTERNATIONAL INDUSTRY NEWS

clusive negotiations with Ascometal, with a view to the sale of its majority holding in the Saint-Saulve steel mill in France. Based on a reinforced industrial and business plan, the Ascometal offer should retain the site’s 320 employees.

At this stage, the two partners envisage creating a joint venture with Vallourec holding a 40% stake and Ascometal having a 60% holding, thus giving the latter exclusive control of operations.

Plans are for the Saint-Saulve steel mill to supply 175,000 t/year to Ascometal and 100,000 t/year to Vallourec. These volumes would secure the steel mill’s long-term operations and competitiveness. Negotiations should be concluded with a final agreement being signed by the end of 2016.

SGL Group’s business unit Performance Products classified as discontinued operations. While SGL Group’s future core business reflects solid development in the first half of 2016, a review of the strategic options for the business unit Performance Products (PP) after the completed legal separation in early June 2016 has led to PP being classified as discontinued operations. SGL Group’s aim is to sell PP by the end of this year. The results of PP continue to be characterized by a significant price decline for graphite electrodes, while the delivery volumes increased slightly. However, the higher volume demand for graphite electrodes will not be sufficient to compensate for the negative effect of the further drop in graphite electrode prices.

Additionally burdened by a one-time deferred tax impact of minus 14 million euros due to the legal separation, PP sustained a loss after taxes of 47.9 million euros in the first half of 2016.

SMS group concentrates areas of intralogistics, aviation and surface treatment. SMS group and Paul Wurth, in which SMS group holds an interest of about 60%, are merging their subsidiary companies SMS Logistiksysteme GmbH and CTI Systems S.A. to form a joint enterprise.

The objective of the new enterprise is to further expand business in the areas MPT International 5 / 2016

of intralogistics, aviation and surface treatment. SMS Logistiksysteme provides individual logistics and service solutions for the steel and non-ferrous metals industries. Since 2013, SMS Logistiksysteme has also offered customer-specific storage, transport and handling systems for air cargo terminals under the brand name ACUNIS. CTI Systems has been a leading supplier of tailor-made turnkey systems in the areas of intralogistics, surface treatment and aviation. The joint enterprise will in future operate under the new name AMOVA and will also focus on markets outside the steel and non-ferrous metals sector.

Houghton International partners with SMS group. Houghton International, specialized in metalworking fluids and services, and SMS group have entered into an exclusive partnership to develop and distribute rolling oils for metal production. Through this partnership, Houghton has become the exclusive distributor of oils for SMS mill equipment.

Somani to strengthen equity of SKW Stahl-Metallurgie Holding.

The Indian Somani group has submitted a non-binding letter of intent to become a shareholder in SKW StahlMetallurgie Holding in the context of a financial restructuring. According to Somani group’s proposal, the execution of the capital increase against cash is guaranteed by the Somani group under the condition that the Somani group is to hold at least 51% of the shares in SKW Stahl-Metallurgie Holding after the transaction. The negotiations are in a very early stage, and it is not secured whether a transaction with the Somani group is going to materialize. Supervisory board and executive board will diligently assess the transaction as well as alternatives for a financial restructuring.

Thyssenkrupp initiates project to convert steel mill gases into chemicals. The Carbon2Chem project initiated by Thyssenkrupp

has the aim to convert process gases from steel production, including the CO2 they contain, into base chemicals. The greenhouse gas CO2 would then no longer be discharged into the atmosphere. The energy required for the conversion process is to come from renewable sources. 16 partners from the areas of basic and applied research and various sectors of industry are involved in the project.

Thyssenkrupp and the Max Planck Institute for Chemical Energy Conversion have carried out preparatory planning and scientific work. At least ten years of development work will be needed before the process is ready for industrial-scale use. It will create a new network of steel production, electricity generation and chemical production. At present, gases from steel production are burnt to produce electricity and heat for the production process.

Personalities New CEO of Thyssenkrupp Asia Pacific. Vivek Bhatia is the new CEO of Thyssenkrupp Asia Pacific. He succeeds Stefan Schmitt, who has moved to Thyssenkrupp AG as head of human resources strategy.

Leadership appointments at Harsco. Harsco has created a chief operating officer position in their Metals & Minerals segment and promoted Chris Whistler to that position. Sam Fenice has been named vice president and corporate controller of Harsco.

On his new position, he will oversee the administration of all corporate accounting policies and procedures, including internal and external reporting.

Outokumpu appoints head of operations Europe. Maciej Gwozdz has been appointed head of operations Europe and member of the Outokumpu leadership team. He will assume the new position as of 1 January 2017 at the latest. Maciej Gwozdz joins Outokum-

Bell Less Top® – THE Charging Solution

Blast furnace top charging under continuous optimisation Since the first successful industrial application of the BLT® in 1972, Paul Wurth has developed a full spectrum of Bell Less Top Charging Systems suited to any blast furnace size. Our experience from more than 650 installations ensures that each system is fully capable of providing excellence in flexible burden distribution.

With latest developments, we constantly strive for optimising the BLT key features: G3 and PC Chute Transmission Gearboxes for reduced maintenance costs and operational costs, extended lifetime and higher process flexibility; MCS Distribution Chute resulting in lower investment costs due to design optimisation and minimised working capital thanks to enhanced spare chute delivery times; Paul Wurth S.A. 32, rue d’Alsace Tel. +352 4970-1 L-1122 Luxembourg paulwurth@paulwurth.com

www.paulwurth.com

Subsidiaries: Brazil, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, Taiwan, Ukraine, U.S.A., Vietnam

Spherical Maintenance Valve for improved safety, increased reliability and minimised maintenance; Dedicated BFXpert models for monitoring and optimising the blast furnace charging.

BF Technology & Equipment cooling & lining concepts and systems, automation, top charging technology, special equipment.

Auxiliary Plants hot blast stoves & energy recovery, stockhouse, pulverised coal injection, gas cleaning, top gas energy recovery, slag granulation and dewatering.

Cokemaking Plants complete plants and batteries, coke oven machines, coke quenching, coke oven gas treatment, plant automation.

Agglomeration Plants engineering & construction of complete sintering and pelletising plants, revamps and modernisations.

Direct Reduction Plants engineering & construction of Midrex® direct reduction plants.

Recycling Technologies PRIMUS® process, RedIron™, RedSmelt™, i-Meltor®, PLD deoiling, CIROVAL™ BF sludge treatment.

Paul Wurth S.A. 32, rue d’Alsace Tel. +352 4970-1 L-1122 Luxembourg paulwurth@paulwurth.com

www.paulwurth.com

Subsidiaries: Brazil, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, Taiwan, Ukraine, U.S.A., Vietnam

Paul Wurth, the Paul Wurth Logo, PRIMUS, RedIron, RedSmelt, i-Meltor, Ciroval are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction. Midrex is a registered trademark of Kobe Steel, Ltd and used under licence.

Blast Furnace Plants engineering & construction of complete blast furnace plants, modernisations, rebuilds and relines.

INTERNATIONAL INDUSTRY NEWS pu from automotive supplier ZF Group/ TRW.

Events ›

14 – 16 November 2016 Bangkok, Thailand Organizers: South East Asia Iron and Steel Industry SEAISI www.seaisi.org

ASEAN Iron and Steel Sustainability Forum. This event will cover a wide range of topics, such as developments in steel trade, production cost and steel price competitiveness, trends and developments in the construction, automotive and shipbuilding sectors, etc, with a focus on the situation in and relevance for the ASEAN region.

›

26 – 27 November 2016 Ranchi, India Organizers: Steel Authority of India SAIL and CSI www.aitism-ranchi.in

AITISM 2016. The 5th international conference on Automation & Information Technology in Iron & Steel Making Processes will be held under the motto “Vision 2025”. Conference themes will include smart computing, networking and wireless technology, modelling and simulation, robotic and embedded systems, power electronics, etc.

›

6 – 8 December 2016 Kaohsiung, Taiwan Organizers: Kaigo Co., Ltd. www.imttaiwan.com

iMT Taiwan and ASF. The International Metal Technology exhibition and the Asia Steel Forum taking place under a common roof will serve as a key platform for information and networking between players active in the South Asian steel industry.

›

13 – 16 June 2017 Shanghai, China Organizers: Hannover Milano

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23

Fairs China Ltd. www.hmf-china.com Metal + Metallurgy China 2017.

Under this collective name, the China International Foundry Expo, the China International Metallurgical Industry Expo and the China International Industrial Furnaces Exhibition will draw international exhibitors and visitors to get latest information on technological developments in these industries.

›

26 – 29 June 2017 Vienna, Austria Organizers: Austrian Society for Metallurgy and Materials ASMET www.eccc2017.org; www.estad2017.org

ECCC 2017 and ESTAD 2017. The 9th European Continuous Casting Conference and the 3rd European Steel Technology and Application Days will be held concurrently at the Austria Center in Vienna. Main topics of the ECCC include advanced technologies for the casting of slabs, blooms and billets; ladle metallurgy, refractories, mould lubrication, heat transfer, product quality control, numerical simulation and modelling, etc.

ESTAD will focus on latest trends and issues, providing a networking and information platform for equipment and service suppliers, plant manufacturers and steelmakers. The two conferences will be accompanied by a joint exhibition.

›

27 – 29 September 2017 Dresden, Germany Organizers: German Society of Materials Science (DGM) and Steel Institute VDEh www.werkstoffwoche.de

WW 2017. After the very successful first edition in 2015, WW WerkstoffWoche (Materials Week) will be staged again in 2017. Under the motto “Materials of the future”, this congress with integrated trade show will provide a forum for all and any questions concerning materials as wide ranging as steel, non-ferrous metals, ceramics, polymers and glass.

New product and process developments will be presented and discussed by experts from industry and science.

MPT International 5 / 2016

Converter platform

)TGGPÆ‚GNF OGVCNNWTIKECN YQTMU UWEEGUUHWNN[ EQOOKUUKQPGF CV 6CVC 5VGGN -CNKPICPCICT ,Q WKH Æ‚UVW SKDVH RI 7DWD 6WHHOÅ’V DPELWLRXV LQYHVWPHQW SURJUDPPH DW WKH .DOLQJDQDJDU ORFDWLRQ LQ WKH GLVWULFW RI 2GLVKD LQ ,QGLD WKH FRQYHUWHU VKRS VHFRQGDU\ PHWDOOXUJ\ IDFLOLWLHV DQG D FRQWLQXRXV VODE FDVWHU ZHUH SXW VXFFHVVIXOO\ LQWR RSHUDWLRQ LQ 0DUFK 7KH LQWHJUDWHG LURQ DQG VWHHO SODQW RI 7DWD 6WHHO LV GHVLJQHG IRU DQ DQQXDO SURGXFWLRQ RI PRUH WKDQ VL[ PLOOLRQ WRQV RI VWHHO VODEV The new steel plant was an ambitious investment project. Tata Steel awarded SMS group the order to supply the main plant equipment, i.e.: â–ª a twin station hot-metal desulphurization plant, MPT International 5 / 2016

▪ a converter shop featuring an Ecoplants gas cleaning and recovery plant, ▪ a CAS-OB unit (composition adjustment by sealed argon bubbling – oxygen blowing),

â–ª RH degasser (Ruhrstahl-Heraeus) and â–ª a two-strand slab caster.

SMS group also supplied the complete X-Pact® electrical and automation package inclusive of level 2. With

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56''./#-+0)

25

The plant thus pays for itself in a short time.

Secondary metallurgy for high-quality steel In the CAS-OB facility, inert gas is used to create a slag-free area at the melt surface into which a refractory bell is inserted. Alloys can now be added into the steel under an inert atmosphere and without recovery loss to the slag or atmosphere. The addition of aluminum and the blowing of oxygen onto the surface of the steel inside the bell create an exothermic chemical reaction which increases the temperature of the steel. The addition of alloys under an inert atmosphere, and the ability to stir the melt after chemical heating, helps to improve the cleanness and homogenization of the steel.

In the RH degasser the steel is subjected to vacuum treatment to perform metallurgical tasks such as hydrogen removal or decarburization. The TOP lance facility of the degasser also allows chemical heating of the steel by exothermic reaction between oxygen and aluminum. Furthermore, the TOP lance incorporates the ability to blow powder for limited desulphurization at the RH unit.

2-strand continuous slab caster

Intelligent slab casting technology availability of all these technologies, the process routes in the steel plant are extremely flexible: the steel can be treated in the secondary metallurgical plant CAS-OB and/or RH facility. This ensures the manufacture of a large variety of steel grades.

Powerful and clean converter shop The first of three converters, each with a capacity of 310 tons, has gone into operation in the new converter shop. The second converter and the

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

RH facility will also be commissioned in 2016.

SMS group supplied the converter vessel, the trunnion ring, the vesselto-ring lock system with the patented lamella suspension system of the latest generation, the tilt drive, material charging facilities and further auxiliary plants. The converter is equipped with a bottom stirring system, which is necessary for the manufacture of several highly demanding steel grades.

The Ecoplants gas cleaning plant is equipped with the Baumco CO system. This enables a large proportion of the chemical energy contained in the molten metal in the form of carbon to be recovered as carbon monoxide (CO) gas during the converter process. The primary gases are cleaned by a venturi scrubber in two stages. The gas recovery plant feeds the gas back into the works network.

The two-strand vertical-bend continuous caster supplied by SMS group is designed for the production of quality slabs in a thickness of 230 mm and widths 1,000 – 2,000 mm. The maximum casting speed of the highly productive caster is 1.9 metres per minute.

The caster equipment includes several ISC® modules (intelligent slab casting) which determine quality and production. Among these are the hydraulically powered resonance oscillation system, remote-controlled mold narrow faces for width change during casting and the position-controlled ‘Cyberlink’ segments for performing dynamic soft reduction.

The production of slabs of high internal quality is thus guaranteed in combination with the width-dependent air-mist secondary cooling and the technological dynamic solidification control process model.

MPT International 5 / 2016

26

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STEELMAKING

Single bucket charging practice with telescopic EAF roof closure $Q HOHFWULF DUF IXUQDFH ZLWK WHOHVFRSLF URRI FORVXUH LQVWDOOHG DW %DÄœWXJ 0HWDOOXUJ\ LQ 7XUNH\ KDG EHHQ VXFFHVVIXOO\ LQ RSHUDWLRQ IRU DERXW Æ‚YH \HDUV 7KH PDLQ WDUJHW RI WKH WHOHVFRSLF GHVLJQ KDG EHHQ WR DOORZ IRU VLQJOH EXFNHW FKDUJH HYHQ ZLWK ORZ FKDUJH GHQVLW\ ,Q D PDUNHW FKDUDFWHUL]HG E\ FRQVWDQWO\ GHFUHDVLQJ VFUDS TXDOLW\ %DÄœWXJ 0HWDOOXUJ\ ORRNHG IRU ZD\V WR IXUWKHU LQFUHDVH ($) SURGXFWLYLW\ ,Q WKH ($) ZDV PRGHUQL]HG DQG HTXLSSHG ZLWK D QHZ ODUJHU VKHOO DQG ELJJHU WUDQVIRUPHU 7KH DUWLFOH SUHVHQWV WKH H[SHULHQFH RI WKH RSWLPL]DWLRQ ZRUN SHUIRUPHG RQ VLWH DQG FRPSDUHV WKH RSHUDWLQJ UHVXOWV ZLWK WKRVH RI WKH RULJLQDO FRQÆ‚JXUDWLRQ Several furnaces operating with single bucket charging practice have proved to be extremely fast and highly productive steel melting tools which can achieve tap-to-tap times of less than 35 minutes and power-off times below 25 minutes [1 - 3]. Also power-off times are accordingly shorter since the furnace needs to be open only one time per heat. Large furnace shell volume required for single charging results in much longer off-gas residence time in the furnace. Thanks to this effect, the yield of chemical energy supplied to the furnace is obviously better than in case of standard furnace design. With a high pile of metallic charge inside the furnace shell, the heat generated by operation of the burners can be more efficiently transferred to the upper charge layers creating favourable conditions for in-shell scrap preheating. A furnace designed with a possibility to adjust its charging volume in function of available charge density is a next step of development, which is likely to reduce the known shortcomings of a standard single charge EAF.

2TKPEKRNG QH VJG VGNGUEQRKE HWTPCEG The main idea behind the design of the telescopic furnace or – to be more precise – the furnace with tel-

Roof and upper shell overlapping

escopic roof closure was to allow for flexible shell charging volume. Key points of this special EAF design are as follows: ▪ Utilization of single bucket with average charge density even below 0.55 t/m³ without expanding shell diameter and height above acceptable limits.

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MPT International 5 / 2016

â–ª Possibility to reduce the exposed area of the shell walls in function of melting progress decreasing furnace thermal losses and increasing thermal efficiency. â–ª Possibility to reduce electrode columns length decreasing elevated risk of accidental breakages which is typical for single charge EAF working with extra-long columns required to match extended shell height.

The telescopic EAF was invented by Fuchs Technology AG – the company well-known for its very innovative approach to and revolutionary solutions

STEELMAKING

‹‹‹

27

Electrode stroke

in EAF technology [4]. In 2015, Fuchs Technology AG was taken over by Inteco Melting & Casting Technologies GmbH which continues to work intensively on further optimization of the design and process technology related to this unique EAF solution.

In the telescopic EAF the electrode column length can be significantly shorter compared to other single charge EAF of similar capacity. During melting, the roof gradually slides down to the lower, fully closed position resulting in almost complete overlapping of the roof and part of the upper shell. The lifting systems for the gantry/roof and electrode are fully independent. This solution allows the electrodes to continuously follow the decreasing height of the charge pile in the furnace down to flat bath condition.

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The larger distance between the top of the scrap pile and the horizontal part of the roof allows for an initial charge bore down with higher power and longer arcs, increasing the average power input. As soon as the scrap mountain starts to melt, the roof with the electrode columns can be lowered to follow the gradual reduction of the charge volume. The cycle of the telescopic movement between the upper closing position after charging and fully closed position is completed after 30 – 40% of the power-on time.

The first telescopic EAF, originally designed for an average tapping weight of 140 t, has been operating at Baątug Metallurgy Melt Shop at Osmaniye Industrial Zone in Turkey since 2010. The shell volume of 300 m³ allowed to operate with single bucket charge using a scrap mix with a minimum average density of 0.58 t/m³.

Furnace charges are prepared using more expensive higher density imported scrap qualities and low density (0.3 – 0.4 t/m³) grades available on the domestic market or imported from

neighbouring countries. If the minimum charge density cannot be guaranteed, the furnace is forced to operate with two-bucket charge with a consequent productivity loss and worse performance results.

For instance, within the period between 1 April and 31 July 2015, the share of single bucket charges was about 40% only. The difference in furnace productivity and specific energy consumption between single and two-bucket operation is obvious.

The observed difference in specific energy consumption between single

2,000 mm Roof fully open for charging After charging

C H A R G I N G

Arc ignition

Melting

1,500 mm Roof lowered

1,000 mm 750 mm 500 mm 250 mm 0 mm

Heat end power on 28 – 30 min 56,000 kWh 315 kWh/t charge

8 – 10 min / Roof fully closed / 20,000 kWh 115 kWh/t charge Sequence of telescopic roof closing MPT International 5 / 2016

28

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STEELMAKING

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bucket charges and two-bucket charges is in the range of 50 – 80 kWh/t (good billets). This clearly indicates that the EAF’s thermal efficiency with single bucket operation is much higher – thanks to in-shell charge preheating by the chemical energy supplied to the furnace and by more efficient transfer of heat to the upper charge layers especially while the burner is in operation. In case of two-bucket operation, the available time for heat transfer to the scrap is shorter, being the reason for less efficient off-gas heat recovery and transfer.

The furnace was originally equipped with a 150 MVA transformer, with 120 MW active melting power. The average active power needed to be limited to about 107 MW due to problems with arc stability and resulting power losses in the middle of the melting time.

The EAF also utilizes an on-load reactor with 2.4 ohm reactance at the highest tap which enlarges the range of available power input set points.

In the beginning, chemical energy was input by five combined coherent burners and oxygen injectors and a slag door manipulator with consumable lances (two oxygen and one carbon). Three carbon injection points were additionally installed on the shell panels. All carbon lines were connected to a single injection machine.

The original arrangement of chemical energy tools showed to be inefficient, mainly due to difficulties in achieving a proper balance between the furnace cold and hot spots. Melting was not uniform with frequent caving and unstable arcs resulting in relatively low average power.

MPT International 5 / 2016

The unsatisfactory performance of the chemical energy package called for modifications. The number of coherent gas/oxygen injectors was increased to eight units. Each carbon injection lance has been connected to a separate injection machine allowing for individual carbon flow control.

All injectors are of the same design allowing to utilize up to 5 MW of burner power – with 500 m³/h (s.t.p.) of natural gas and 1,000 m³/h (s.t.p.) of oxygen, and up to 2,000 m³/h (s.t.p.) of oxygen in the supersonic lancing mode.

Carbon is injected through shell walls at three points (each one with a flow rate of up to 80 kg/min). Carbon injection through the door lance is used as a back-up for the wall injectors. Injection of oxygen through a consumable door lance is limited to melting of scrap pieces resting on the slag door sill (200 – 300 m³ (s.t.p.) of oxygen per heat).

6GNGUEQRKE '#( RGTHQTOCPEG The thorough analysis of the operation of the telescopic EAF carried out

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in May 2015 was concluded with the following results: â–Ş Specific energy consumption is significantly lower compared to a standard EAF operating with a similar structure of charge materials and similar chemical energy input (specific gas, oxygen and carbon consumptions). â–Ş The melting rate of the furnace was still below the optimum level. The main reason identified for this problem was the fact that the coherent injectors in burner mode were operated at less than 40% of the available power (specific gas consumption below 2.0 mÂł (s.t.p.) per t) generating less heat for in-shell preheating of the scrap [5]. â–Ş Insufficient burner power and early beginning of oxygen lancing resulted in frequent caving phenomena and arc disconnections when the scrap pile started to move down inside the shell.

MPT International 5 / 2016

â–Ş The use of higher burner power allows for more intensive melting of scrap from the walls to the centre of the furnace resulting in a more uniform sliding of the scrap layers.

By more precise coordination between the electrical and chemical power supply, it would be possible to significantly improve the melting rate and EAF productivity [6].

It was also concluded that the electrical power input had to be revised with the focus on the average power increase. â–Ş Much lower electrode consumption thanks to gradual reduction of the electrode hot length during melting and a significantly lower side oxidation rate are other clear advantages of the telescopic EAF. Possible improvement in melting behaviour with more uniform conditions should also be able to reduce the occurrence of electrode breakages. In addition to pure cost sav-

ing, less electrode breakages would also result in operational time savings.

Some improvement related to the burner operation mode had been introduced increasing the burner power from 3 to 4 MW. Simultaneously extension of the burner operation time and further adjustment of individual burner power input were to achieve more uniform melting across the whole shell volume. Increase of oxygen consumption in the burner mode required to reduce lance oxygen consumption in order to maintain the total consumed oxygen below 30 mÂł (s.t.p.) per t of billets. BaÄ…tug defined this condition as very critical, aiming to maintain the yield of good billets from charge at a level close to 90%. The introduced changes improved furnace performance (see graphs showing long term specific energy consumption trends).

It can be seen that the gas consumption increase was a key factor allowing

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to stabilize the trend of decreasing energy consumption. Except for direct scrap melting with burner flames, the off-gas temperatures could be raised by increasing the intensity of in-shell scrap preheating. Minor variations in oxygen consumption had practically no influence on the results.

5ETCR DWEMGV NQCFKPI RTCEVKEG CPF RTGJGCVKPI GHƂEKGPE[ Better understanding of the phenomena of heat transfer between the combustion gas and the steel scrap can greatly improve melting process efficiency – for example by determining the time at which heating efficiency drops below economically accepted levels and/or by determining the best scrap type, size and density to charge near the burners for making use of the in-shell preheating effect.

Analysis of practical experience results in the following conclusions: ▪ Scrap temperature increases to maximum after about 8 minutes of burner operating time; efficiency of preheating at that moment is 85 – 90%.

▪ Scrap type, density, shape and specific surface have a significant influence on the achieved preheating temperature (+ 50°C higher temperature for HMS1 scrap compared to small size shredded scrap).

▪ Smaller size scrap captures the heat more efficiently because of a greater surface-to-volume area.

▪ If more heat is transferred to the scrap, the off-gas temperature will be lower.

The off-gas heat penetrates more deeply as the scrap heats over time. More burner power produces more heatMPT International 5 / 2016

ing. Based on the monitored off-gas temperature it can be concluded that heating is more effective (in the sense of higher temperature achieved) for smaller size scrap. With large size scrap, the ratio between pre-heated area and the whole charge volume is greater due to easier off-gas flow through the scrap layer.

At this point, it can be concluded that loading of the scrap bucket with different scrap qualities should be optimized in view of the combustion gas flow through the charge volume and expected pre-heating efficiency, which additionally can be enhanced by the strong chimney effect through air inflow from the slag door to the 4th roof hole.

(WTPCEG WRITCFG CPF OGNVKPI RTQEGUU QRVKOK\CVKQP The EAF upgrade in August 2015 was focused on solving the problems resulting from the tap weight increase above the original design. The diameter of the lower shell was increased to 8,700 mm allowing for 200 t of liquid steel capacity (160 t of tap weight with 40 t of hot heel). The new upper shell expanded the shell volume up to 330 m³. A new 165 MVA transformer replaced the old one.

With shorter power-on times, the time available for chemical power input decreased as well. The gas, oxygen and carbon flow rates needed to be continuously adjusted to ensure minimum consumptions resulting from calculated energy balances without exceeding the limit of the total oxygen consumption of less than 30 m³ (s.t.p.) per t of good billets. As can be

seen, the average oxygen and gas consumption could be maintained at relatively stable levels.

Simultaneously, trials with alternative bucket loading patterns were carried out to find the optimum configuration. The trends for specific energy consumption relative to the actual yield values can be taken as process efficiency measures.

The presented results need to be considered with regard to the observed deviations among the individual heat results. The performance values are related to the actual good billet weights which change from heat to heat. These variations were caused by so called “billet migration” from one heat to another related to erroneous marking with improper heat numbers.

Low quality of scrap called for an increase in lime consumption which is definitively higher than the EAF steelmaking average (30 – 35 kg/t). The additional lime increases specific energy consumption in the range of 20 – 25 kWh/t.

Optimized melting conditions and reduced caving phenomena drastically decreased the number of electrode breakages from 8 to 4 per month on average. Specific electrode consumption – including the weight of broken pieces – remains extremely low in the range of 0.85 – 0.91 kg/t of billets. The percentage of heats with single bucket charge increased from 40 to 54%.

%QPENWUKQPU The main conclusions related to the telescopic EAF design and operational features can be summarized as follows.

STEELMAKING The telescopic EAF achieves higher efficiency than other single charge furnaces. The special furnace design allowed for partial elimination of negative aspects related to the large volume and height of the shell. In-shell charge preheating efficiency entirely depends on the proper set-up of the electrical and chemical energy input parameters. The influence of scrap quality on the furnace performance is clearly visible and can be influenced by optimized scrap bucket filling recipes.

‹‹‹

33

References [1] S. Laurenti, R. Gottardi, S. Miani, A. Partyka, A Single Bucket Charge EAF at Nucor Jewett, Texas, Proceedings 8th European Electric Steelmaking Conference, Birmingham 2005.

[2] R. Gottardi, S. Miani, A. Partyka, A Faster, More Efficient EAF, Proceedings 9th European Electric Steelmaking Conference, Krakow 2008.

[3] D. Ellis, V. Varrick, M. Abel, T. Daum, EVRAZ Pueblo Best Practice Operation with SIMETAL EAF Ultimate Technology, Proceedings AISTech 2013 Conference, Pittsburgh.

[4] G. Fuchs, K. Rummler, New Energy Saving Electric Arc Furnace Designs, Proceedings AISTech 2008 Conference, Pittsburgh.

[5] K. Mandal, G.A. Irons, A study of Scrap Preheating by Burners, Proceedings AISTech 2008 Conference, Pittsburgh.

[6] R. Gottardi, S. Miani, A. Partyka, Ultra-High Chemical Power Electric EAF for 320 t/h, Stahl und Eisen, August 2008.

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MPT International 5 / 2016

34

››› 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.

SMS group has successfully commissioned an electric steel plant with efficient environmental technology and a single-strand continuous slab caster at PT. Gunung in Bekasi, West Java province in Indonesia. The meltshop with EAF and ladle furnace is designed for an annual production of 1.2 million tons of steel to be cast into slabs on the new continuous caster.

B.K. Dutta, general director: “The new works is of high strategic importance to us. Until now, we had to purchase slabs. By producing slabs ourselves, we do not only achieve a higher creation of value, but also ensure high quality thanks to the plants supplied

by SMS group. Of course, all our plants are energy-efficient and easy on the environment. That is why we purchased them from SMS group.�

SMS group supplied the complete basic and detail engineering, the mechanical and electrical core components and the supervision of erection and commissioning. The SMS group scope of supply furthermore includes the complete X-PactŽ electrical and automation system including level 2 automation and commissioning according to the tried and tested “plug & work� concept.

*KIJN[ GPGTI[ GHĆ‚EKGPV OGNVKPI WPKV SMS group supplied an 120-t ARCCESSÂŽ electric arc furnace and a 120-t ladle furnace. This specific EAF type is optimized for highly efficient

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MPT International 5 / 2016

Electric arc furnace with the patented oxygen injection system

use of electrical and chemical energy.

The EAF at PT. Gunung is equipped with the latest generation of the patented SIS (SMS injection system) oxygen injection system, which combines innovative injection and burner technologies. This concept proves its worth through high productivity while keeping production costs low.

The EAF is equipped with a gas cleaning system. The dust-laden gases arising at the furnace and ancillary plants during the steelmaking process are efficiently captured and reduced to a residual dust content of less than 10 mg/ mÂł (s.t.p.). The system is operated by speed-controlled fans which consume a minimum of electrical power as the suction capacity is optimized depending on the specific process.

5QRJKUVKECVGF UNCD ECUVGT The continuous caster is designed for the production of slabs with thicknesses of 220 – 250 mm and widths 800 – 2,100 mm. The range of grades produced will comprise structural steels as well as pipe and heavy-plate grades.

The caster segments are equipped with STEC-RollÂŽ technology. Such rolls optimize the casting process and set new standards for cost-effective maintenance and servicing, thanks to their long service life and the possibility of re-using them.

The continuous caster is equipped with modules from the ISCÂŽ (intelligent slab casting) package, which ensure optimal plant productivity and slab quality. These modules include the hydraulically actuated resonance

STEELMAKING oscillation system, the mold with remote-adjustable narrow faces for changing the slab width during casting, as well as the mold monitoring system.

The horizontal part of the strand guide system uses position-controlled CyberLink segments. Dynamic Soft Reduction® in combination with the metallurgical process model DSC® (dynamic solidification control) to control secondary cooling allows the production of slabs with perfect internal quality.

On the new plant, PT. Gunung produces high-quality slabs for further processing in its own Steckel and heavy plate mills. At the Bekasi location, PT. Gunung operates a long-product line for the production of sections and wire rods, as well as a flat-product line for the production of heavy plates and pipes. All major production lines were supplied by the SMS group.

‹‹‹

35

The CCM is designed for the production of slabs 800 – 2,100 mm wide

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››› COMPANY PROFILE

Plans for a minimill powered by renewable energy at Newport, South Wales Liberty House Group has a Greensteel vision for the UK, using renewable energy to melt the readily available supply of scrap in Britain. It intends to change the steel industry in WKH 8. HQDEOLQJ LW WR EH PRUH FRPSHWLWLYH ĆƒH[LEOH DQG VXVWDLQDEOH

Liberty chairman Sanjeev Gupta (left) together with Newport city’s elected representatives during a site visit in May (Courtesy: Liberty House Group)

In spring this year, when Tata Steel UK announced it would sell two Scottish plants – Clydebridge and Dalzell steel facilities – to Liberty House Group, this news brought into focus the steel related activities of the Gupta family. Liberty House Group is an international business, specializing in metals trading and the manufacture and distribution of steel and advanced engineering products. Operating from four strategically-positioned hubs in London, Dubai, Singapore and Hong Kong, the group has a network of operations spread across 30 countries. Within Lib-

Liberty Steel Group, Newport, Wales, UK Contact: www.libertyhousegroup.com E-mail: libertysteel@libertyhousegroup.com

MPT International 5 / 2016

erty House Group, Liberty Industries Group is the steel manufacturing and distribution division. Divided further into Liberty Steel Group and Liberty Engineering Group, the steel division has sites in the UK, Africa and India, and employs circa 1,500 people.

Its global steel production capacity exceeds 4 million tonnes per annum.

Liberty House Group and SIMEC are members of the Gupta Family Group Alliance (GFG Alliance) – an association between the business interests of Parduman K Gupta and Sanjeev K Gupta. Liberty’s sister company SIMEC is an international resources group focused on sustainable power, mining and infrastructure assets.

Besides the Scottish plate facilities mentioned before, Liberty Steel Group operates a hot strip mill in Newport, South Wales. Restarted in October 2015, this rolling mill is already produc-

ing 10,000 tonnes a week of hot rolled coil targeting to increase the output to one million tonnes a year. Although the group has steel production facilities in other countries, the re-commissioning of the rolling mill at Newport was its first invstement in UK production capacity. Since then it has gone on to acquire most of the former Caparo steel businesses in England and also a rod and bar mill and the meltshop equipment of the former Thamesteel works at Sheerness Docks in Kent.

Liberty chairman urges UK industry to embrace Greensteel future Sanjeev Gupta, executive chairman of the Liberty House Group, has set out the company’s vision for radical change to make the struggling UK steel industry competitive again. In a video

COMPANY PROFILE published online in early June he calls on everyone with a stake in the industry to embrace the Greensteel vision, which involves extensive investment in facilities for melting and upcycling Britain’s growing mountain of scrap steel, powered by renewable energy.

This, he said, would mean the introduction of modern electric arc furnaces. In addition it would mean the development of low-cost, low-carbon power sources close to steel plants across the country.

Moreover, it would require greater integration of steel production with value-added engineering and manufacturing businesses to reinvigorate the industrial supply chain in the UK and drive innovative product development.

Mr Gupta said, the struggling UK industry now supplies only 20% of Britain’s annual steel demand and is in a ‘precarious and unsustainable’ position. But he added: “We need to look at the present challenge as a great opportunity to reshape the industry so that it can be successful again.” He said, Liberty had made its own choice to follow the Greensteel route.

Plans unveiled for a Greensteel minimill at Newport, South Wales GFG Alliance companies, Liberty House and SIMEC, have unveiled major plans to turn their adjacent Newport sites (the steel mill and the Uskmouth power station) into a two million tonne a year steel super-plant, powered by renewable energy. It would be the first Greensteel facility in the UK and would play a major part in a renaissance of the struggling sector.

Together, the plants shall help realize the vision for a sustainable steel sector, powered by renewable energy. It would help achieve the dual objective of reducing carbon emissions while making the UK steel sector competitive again.

According to Liberty executive chairman Sanjeev Gupta, the firm intends to install 2 million tonnes of liquid steelmaking capacity at Newport and almost double the existing rolling capacity at the site. At the same time, SIMEC aims to power the steel plant by converting its existing coal-fired power-station to eco-friendly biomass generation. Longer term, it will develop a centre of excellence for renewable

.KPM VQ YCVEJ VJG ƂNO QP ;QW6WDG https://youtu.be/dZknnzSMpcA

energy that includes various forms of green power, including waste-to-energy and tidal lagoon power in the adjacent estuary.

All of this can provide low-cost, low-carbon fuel sources to power a steel industry which in turn can be made more competitive and sustainable through recycling and upcycling of UK’s growing mountain of scrap.

A recent University of Cambridge report predicted that the UK’s supply of scrap will rise from 10 million to 20

‹‹‹

37

million tonnes a year within a decade.

At present, 70% of Britain’s scrap steel is melted abroad, because of high power prices, but melting at home instead would generate thousands of new jobs.

Following significant investments, SIMEC reopened Uskmouth Power Station and Liberty restarted the adjacent steel rolling mill in 2015, both of which had been mothballed by previous owners. At present, the two sites employ over 200 people with plans for many hundreds more when SIMEC rolls out its energy park plan and Liberty recommences the melting of scrap steel at Newport.

Liberty executive chairman Sanjeev Gupta said: “We believe our Greensteel vision will generate many new skilled jobs in the city and ultimately make a major difference to the whole UK steel and wider manufacturing sectors. Historically, Newport has been one of the country’s most important steelmaking locations, so it’s very appropriate that this is the springboard for our Greensteel plans. If we can make steel competitively in the UK, we can generate potentially hundreds of thousands of jobs in the manufacturing sector nationwide,” he added. He explained that he and his colleagues wanted to create a major fully-integrated ‘endto-end’ business which encompassed everything from green power, through liquid steel production, to steel processing and the manufacture and distribution of high-value steel products.

Mr Gupta added, that government support in removing carbon tax on power stations feeding steel plants, their backing for conversion of coal-fired stations to biomass and the green light for tidal lagoon power would give the steel industry and manufacturing a huge boost and a bright future.

STEEL INDUSTRY

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MPT International 5 / 2016

38

››› MODERNIZATION

Performance modules increase GHĆ‚EKGPE[ QH NQPI RTQFWEV OKNNU Dedicated upgrade and automation packages for long product rolling mills provide a very fast return of investment. “Performance modulesâ€?, such as process modules, JXLGH DGMXVWPHQW GHYLFHV FURVV VHFWLRQ PHDVXUHPHQW GHYLFHV SURĆ‚OH JDXJHV RU HYHQ a process guidance system, added to plants as an upgrade improve mill operation and PDNH SURFHVVHV PRUH HIĆ‚FLHQW SMS group has developed various technologies and equipment that are highly suitable to be retrofitted to existing mills in order to increase the competitiveness of a mill by improving productivity and efficiency, and consequently reducing overall conversion costs. They additionally improve the product quality and allow steel producers to make more value added products. In addition, inexpensive performance packages like process models and measuring gauges help to make the production process transparent and more efficient.

Precision sizing mill increases TQNNKPI GHĆ‚EKGPE[

Precision sizing mill in operation at Steel Dynamics Ind., USA

The steel industry has been coping with the problem of overcapacity and the associated deterioration of steel prices. Therefore steelmakers are reluctant to build up new steel plants and increase production capacity. Instead, operators aim at making existing mills more efficient by modernizations or by adding more value to the steel products by improving their quality. In times of overcapacity and tough competition that results in low steel prices, only the best performers are able to make profit, whereas the low and average performing compa-

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MPT International 5 / 2016

nies may not be able to survive in the medium term.

In addition to factors like raw material sourcing, cost of labour and energy, efficiency of the production route plays a major role. Bringing the plant to the highest possible level of efficiency in terms of yield, utilization rate, manpower requirement and energy efficiency will result in low conversion costs. Some of these targets are achievable only by major modifications to the production process, for example, by eliminating entire production steps. For instance, introducing beam blanks in section rolling would reduce rolling work in the mill, or replacing a continuous section mill by a tandem reversing mill would increase mill efficiency and reduce the production costs as a result of reduced roll inventory and higher availability.

The precision sizing mill (PSMÂŽ) is used as finishing mill in a SBQ bar mill. It comprises a 4-stand finishing mill with 3-roll cassettes. This plant configuration is a key success factor in SBQ mills since it provides the following advantages: â–Ş one family rolling, which means that all size changes will take place in the PSMÂŽ only and no rolls in the roughing or intermediate mills have to be changed, â–Ş close bar tolerances of up to 1/8 DIN standard resulting in increased material yield, â–Ş due to the close tolerances, peeling losses can be reduced by up to 2.5 %, â–Ş increased mill flexibility due to the short roll change time of only 5 minutes, â–Ş free size rolling by adjusting the rolls (instead of roll change), â–Ş high mill availability.

An outstanding feature is the ability to adjust the rolls under load – fully automatically and in real time. Each roll is adjusted by a hydraulic cylinder. This proven concept is in operation at many

MODERNIZATION mills. It offers a number of advantages like automatic gap control, monitor control, roll force measurement and overload protection. In combination with a MEERgauge® bar measuring system, automated feedback of actual dimensions into the adjustment system is possible by the ‘monitor control’ feature.

The system is able to automatically compensate any mill spring, feeder variations and bar entry impacts. It can also level out temperature variations along the bar. Based on the TCS closed-loop control system, the system adapts to different rolling conditions and thus instantly optimizes the process for maximum yield, availability and product quality. The PSM® is a stand-alone system well suited as a retrofit to increase product quality or increase mill efficiency. Compared to a traditional two-high finishing mill, mill availability can be increased by up to 15%.

*KIJN[ ƃGZKDNG RTQFWEVKQP D[ WUKPI VJG /''4FTKXG® wire TQF ƂPKUJKPI DNQEM Highest efficiency and maximum flexibility within the production process – these are the key factors for success in the wire rod market. In this respect, conventional group-driven wire rod blocks set limits as they are only able to roll with fixed reduction ratios which require fixed roll ring diameters within the individual block. Complex gear box configurations are necessary which are subject to wear and maintenance. Furthermore, conventional blocks require huge medium-voltage motors with capacities of up to 7,000 kW. With MEERdrive®, SMS group provides an intelligent drive concept that overcomes the limitations of conventional solutions. The special feature of this concept is that it is based on individual drives for each stand position.

MEERdrive® offers a number of advantages over a conventional block: ▪ reduced maintenance and spare parts, ▪ increased flexibility, ▪ reduced roll costs, ▪ reduced energy consumption, ▪ better product quality.

A large distribution gear box as well as line shafts and bevel gears for driving the individual stands are no longer re-

‹‹‹

39

quired. Further, all moSAVING OPERATING COSTS tors are small low-voltage A comparison of operating costs on different blocks motors. In case of a motor MEERdrive® CONVENTIONAL failure, only a small spare motor is required. All this reduces spare parts costs and the effort of regular maintenance.

- 31 % The individual drive 6 Roll ring concept provides total management flexibility in roll pass de6 Electric sign: customers may freeenergy ly select reductions that Maintenance fit their needs, e.g. different reductions for differRedressing ent sizes or steel grades.

Roll rings in Also free roll adjustment operation is possible to compensate for wear or different ma- Comparison of operating costs – MEERdrive® block terial spread behaviour. versus conventional wire rod block Roll diameters can be freely selected so that only the worn be optimized and with it the tolerance out roll set has to be replaced or re- along the rod length. dressed. In the conventional mill all All these advantages sum up to a total rolls have to be redressed to the same cost saving in the block arrangement of dimension, resulting in massive roll up to 31% compared to a conventionwear. The MEERdrive® concept reduc- al block arrangement. The MEERdrive® es redressing work in the roll shop. The provides for highest flexibility and best roll inventory is only one third of that product quality while reducing operatof a conventional block arrangement. ing costs. Additionally, thanks to the Since less mechanical parts are re- modularized design, the stands can quired, the idle power is reduced. The be flexibly arranged, for example as 6 overall concept results in lower ener- + 4 stands, 4 + 4 stands or in any othgy consumption and fewer CO2 emis- er combination. Thermo-mechanical rolling is possible in this split bock arsions.

The possibility of freely adjusting rangement. Also in a 4-stand MEERthe rolls to compensate for wear and drive®plus all sizes can be finish-rolled spread and the optimized pass design applying the single family rolling conresult in better tolerance and ovality. cept. The MEERdrive® concept is well Additional small motors recognize the suited for modernizations replacing extension between two blocks in a two- isting blocks to increase rolling speed, block arrangement. This allows the product quality and flexibility while rolling speed in low tension rolling to reducing operation costs.

Screenshot of MEERgauge® measurement MPT International 5 / 2016

40

››› MODERNIZATION

4GCN VKOG SWCNKV[ OQPKVQTKPI

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Euros / ton for each ton produced

The MEERgaugeŽ laser system operates on the basis of the “ laser light cut� technology. Four sensors perform synchronous, contact-free measurements over the entire cross-section of the bar.

With no moving or oscillating parts, the system is almost maintenance-free.

With a scanning rate of 500 scans per second, a true-shape cross-section is created from up to 720 synchronous measuring points in a shared coordination system, and is then displayed with maximum precision. Unlike in conventional systems, the true shape of the bar or section will be represented, so that the complete shape with all dimensions can be recorded, for example, of complex sections like rails where all dimensions are important.

With the installation of a MEERgaugeÂŽ system it is no longer necessary to stop the mill and take samples for dimension measurements. The system rather provides a real-time feedback, which is required to adjust the rolling mill accordingly. As a separate module (SurfTec), a surface inspection function can be added to see product anomalies and surface defects of the hot bar or section online. By this, cobble and inferior manufacture can be almost avoided. It also makes visual inspection by humans superfluous, saving time and labour.

Sales by no. of bars Guide cost difference Less cobbles & crop Less short bars

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Bar size Production cost comparison – high-speed delivery HSDŽ system versus slitting

*KIJ URGGF FGNKXGT[ U[UVGO HQT UOCNN FKCOGVGT TGDCT Two different technologies are available for efficient production of small rebar sizes: either slitting of the billet (into two or four finished sizes in order to increase mill output) or rolling a single strand at high speed of up to 50 m/s onto the cooling bed. For installation in the latter mill configuration, the high speed delivery system (HSDÂŽ) comprises a finishing block with tungsten carbide roll rings, a dividing shear, pinch rolls, bar braking rolls and a drum-type system to discharge the bars into the notches of the cooling bed.

With a HSDÂŽ system, production costs can be minimized due to: â–Ş lower guide costs as HSDÂŽ eliminates the need of slitting boxes and twister guides, â–Ş less cobbles and crop end losses and less trial bars thanks to easy operaMPT International 5 / 2016

Bar coils at the exit of a vertical compact coiler VCCÂŽ

tion of HSDÂŽ, while multi-slitting of small sizes requires demanding and delicate set-up of the equipment, â–Ş considerably higher yield as there is only one bar per cooling bed notch. Multiple bars per notch generate overlapping or misalignment which would affect downstream operations such as cold cutting, counting and bundling.

Further, it provides for excellent control of the bar tolerance, since only one strand is being rolled in each stand and the size can be precisely adjusted in the finishing block. Since rebars are generally sold by number of bar or theoretical weight, rolling of dimensions in the lower tolerance zone (‘minus toleranc-

es’) is possible, which will considerably increase the material yield. The HSDŽ also allows production of small sizes from 6 mm in straight lengths. Such sizes are usually rolled on wire rod mills as bar-in-coil, which have to be re-straightened afterwards. Depending on the bar size, savings of up to 13 euros/t are possible as a result of this possibility, which may result in several million euros saved per year.

6GEJPQNQI[ HQT RGTHGEVN[ EQKNGF TGDCT The vertical compact coiler (VCCŽ) is today’s state-of-the-art technology producing compact and torsion-free

Produce and process metal more efficiently.

Powerful solutions for the metal industry As a global provider of automation solutions, Endress+Hauser has the necessary expertise to deliver robust and reliable field devices as well as customized solutions and services. Our industry-optimized packages enable you to lower energy and process costs efficiently and comply with environmental requirements. www.endress.com/metal Endress+Hauser Instruments International AG Kägenstrasse 2 4153 Reinach Switzerland

Phone +41 61 715 8100 Fax +41 61 715 2500 info@ii.endress.com www.endress.com

42

››› MODERNIZATION

Working principle of automatic size control ASC®

rebar coils – exactly what more and more rebar processors are requiring for their automatic downstream bar processing facilities. To get the perfectly shaped coil, one of the most important feature is coiling in the vertical position. This eliminates the need for turning manipulators and at the same time reduces the process cycle time, as all coils are formed in their final position. The VCC® is able to process coils of up to 3,500 kg. The high weight contributes to the efficiency of the downstream process.

The VCC® produces very dense coils of high weight, all layers are in order and spooled torsion-free. At the same time, the compact coil dimension is ideal for storage, transport and handling. The VCC® can be added to any rebar mill either to have coils as an additional product or to replace conventional pouring reels. VCC® lines can operate at rolling speeds of up to 40 m/s and spool dimensions from plain round 6 to 50 mm, rebars from 6 to32 mm or even small flats, hexagons and squares. Adding such an installation to existing mills, substantially improves productivity of the mill and the shape of the coils.

MPT International 5 / 2016

Tight tolerances for large DCTU CPF UGEVKQPU HCS hydraulic compact stands have been developed for the production of large bars. Whereas 3-roll sizing systems are only economical up to 150 mm, hydraulic compact stands can produce large bars of up to 280 mm with very tight tolerances. These stands are also suited to roll sections and H-beams, achieving improvements in product tolerances.

The modernized medium section mill of Hyundai Steel, Korea, demonstrates the wide field of possible applications for such stands. The aim of the modernization was to improve the tolerances of the sections produced and introduce close-tolerance SBQ bar production.

The stands are designed for modular arrangements allowing them to be used in two-high or universal mode to also produce H-beams. At Hyundai Steel the last four stands have been replaced

by HCS. These very compact and rigid stands come with hydraulically adjustable rolls. For rolling round bars, the last four stands are used as two-high stands in V-H-V-H arrangement.

All continuous stands are designed as HCS with hydraulic roll adjustment. The MEERgauge® is arranged behind the last

stand which allows automatic size control (ASC®) to obtain close tolerances of ¼ DIN also for large bars. This increases efficiency in downstream processing, e.g. in peeling operations due to the higher yield achievable or during forging as a result of the more precise piece weight. Also existing large bar mills can be equipped with new stands and ASC® control to increase their efficiency.

Another example is the large bar mill of Xing Special Steel, China, which comprises a breakdown stand and an 8-stand continuous train. The mill produces a wide range of SBQ and special steel grades in dimensions from 80 to 280 mm diameter.

%QPENWUKQP By retrofitting the equipment and processes presented above, the efficiency of existing mills can be improved.

With such revamps production costs can be reduced and the product quality improved, for example, in order to serve a more demanding market segment with higher profit margins.

The precision sizing mill (PSM®) increases efficiency compared to conventional bar mills by 10 – 15%. In addi-

MODERNIZATION

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43

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

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Küttner GmbH & Co. KG Essen/Germany

info@kuettner.com www.kuettner.com

www.koeppern.de

MPT International 5 / 2016

44

››› MODERNIZATION

tion, this system allows production of bars with close tolerances which markedly reduces peeling losses.

The MEERdriveÂŽ wire rod finishing blocks are well suited for modernizations of existing wire rod lines. They improve tolerances, cut energy consumption and save operational costs as roll consumption and roll inventory are reduced.

The MEERgaugeÂŽ laser gauge system measures the final product and performs in-line surface inspection. The system improves mill efficiency and avoids manual sampling.

The high speed delivery HSDÂŽ system reduces operating costs and improves efficiency in rebar production by feeding the product onto the cooling bed at a speed of up to 50 m/s.

Compared to the traditional slitting method, conversion costs of 6 to 13 euros/t can be saved. The vertical compact coiler VCCÂŽ spools rebars most efficiently and produces coils that save costs during downstream processing.

Large bar mill of Xining Special Steel, China, featuring HCS stands with ASCÂŽ control

The HCS compact stands for large rounds or sections are equipped with hydraulic roll adjustment and suited for monitor control to ensure close tolerances.

These are just a few examples out of many of how existing mills can be modernized to become more efficient by reducing operating costs.

framag Industrieanlagenbau GmbH /FVLJSDIOFS 4USB•F " 'SBOLFOCVSH 5FM

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Morgårdshammar AB Sales office Krefeld

“Contour Check Shape� measuring system in a wire rod mill

Contour measurement and dimensional surface inspection of long products during hot rolling A newly developed system from LAP inspects the entire contour with no shadowing HIIHFWV DQG VXSSOLHV VSHFLĆ‚F UHFRPPHQGDWLRQV IRU DFWLRQ LAP’s new “Contour Check Shapeâ€? system scans the entire contour and detects dimensional surface defects on long products during hot rolling. It detects at high resolution rolling defects which the systems routinely used up to now were unable to differentiate from one another. It thus provides specific recommen-

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MPT International 5 / 2016

dations for action for optimum adjustment of rolling stands. It also detects and classifies – on-line – both isolated and recurring surface defects which have, up to now, mostly only been discovered at the end customer’s. Its complete and precise measurement of contours also makes numerous sampling operations unnecessary, thus significantly reducing quality assurance costs.

&GĆ‚EKVU QH EQOOQP KP NKPG OGCUWTGOGPV RTKPEKRNGU Optical measuring systems based on the shadowing method have been

in successful use for in-line measurement of the contours of long product for decades. They have become established in rolling of long products and have become an indispensable part of this process. Systems featuring fixed or rotating sensors – LAP’s “Contour Check Round� or “Contour Check Edge�, for example – are notable for precise diameter measurement and perform extremely well in many wire and merchant bar mills.

Such systems generate shadow outlines of the sections in up to six axes. In some rolling defects, parts of the contour remain concealed in the shadow.

HOT ROLLING – QUALITY ASSURANCE It is therefore not possible to differentiate geometrical deviations such as overfills/underfills and roll misalignment or wear with certainty using these systems. The inspection results in all cases require more or less subjective interpretation by experienced operators. Defects affecting only a small portion of the contour, such as seam caused by overfill, for instance, cannot be reliably detected by shadow sensors.

Isolated surface defects, such as rolling inclusions, scabs and scoring, can also in principle not be detected from only a few diameter measurements.

Cyclical defects, such as roll spalling, for example, are also only discovered by the end customer, resulting in claims. Even rotating systems scan the surface in all cases only in a spiral pattern, and fail to detect these defects.

The producers of long products need zero-exception high-resolution scanning of the contour around the entire periphery, particularly on production lines for high-quality products. Even rolling seam of only a few tenths of a millimetre in height, caused by an incorrect filling ratio in the roll gap, can significantly impair the quality of a wire product.

In addition, systems are also needed which classify geometrical deviations such as rolling defects and surface defects automatically on the basis of objective criteria and provide the operators with unequivocal recommendations for countermeasures.

‹‹‹

47

In case of roll misalignment the system also indicates in quantitative terms how the roll should be readjusted

6JG UQNWVKQP EQORNGVG EQPVQWT FCVC LAP has developed the new “Contour Check Shape” system for long products with convex contours and for unequal-angle and U-section products. This system is based on the light-section principle and is equally suitable for steel billets, bar and sections with a round, rectangular or hexagonal cross-section, and also for tubes and wire. These systems detect dimensions and surface defects of relevance for the process on simple sections with concave elements, such as unequal-angle and U-sections.

This new system expands LAP’s range of measuring procedures for long products and provides a solution which meets the requirements for complete automatic quality as-

Other techniques are unable to measure complete roll wear. Only the light-section principle is able to scan the entire contour

surance. Unlike shadowing systems, “Shape” measures the contour across the entire periphery, with no shadow effects, and depicts the true cross-sectional surface of the section with no omissions. It scans up to 1,000 complete sections per second at a resolution of several thousand measuring points simultaneously. The system detects geometrical deviations at a resolution of up to 5 μm.

It thus now automatically classifies rolling defects which could not be differentiated from one another using shadowing systems and always re-

quired a – subjective – interpretation by the operator. The new system is therefore not dependent on the skills of individual employees, either at commissioning or during operation.

The system uses the data to generate specific recommendations for action.

In case of roll misalignment, for example, it signalizes not only the defect type, but also the degree of misalignment. The operator thus knows immediately what change needs to be made to the setting of the rolling stand.

The high data volume permits not only greater accuracy in contour measMPT International 5 / 2016

48

››› HOT ROLLING – QUALITY ASSURANCE

urement and detection of rolling defects, but also the inspection of isolated and cyclical surface defects. It thus allows comprehensive and objective monitoring of the entire rolling process.

These systems can be used at all stages of the rolling process, from the billet to the finished section or wire. LAP supplies a variety of standardized systems with measuring ranges of between 50 and 450 mm. These systems function at material temperatures of up to 1,200°C. Thanks to the short exposure time, the system “freezes� movement of the stock. Mistracking and rotation of the section during measurement therefore no longer have any effect.

stream rolling stands on the contour of the finished product across a number of process stages. LAP’s “Contour Check CC� software permits the display of data from multiple systems on the same monitor screen. Geometrical data from the roughing and medium-section mills can thus be compared against that of the finishing block in real time. It is of no importance in this context whether the upstream systems function using the shadowing method. This makes it possible to detect trends on a supra-machine basis, take corresponding action, and check its effectiveness immediately.

6JG VGEJPQNQI[ KP FGVCKN 5KPING U[UVGO EQPVQWT Four light-section sensors are inOGCUWTGOGPV CPF FKOGPUKQPCN stalled in the gauge. Each sensor projects onto the profile a laser line which UWTHCEG KPURGEVKQP These systems measure the entire profile, including the corner radii, on rectangular cross-section stock, such as billets, steel bars and sections. On round-section steel bar and wire they also detect geometrical deviations such as ovality and a range of rolling defects. They generate warnings and alarms if the contour data deviates from specification. They also determine across the length of the stock data such as off-size length, which is necessary for optimization of trimming scrap at both ends of the product. “Contour Check Shapeâ€? detects and measures rolling defects and surface defects simultaneously on steel bar and wire, for example: â–Ş technological rolling defects (overfill and underfill on one or both sides, incorrect roll-gap setting, ovality, roll misalignment, roll wear), â–Ş isolated surface defects (rolling inclusions, scale, scabs, scoring), â–Ş recurring surface defects (roll spalling, roll eccentricity).

The system is also suitable for use with the three-roll system for bar and wire.

Correction data for the rolling block is calculated with high accuracy, since the entire contour is known.

2TQEGUU CPCN[UKU CETQUU OWNVKRNG RTQFWEVKQP UVCIGU The interlinking of the data from a number of systems makes it possible to detect immediately the effects of upMPT International 5 / 2016

is received and recorded by the camera integrated in the housing. Deformation of this line is mathematically converted to contour information.

The profile can move without restriction within the scan field.

LAP uses blue laser light in order to generate optimum contrast with the red-hot surface of the metal. The lines overlap in order that the entire periphery of the profile is scanned without omission.

The image data is pre-processed in the sensor; an integrated real-time controller assembles the results from the four sensors to produce a complete and true cross-section profile. This procedure eliminates entirely the necessity of interpolating or reconstructing the profile. Measuring frequency is up to 1,000 Hz. The “Contour Check CC� software classifies the rolling defects and surface defects. In the case of roll misalignment, for example, it states the direction and size of the misalignment.

The measured data for temperature supplied by an integrated pyrometer can be used for conversion of data to cold dimensions. Any length-measuring system installed assigns the data accurately to the continuous length of the stock. The measured data is displayed graphically and numerically, in the form of a pie chart or line chart, for example. These show the trend in contour or in significant measured data across the length of the stock, togeth-

er with the corresponding tolerance bands. Where multiple systems are in use, their results can be displayed on a common monitor screen.

The software detects the orientation of the roll gap and depicts the contour in the correct position at all times, since the section may have rotated between the roll gap and the location of the measuring system. The LAP system thus makes rolling-stand adjustment significantly easier. With only a few mouse clicks, each individual operator can configure all screen masks so that that he can view only the data relevant to him. The software displays the profiles in the form of a pie chart or line chart for employees working on the rolling line, for example, while quality assurance is supplied with higher-level information and statistical data. The integrated data-base stores measured data for a number of months. Extensive statistical tools permit evaluation of stored data on the basis of a range of criteria - by coil, rolling charge or batch, for example.

'CU[ KPVGITCVKQP The system’s installation length of between 370 and 820 mm in the direction of rolling permits easy integration into existing rolling lines. Integration into level 2 materials tracking on the rolling line is possible using standard interfaces. LAP has also developed a multiply-acting protection concept for the new system on the basis of experience gained from hundreds of measuring systems installed on rolling lines. A heat shield protects the gauge against radiated heat.

Air flushing, optimized by means of guide baffles, assures constantly low temperature levels in the hermetically sealed interior of the gauge. Calibration remains stable even at high ambient temperatures, thanks to the flushing of the sensor base plate with conditioned air and water-cooling of the cameras. “Contour Check Shape� is therefore suitable for use within an extremely large service-temperature range. The system can be calibrated extremely easily using a calibration piece which is positioned in the scan field. This system is very largely maintenance-free, since there are no moving parts.

HOT ROLLING – QUALITY ASSURANCE 0GY RQVGPVKCNU

‹‹‹

49

of quickly producing within the specified tolerance band again after product-dimension changes is significantly increased. Unequivocal automatic classification of rolling defects means that their causes can be systematically eliminated – rolling-parameter settings are no longer dependent on subjective estimates or on the skills of the operator. Process-induced deviations,

The new system expands LAP’s “Contour Check” family of products with a system which measures the contour completely and at high resolution and supplies reliable geometric data that does not require interpretation. The combination of contour-scanning and defect detection opens up a whole range of new

Technological rolling defects

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bles this system to recover its costs in only a few months. Users have reported that, before installing the dimension-checking system, they used to cut a sample from every billet and measure it manually. This new system eliminates this operation entirely, thanks to its high precision and dependability, and these users now no longer cut samples from their billets.

Total dimensional inspection of the surface also makes it possible to detect isolated Isolated surface defects, classify them by sedefects verity, mark the corresponding zones and to downgrade the material if necessary. Process dependability is also enhanced. Scabs on billets which would rapidly result in product breakage and long production downtimes on downstream stands are detected, for example. Analysis of cy0MJJGLE GLAJSQGMLQ clical defects permits deductions concerning defective and worn rolls, and therefore timely roll changing. In a nutshell: the rolling-line’s process reliability and availability are boosted, costs are reduced, and only high-quality mate1AMPGLE rial that meets the customer’s specifications leaves the mill.

Claims are avoided.

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Typical rolling defects which other systems cannot fully capture for technological reasons

potentials for optimization of rolling of long product.

The dimensions of the stock can, for example, be checked on-line and rolling-stand settings corrected immediately. Thanks to high-density measurement, trimming achieves great accuracy, reducing scrap. The certainty

such as an irregular temperature profile in the feed materials, for example, are detected in real time.

This system makes a significant contribution to cutting costs insofar as off-line samples from every coil are no longer necessary in the finishing shop.

At many mills, this effect alone ena-

“Contour Check Shape” is a new LAP system for contour scanning and dimensional surface inspection of long product directly during hot rolling. This is an optical non-contact system which performs up to 1,000 measuring cycles per second. Several thousand measuring points are distributed across the entire surface of the stock, thus assuring high-resolution scanning of the entire profile. The system detects both rolling defects and surface defects automatically. It automatically classifies rolling defects which previously required interpretation by an experienced user. It operates in real time, thus permitting immediate correction of rolling parameters and shortening restart times after product changes.

MPT International 5 / 2016

Hardening unit of the heat treatment line (all pictures by courtesy of Steeltec, Germany)

Induction hardening and tempering of individual steel bars The secret of reproducing steel bars that have exactly the required mechanical attributes is a combination of profound understanding of the steelmaking process and using of modern heat treatment technology.

By subjecting single steel bars to controlled induction hardening, quenching and tempering, the microstructure and material properties of each individual bar can be carefully adjusted enabling continuous production of premium quality steel that exploits the full potential of the material. The result is high-strength, high-performance steel, with each bar and each

Guido Olschewski, Steeltec, EmmenbrĂźcke, Switzerland Contact: www.steeltec-group.com E-mail: thorsten.mueller@steeltec-group.com

MPT International 5 / 2016

production batch exhibiting uniform mechanical properties. Carrying out a carefully monitored quench-andtemper (Q&T) cycle on individual bars yields a product that meets the stringent demands of the automotive industry – demands that are set to become even stricter as a result of tighter DIN tolerances and standards. Such precise control of the steel’s properties would simply not be achievable if the bars were subjected to bulk quench and tempering in a furnace.

Homogeneity is the key Precision is the top priority when fabricating components for the auto-

motive sector. Component suppliers need to know that the steel they are using is always of the same high quality and that it can be machined or otherwise processed with absolute reliability. That is the ideal. In reality, however, the crux of the matter often proves to be the steelmaking process itself.

Quenched and tempered steel is frequently the material of choice for the highly stressed components used in the automotive industry. In many cases, the mechanical properties of the steel are adjusted during a bulk Q&T process. However, there are a number of disadvantages when steel is hardened, quenched and tempered in a bulk operation rather than by treating the indi-

HEAT TREATMENT

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51

Transitioning from the heating coil to the water quenching zone

atures for hardening, quenching and tempering and the ideal feed velocity, are stored in a database. Whenever a new or modified steel is to be processed in the heat-treatment line, Steeltec carries out lab studies to determine the necessary adjustments to the process parameters so that the desired microstructure and mechanical properties are attained. Automation also enhances product traceability. If the bars passing through the heat-treatment rig require mandatory documentation, as is the case for materials used in the automotive sector, Steeltec is able to provide comprehensive verification of the steel properties.

Premium quality steel bars up to 13 metres in length

vidual bars. Steeltec – a company of the Schmolz + Bickenbach Group – understands the risks associated with bulk heat-treatment and it knows how these risks can be avoided. One of Steeltec’s areas of expertise is in the production of high-performance steel – an area in which it has an excellent understanding of the technical details of the production process. “Bulk heat-treatment produces differences between the core of the bar and the surface of the bar and between the beginning and end of the bar. In many cases, these differences are critical particularly when the material shall be used for high-performance safety-related components,” explains Thorsten Müller, head of the Heat Treatment unit at Steeltec’s Düsseldorf site. If the steel is subjected to bulk heat-treatment, the scatter in the strength values is about 150 MPa and the material’s microstructure may also be inhomogeneous. If the required strength and toughness values are not distributed evenly over the entire component, the component could, in the worst case, fail, potentially leading to expensive and damaging product recall campaigns.

The solution is to give top priority to each individual bar “Tolerances are being continuously tightened by companies in the automotive and mechanical engineering sectors,” says Thorsten Müller. As one of the leading producers of special bright steel in Europe, Steeltec operates a single-bar heat-treatment line at its Düsseldorf site. Each bar is subjected to individually controlled heating, quenching and tempering. The continuous rotating feed mechanism ensures that each bar is heated evenly, gradually improving the mechanical properties of the steel until the required quality level has been achieved. This also helps to improve bar straightness. “We measure and monitor the feed velocity using a laser that is integrated into the heat-treatment line. Any problems, such as a bar jammed in the heat-treatment line, are immediately indicated,” explains Müller. “We not only have an efficient means to avoid technical defects in the material, but we can also maintain a constant feed rate and thus a uniformly high product quality level.” All of the relevant process parameters, such as the optimum temper-

The bars are individually fed in to the heat-treatment line via a worktable that is 13 metres long. Steeltec can therefore process bars with lengths ranging from 2.80 metres to 13 metres. Steeltec matches the size of the induction heating coil to the diameter of the round steel bar being processed.

Three different heating-coil sizes from 15 mm up to 80 mm are available. Selecting a heating coil that closely fits the diameter of the steel bar increases the efficiency of the non-contact induction heating process. “Choosing the coil of best fit also means that the heat-treatment process can be carried out even more precisely, which helps to enhance the quality of our steel products,” says Thorsten Müller. Technical details such as these enable Steeltec to conduct induction hardening and tempering of individual steel bars across the entire dimensional range from 15 mm to 80 mm. The company’s service portfolio also includes the heat-treatment of steel tubes, where again the key feature is the uniformity and precision of the process. The heat-treatment line is equipped with two pipe-lifting levers that enable the quenching medium to be drained from the tubes, thus ensuring that the microstructure is homogeneous, that the mechanical properties are uniformly distributed and that the tubes are straight.

MPT International 5 / 2016

52

››› HEAT TREATMENT

The pressure in the ring jets that spray quenching medium at the steel after hardening is carefully controlled by a flow meter. After quenching, the bar is then tempered. Here,

bar can, if desired, be subjected to additional controlled uniform quenching. As a result of the rapid heating, fast quenching and the high pressure generated by the ring jets, the indi-

Heat-treatment line showing the cooling bed in front

too, induction heating is used. In order to further optimize the physical properties of the steel, the heat-treatment line is configured so that each

vidual steel bars do not suffer from excessive decarburization or scaling.

Ensuring that all steps are carried out evenly and uniformly effective-

ly prevents mechanical distortion of the bars.

No compromises on quality A further special feature of the single-bar heat-treatment line in Düsseldorf is the two saws that are installed on the cooling bed. Thorsten Müller explains the need for the integrated saws as follows: “Some materials have a tendency to flake or spall at the bar ends. In the worst case, these surface defects can cause damage to the tools or sensors used in downstream processing.” To reduce the risk of this type of damage, Steeltec can automatically cut off a short section at the beginning and end of each bar immediately after it has undergone heat-treatment. Finally, the bars are carefully collected and stored in bundles. “Our extensive experience in the induction hardening, quenching and tempering of individual steel bars has been the basis for the continuous optimization of our heat-treatment system, and will continue to drive further improvements in future,” says Thorsten Müller in summary. A new advanced heat-treatment line is promising precision manufactured, high-performance steel bars of even better quality.

www.vip-kommunikation.de

www.siempelkamp.com

Precise rings – even from very demanding materials – can be rolled utilizing Siempelkamp’s latest process control along with our innovative machine design.

Our quick change tooling system enables customers to react quickly and meet the demands of even small batch sizes.”

Jim Kravec Global Sales Manager Ring Rolling

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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 as well as high temperatures and high loads. Additionally, it is essential that the grease chosen provides adequate performance for the application to reduce the occurrence of component damage.

Recently, there has been development in technology Previously, in the metallurgical industry, it was common to use simple lithium soap greases and mineral oils for many applications. Today, high-performance grease with different thickeners and additive packages allows for extended lubrication intervals and increased bearing life. One example is the use of polyurea greases which offer constant lubrication and protection in processes with high temperatures. Additionally, this type of grease will not clog the ducts of a centralized lubrication system.

Case history A large steel mill was accumulating plates at extreme temperatures on their output tables, causing the bearings to work under high loads and extreme temperatures. As a result the output table rolls were constantly locking and breaking, on average there were four roll breaks per month, which was interrupting production and increasing the risk of not meeting delivery dates.

Additionally, workers were having to change the rolls while the machines were still in operation.

Nilton Barbosa, South America Business Development Manager – Grease; Corporation: Quaker Chemical Corporation (“Quaker”), Conshohocken, PA, USA Contact: quakerchem.com E-mail: sabedraj@quakerchem.com

MPT International 5 / 2016

The gravity of the situation caused the mill to look for an alternative lubricating grease to their current calcium-lithium based grease that would not melt and remain in the bearing when exposed to the extreme temperatures. Therefore, eliminating the locking and breaking of the rolls would also help to improve worker safety, too.

The steel mill reached out to Quaker Chemical Corporation for a replacement to their current grease due to their relationship from providing other products and continuous technical assistance. Quaker walked the customer through assessing the situation and turntable and output machine application. After the assessment they suggested a conversion to QUAKERTEK™ UX 4615-EP for lubrication of the roll necks.

This suggestion was made based on the following qualifications: ▪ It is a polurea grease with a special combination of additives that provide excellent corrosion protection and oxidation.

▪ A high dropping point and excellent lubrication properties.

▪ Has been shown to replace lithium and lithium complex greases in applications subject to high temperatures.

The mill decided to trial QUAKERTEK™ UX 4615-EP, and throughout the trial period, the grease did not melt away and remained at the application point on the roll neck. Due to the positive results of the trial, the mill decided to also apply this polyurea grease to the output tables and swivel. Since converting to the new product there have been

QUAKERTEK™ UX 4615-EP did not melt and remained at the application point on the roll neck

no more crashes on roll breaks. Additionally, the mill was able to achieve cost savings from reductions in lubrication cycles, monthly roller replacements, and elimination of labor costs.

Supplier expertise and responsiveness also factored into the final decision. During the selection process, Quaker demonstrated their ability to quickly and thoroughly respond to the operator’s questions and fulfill requests for technical data quickly and thoroughly.

QUAKERTEK™ UX 4615-EP is polyurea thickened lubricating grease that has been specifically formulated and manufactured to provide outstanding lubrication in high temperature applications. Because of its high dropping point and excellent lubricating properties, this grease: ▪ can replace lithium and lithium complex greases in high temperature applications, ▪ provides excellent corrosion protection,

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

German engineering leads the way Revamp, Upgrades & Modernizations • Process improvement • Improved quality • Increased availability • Improved safety and reliability • Cost efficiency • Increased capacity Environmental Protection • Environmental improvements • Health, safety & sustainability • Emissions reduction • Energy savings • Compliance with statutory requirements Operation & Maintenance • Customized maintenance services • Minimized downtimes • Highly qualified staff • Backbone of maintenance management (CMMS) • High availability of correct spare parts

SPECIAL EQUIPMENT ▪ provides good oxidation stability, ▪ can be used in a broad range of service temperatures.

Keeping operations running smoothly

Approach to grease South America business development manager – grease, Nilton Barbosa, talks about Quaker’s total cost of ownership approach to grease. “Taking care of a customer’s operation doesn’t just mean keeping the mill rolling, but also means finding ways to reduce costs, improve performance and extend the life of their

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machines. “ Nilton continues, “A cornerstone of competitive advantage in manufacturing today are suppliers that can provide solutions to keep total cost of ownership at a minimum so grease manufacturers need to provide sustainable product solutions that require less volume and reduce energy during use, to bring real value to the customer.”

Mill operators should work with a grease supplier who has the expertise to offer technical advice to help evaluate situations, Competitor calcium-lithiQUAKERTEK™ UX 4615and who can offer realistic Grease um grease with black solids EP polyurea grease solutions to solve problems ranging from production Usage without leaking 1,067 kg/month 400 kg/month efficiency to worker safety. A good supplier should Lubrication cycles 4 per hour 1.5 per hour be looking for ways to help Drop point 170°C 304°C operations: ▪ lower costs by providMonthly rollers replacements 4 0 ing product solutions Monthly spare part costs $ 25,358.56 0 that require less volume and reduce energy durLabor cost $ 584.68 0 ing use, Total monthly costs $ 30,699.13 $ 2,928.09 ▪ improve performance through extending ma- Comparison of total monthly maintenance costs (roller price $ 6,339.64; labor cost for 4 chine life. mechanics plus 2 welders, per 8 hour period, cost $12.18/men hour)

Improve your profile with our hot-work tool steel.

In non-cutting shaping techniques, for example when extruding aluminium, tools and machines are subjected to particularly demanding conditions: high pressures and temperatures of over 500 degrees Celsius, including additional heat from friction and deformation. In order to preserve their hardness even under continuous use, they are made from specialty steel. Deutsche Edelstahlwerke’s Thermodur® brand of hot-work tool steels features characteristics

that are precisely tailored to these applications, such as high thermal stability and resistance to changes in temperature and to temperature-induced wear.

This enables them to deliver consistent quality – beginning with the primary material and extending all the way from tool construction to the final product.

SCHMOLZ + BICKENBACH GROUP www.dew-stahl.com

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'HĆ‚EKGPV CPF EQOOC HTGG ITKPFKPI QH JCTF TQNNU HQT EQNF TQNNKPI OKNNU 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, VLQFH WKH\ HQDEOH VLJQLĆ‚FDQWO\ KLJKHU TXDOLW\ VXUIDFHV ZLWKRXW FRPPDV

Roll grinding in the cold rolling mill (Courtesy: Tyrolit).

Austrian producer of technical abrasives, Tyrolit, has developed ‘Genis Roll Star’, a new generation of grinding wheels with CBN abrasive lay-

Gebhard Melchior, Head of business unit Metal Fabrication, Metal Industries; Tyrolit Schleifmittelwerke Swarovski K.G., Schwaz, Austria Contact: www.tyrolit.com E-mail: gebhard.melchior@tyrolit.com

MPT International 5 / 2016

ers on innovative cores for rolls used in cold rolling mills. It is the first truly cost-effective solution for machining ultra-hard (HSS) rolls and produces significantly higher quality surfaces without commas.

The most impressive feature of the new HSS rolls for use in cold rolling mills is their outstanding wear resistance and long lifetime. Their thermal resistance and mechanical stability ensure high operating safety in the harsh day-to-day working environment of

cold rolling mills. These characteristics are made possible by using special manufacturing methods and through the inclusion of ultra-hard alloy elements in the area of the roll shell. Such rolls are, however, very hard to grind using conventional grinding wheels.

It is often not possible to achieve the required results with conventional grinding tools, or only after extremely lengthy grinding times. Furthermore, constantly increasing requirements for the surfaces of the work rolls allow al-

SPECIAL EQUIPMENT

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59

Genis Roll Star grinding tool (left) and blow-up of the grinding segment (Courtesy: Tyrolit)

most no indentations (so-called commas); something which is very hard to achieve using conventional abrasives.

Previously, grinding high-strength materials using conventional grinding wheels was complicated and expensive. For this reason, rolling mills have delayed switching to harder rolls, despite being aware of the significantly longer lifetime of these rolls. However, with Genis Roll Star, Tyrolit has successfully developed an efficient alternative with CBN abrasive grain for grinding harder rolls. This grain is much harder than conventional abrasive grain and therefore provides highly efficient grinding of ultra-hard work rolls.

Focus on the grinding pattern CBN abrasive grains are not only harder and more durable, but are also better embedded in the abrasive layer than conventional aluminium oxides. Gebhard Melchior, head of marketing Metal Fabrication at Tyrolit, explains: “Wear in vitrified bonded CBN grinding wheels is considerably reduced compared with conventional resin bonded grinding wheels. This also reduces the risk of grain break-out, enabling us to guarantee our customers a uniform, practically comma-free surface structure with Genis Roll Star.”

The good damping properties of the core also contribute to an excellent

surface finish. This is why Tyrolit also relies on an innovative, resin bonded core in the Genis Roll Star, offering extremely smooth operation even at operating speeds of up to 80 m/s. The new grinding wheel though is also fast and effective at speeds of up to 50 m/s, which are commonly used in cold rolling mills.

The objective: ultra-hard rolls that deliver both quality and economy A special feature of the Genis Roll Star is the combination of the CBN segments with their high-strength, vitrified bond matrix on the one hand, and the resin core with its damping properties on the other. Tyrolit has already enjoyed a number of years of success with a similar design in the automotive industry. Initial tests with this design were started in cold rolling mills back in 2014, and the positive results have now been implemented in this innovative grinding tool.

As with other grinding wheels, the Genis Roll Star can be produced to different specifications. Experienced Tyrolit application engineers liaise closely with customers worldwide to assist in optimizing their processes.

A further innovative feature is the edge design of the Genis Roll Star. The outer edges of the CBN segments are rounded. This prevents spiral groove formation on the roll surface, which is

otherwise possible as a result of the feed motion of the grinding wheel.

The customer-focused and practical development approach is reflected in the low cost and ease of use of these CBN grinding wheels.

Gebhard Melchior explains: “The resin bonded core is not only very smooth in operation, but also more cost-efficient than other steel or carbon fibre cores. The customer simply discards the grinding wheel once the abrasive layer has been completely worn down.

This reduces the logistical costs that would otherwise be involved in replating used abrasive layers.” Another feature is the neutral zone of the new grinding wheels, which is clearly visible between the core and active abrasive layer. The end-user can thereby optimally monitor the lifetime, and 100% utilization of the abrasive layer is ensured.

Genis Roll Star is Tyrolit’s response to the technical trend towards increasingly hard rolls in cold rolling mills. With this innovation, the Austrian abrasives manufacturer is one of the first suppliers to offer a cost-efficient solution that increases the surface quality of hard rolls and therefore also cold strips. The grinding parameters, as well as the grinding tool itself, have been specifically designed, so that the CBN grinding wheel can be used on existing cold rolling mill machinery without having to undergo any adaptation.

MPT International 5 / 2016

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If cold rolling mills switch over to hard rolls in the future, for example to take advantage of the longer lifetimes, Tyrolit will support its customers on site with experienced application engineers. This ensures that it will be possible to optimize individual processes for maximum productivity and efficiency during manufacturing. Initial feedback from roll and machine manufacturers as well as customers confirm Genis Roll Star’s ease of use and effectiveness as a grinding tool for ultra-hard rolls: grinding times are significantly reduced and surface quality greatly improved.

Microscope image of abrasive layer

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MPT International 5 / 2016

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Crane for remote-controlled coil handling LOGISTICS Danieli Centro Cranes has supplied a 45 t coil handling crane to AM Gent. The new crane has been designed with the goal to be easily convertible from on-board cabin operation to fully automatic mode. ArcelorMittal is currently implementing a project entailing the conversion of the semi-finished product storage to largely remote-controlled operation. This is the reason why the crane automation platform is PLC-based and conceived to handle relevant sensors, such as cameras for remote view, radio remote control and supplemental encoders that will enable remote/ automatic handling. The crane spans 41.1 m. Travel speed is 120 m/min for long travel and 60 m/min for trolleys. Combined with a hoist speed of 20 m/min optimized coil handling cycles are achieved.

The crane was erected within 15 days, measured from the day the main crane components arrived at the building to the handling of the first coil. Self-propelled modular trailers with hydraulic lifting equipment were used for the erection work, instead of conventional mobile arm-type cranes.

AM Gent and Danieli Centro Cranes teams signed the final acceptance certificate in September 2015. ArcelorMittal already awarded Danieli an order for a copy crane, which is in the manufacturing stage.

Contact: www.danieli.com

Coil handling crane

Customised 4-Way Handling www.combilift.com

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MPT International 5 / 2016

INNOVATIONS FOR STEEL

www. b ra u n - s te el .c o m

BRAUN Maschinenfabrik GmbH - Austria BRAUN Machine Technologies, LLC - USA BRAUN Machine Technologies (Beijing) Co., Ltd. - PR China

TECHNICAL INNOVATIONS

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Preparation technology for metal recovery from dusts RECYCLING For the recovery of metals and metal compounds contained in dust, the dust is agglomerated by granulation, pelletization or compaction/briquetting. In virtually all cases the agglomeration process is preceded by a mixing process. This is because the inherent moisture of the dust alone does not provide sufficient compactability and other materials, e.g. carbon carriers, liquids and additives, often have to be mixed in along with binders. In addition the moisture, additives and binders need to be evenly distributed in order to achieve a sufficiently homogeneous product. Eirich mixers are used in a great many recycling plants. Where the granules (diameters of up to 8 mm) are suitable for the downstream process, mixing and granulating takes place in a single step, without transferring. Exam-

ples include the agglomeration of dust from steelworks for recirculation to the sintering belt or charging to reduction processes, or for the agglomeration of converter dusts containing zinc for charging to the Waelz process.

A stainless steel recycler in France used to achieve insufficiently homogeneous mixing and inconsistent briquette strength as a result. He replaced its planetary mixer with an Eirich mixer. Afterwards the briquette strength was up to 20% higher than the target strength. This made it possible to reduce the amount of binder by 25% and the mixing time from 5 to 3 minutes. Although only operated in a single shift, the new mixing system will pay off in just one year.

Contact: www.eirich.de

Right choice of grease improves roller table performance LUBRICANTS When selecting a grease, users must take into consideration the variety of applications and operating conditions in their metallurgical processes. The biggest challenge is selecting the right blend of characteristics for the best lubrication performance over the longest period of time.

In the hot mill area of a large steel mill, slabs at extreme temperatures were accumulating on the output tables, causing the bearings to work under high loads and extreme temperatures. As a result, the output table rolls were constantly locking and breaking. On average, there were four roll breaks per month, which was interrupting production and increasing the risk of not meeting delivery dates. Additionally, workers had to change the rolls while the machines were still in operation, creating an unsafe environment. Quaker Chemical Corporation assessed the challenges the customer was experiencing with their output machine application. After the

evaluation, Quaker suggested a conversion to Quakertek™ UX 4615-EP, a polyurea grease, for lubrication of the roll necks. This recommendation was based on the following qualifications of the grease: It is formulated with a special combination of additives that provide excellent corrosion protection and oxidation and it has a high dropping point, so it does not melt away but remains at the application site to provide excellent lubrication properties.

Due to the positive results of a trial, the mill decided to apply the same grease to the output tables and swivel as well.

Since converting to Quakertek™ UX 4615-EP there have been no more crashes on roll breaks. Additionally, the mill was able to achieve major cost savings from reductions in lubrication cycles and roller replacements.

Contact: www.quakerchem.com

Skin-pass mill design FLAT ROLLING For high-quality finishing of steel strip and sheet, a skin-pass mill is essential to remove the yield-point elongation effect and greatly improve surface roughness and flatness.

Fives has developed a new skin-pass mill design, the DMS SkinPass 4Hi mill, which allows steel sheets up to 1,600 mm wide to be processed at 300 m/min with a maximum roll force of 5,500 kN. A complete range of mills is available for different applications. DMS SkinPass 2Hi mills are designed for stainless steel production applications that require a high level of brightness, while DMS SkinPass 4Hi and 6Hi mills are suitable for a wide variety of galvanized or annealed steel products of very low to very high strengths.

Contact: www.fivesgroup.com Layout of a four-high skin-pass mill

MPT International 5 / 2016

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Confocal chromatic controller for high-speed measurements INSPECTION TECHNOLOGY The highspeed confocalDT 2471 HS controller from Micro-Epsilon provides a measuring rate of 70 kHz. This confocal chromatic controller is used for fast distance and thickness measurements of highly reflecting surfaces. It offers more powerful measurement characteristics, enhanced optical components and operates without external light source. Compared with a Xenon light source, the integrated light source is more durable, resulting in reduced maintenance and purchase costs. An active exposure time regulation feature allows different surface types to be compensated for quickly and precisely even with dynamic processes.

Two different controller versions are available: the standard version and a multi-peak version. The latter enables one-sided thickness measurement of transparent measurement objects with up to five layers. The confocalDT 2471

Confocal measurement unit

HS is compatible with all sensor types of the IFS series. Data output is via Ethernet, EtherCAT, RS422 or analogue output. The configuration of the controller and the sensors is performed without

additional software using a user-friendly web interface. Material data are stored in an expandable materials database.

Contact: www.micro-epsilon.com

Automation & Information Technology in Iron & Steel Making: Vision 2025 Participation requested through Technical papers, Sponsorship, Technical Exhibition, Manufacturers presentation and Delegates

- - - - - - - -

Application of IT in Business Functions in Steel& Mining Industry.

SMART Computing Networking & Wireless technology Modeling & Simulation in Steel & Mining Industry Robotic & Embedded system Power Electronics Electrical & Instrumentation Current automation & engineering practices in Steel & Mining Industry

Venue : Ispat Bhawan, Ranchi, India Date : November 26 - 27, 2016 Conference web site :

www.aitism-ranchi.in

E-mail : aitism16@gmail.com, csi.ranchi@gmail.com Important Dates : Receipt of abstract

15.09.2016

Communication to the author of accepted paper

30.09.2016

Receipt of full text of paper

31.10.2016

MPT International 5 / 2016

I wear out fans in a flash!

Scanning sensor for hot metal MEASURING EQUIPMENT DELTA has introduced a new hot metal detector for use in rolling mills and at continuous casters. Rota-Sonde DC4500 is a robust, reliable and easy to handle sensor equipped with a back panel including an LED bar graph, which shows the live level of the signal from the pho- Detector for hot environments tocell and the setup of the threshold. The user can switch on a laser line which corresponds exactly to the scanned field, making the setup, diagnostics and the alignment of the system extremely easy.

No tools are required for regular maintenance, as the unit is equipped with a flip cover on its back and a draw latch on the hood. The larger sensitivity ranges allow detection of steel products at a temperature as low as 180°C. For applications where the sensor is exposed to direct radiation, DELTA proposes an optional stainless steel heat shield. Another very useful accessory is the junction box for remote settings and diagnostics, when access to the sensor is difficult.

But not our fans.

They are protected against wear and long-lived.

Provision of effective wear protection on the fan impellers ensures a VLJQLÀ FDQW LQFUHDVH LQ resistance to wear and service life.

Long service life High availability Extremely reliable

Contact: www.deltasensor.eu

High-capacity roll unit for wire rod mill LONG PRODUCTS ROLLING Primetals Technologies has produced a high-capacity 250 mm ultra heavy-duty (UHD) roll unit for the first phase of a high-speed wire rod mill upgrade for a Chinese steel producer. The new roll unit will be used as a finishing block. As a high-speed finishing stand, the 394 kN separating force allows larger sizes to be rolled at lower temperatures, enabling thermomechanical rolling in the wire rod mill at temperatures as low as 750 °C. The mill is designed to roll at speeds of up to 120 m/s and sizes up to 28 mm in diameter.

We make air work for you.

Process and hot gas fans Process gas dust collection

Contact: www.primetals.com Ultra heavy-duty roll unit prior to shipment

Process gas cleaning plants Secondary fuel technology Belt drying plants Vapour exhaust plants

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"TRSNLHYDC "-" ×@LD BTSSHMF L@BGHMD PROCESSING EQUIPMENT Framag has designed a CNC flame-cutting machine for Dillinger Hüttenwerke. The machine was to be capable of longitudinal and transverse cutting, as well as contour cutting (circles, round blanks and tooth bar profiles) and trimming.

Framag equips their flame-cutting machines with a Siemens PLC as standard. As Dillinger was using BURNY controls on their existing CNC machines, Framag was presented with the challenge to install two control types: Siemens PLC for longitudinal and transverse cutting and BURNY for the CNC application. This allows the operator to control the entire system from one operating panel and switch between the two controls.

The machine for Dillinger uses a new nozzle technology which ensures a small cut gap. The wide range of material sizes required a height-adjustable and swivelling flame cutter, as the slabs have to be sharpened for further

Flame-cutting unit with CNC application

processing. The machine cuts slabs of max. 400 mm cutting thickness and 4,000 mm cutting width as well as ingots of max. 1,000 mm cutting thick-

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MPT International 5 / 2016

ness and 2,500 mm cutting width at temperatures of up to 400°C. Contact: www.framag.com

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Transport and handling solutions

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LOGISTICS Combilift offers a very extensive range of specialist handling solutions, including models that have lift capacities from 1.5 to 80 t, with choices of electric, LP gas or diesel power, and are all customized to individual requirements. For handling and storage of even the longest and bulkiest loads, pallets or containers, the company supplies straddle carriers and other materials handling solu-

Versatile handling of long, heavy loads

tions. For operations handling lighter loads the Combi-WR4 four-way pedestrian reach stacker is ideal. It is the only machine of its type that can work in aisle widths of 2.1 m pallet to pallet. A key feature is the unique patented multi-position tiller arm for easy push button rotation of the rear wheel parallel to the chassis and back again.

This guarantees a high level of operator comfort and safety when picking and placing in narrow aisles. The compact Combi-CB counterbalance forklift provides the added benefit of multidirectional travel. This versatile truck, which comes with lift capacities of up to 4 t, easily handles pallets as well as long loads and its low profile enables it to fit into containers for convenient destuffing.

Contact: www.combilift.com

HOKÂŽ. Activated lignite. Flue gas adsorbent and catalyst.

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

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Rheinbraun Brennstoff GmbH D-50416 KĂśln Tel.: +49 221-480-25424 HOK@rwe.com www.hok.de

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“I’d like to reduce unscheduled and scheduled downtime – how can lubricants help increase the reliability of my operations?�

Proactive maintenance programmes are an essential way to achieving production goals by monitoring the condition of equipment and oil. One programme that can be implemented in the steel mill is used oil analysis – a series of tests that determine the condition of equipment components and in-service lubricants.

Oil samples are collected and assessed to detect its quality, providing early warning signs of contamination.

This helps steel mill operators better plan maintenance programmes to increase productivity and reduce unscheduled downtime. Alongside the use of high quality lubricants, oil analysis can help extend equipment component and lubricant life.

One of our customers using our SignumSM oil analysis programme was able to safely increase oil drain intervals by 700%. When the plant switched its hydraulic oil to Mobil SHC™ 524 with the goal of reducing planned maintenance and unscheduled downtime, it used oil analysis to guide decision-making. As a result, oil drain intervals of the bridge cranes using the oil have been increased safely from 4,000 to 32,000 hours.

Response from Jarmo Vihersalo, ExxonMobil Industrial marketing advisor EAME and MPT’s expert Contact: www.mobilindustrial.com

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

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Ultrasonic weld line tester TUBE MAKING The Echomac® WLD ultrasonic weld line test system offered by Magnetic Analysis Corp. features new operating conveniences for inspecting tube weld zones online during continuous production. The system is designed to test for longitudinally oriented defects that are typical of the ERW welding process. The test head incorporates transducer assemblies with irrigated shoes for constant coupling with the tube being tested. A key issue in weld line inspection is keeping the transducers focused on the weld zone, despite changes in the weld location during production. A new “joystick” allows the operator to rotate the entire test head by means of a high resolution stepper motor. At any time, the operator can verify that the transducers are correctly positioned by observing a monitor which shows a laser beam that must bisect the weld centre. The test head is supported by a strong gantry that allows for operating on the weld line for mill testing or, off line, for easy calibration for a new tube size. A precision roller assembly is located in the off-line position to allow for easy calibration of the transducers. Once the calibration is achieved, the test head is simply moved back to the on-line position for production line testing. A large, oversize stainless steel catch pan is used to help control splash water. The Allen Bradley system controls are designed for simple operation, but have flexible features accessible in the flat panel control display. Siemens controls are also available, if requested.

Ultrasonic weld line tester conducting production testing of a tube. A separate calibration tube is shown in the off-line position in the foreground

Contact: www.mac-ndt.com

Self-maintaining air cleaner SPECIAL EQUIPMENT Critical airflow areas in steel mills have traditionally been maintained with standard HVAC filters. While in offices and homes, those can last three to six months, in steel mill environments, filter life is cut

down to days. It is extremely critical when HVAC filters fail on transformer vaults and motor control rooms, resulting in highly conductive steel dust accumulating and arcing across high voltage electrical components.

The Systems Group, a group of companies engaged in construction, maintenance and products for steel manufacturing and other heavy industry, has now introduced the first auto-cleaning air filtration system for steel mill trans-

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

Contact us for our competence.

Kuhlmann-System-Kühltechnik GmbH D - 45721 Haltern am See . An der Ziegelei 11 Phone: +49(0)2364/10 53 9-0 . Fax: +49(0)2364/10 53 9-16 E-mail: info@k-s-k.de . Web: www.k-s-k.de

MPT International 5 / 2016

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››› TECHNICAL INNOVATIONS

former vaults, motor control rooms, air compressor systems, engine intakes and other critical spaces. Through a strategic partnership with Camfil APC, specialists in industrial air pollution control, the two companies have developed the self-maintaining air cleaner (SMAC) designed specifically for the harsh environments that exist in steel mills. While Camfil APC will contribute their exper-

tise in the latest air filtration R&D and product manufacturing, The Systems Group will engineer, install and maintain the units. The new SMAC units coupled with high-efficiency filters and self-cleaning technology result in filter service life of two years or longer with minimal maintenance.

Contact: www.tsg.bz

Air cleaner unit for environments in steel mills

Optical width measurement for strip and plate mills MEASURING EQUIPMENT NDC Technologies introduces its new W200 width measurement system for strip and plate mill applications. The system accurately and consistently measures product width across a range of process conditions. It is designed to be installed above the roller table in hot strip and plate mills, and provides high-resolution true width measurement from an ultra-stable optical bench with long-life lasers.

The W200 is a complete platform that includes an easy-touse operator interface, a powerful real-time operating system for continuous width measurement, plus network communications to the mills’ control platform and management reporting systems. It comprises a single enclosure including the sensor components and the platform architecture. Depending on the application, the W200 uses a combination of cameras, laser line projectors and laser point sources to accurately measure the product width. For strip temperatures above 800°C, the gauge measures the radiant energy to determine the edge location. For locations with a cooler strip, front light technique is used. Additionally, to compensate for strip curvature, laser point sources are added to measure the strip height across the entire width. The W200 multi-stereoscopic measurement technique and unique edge detection software measures the true strip width, regardless of strip movement, tilting, bouncing and strip curvature.

Measuring modes depending on the application

The system can also be equipped with NDC’s Beta LaserMike LaserSpeed® length and speed gauge for crop shear optimization, marking and cutting control, discrete coil and plate length, elongation and differential speed applications.

The W200 network capability integrates level 1 and 2 plant networks providing connectivity with many common PLCs and automation platforms.

Contact: www.ndc.com

WORKING SOLUTIONS FOR EXTREME CONDITIONS

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

MPT International 5 / 2016

ENGINEERING | PRODUCTION | SERVICE

TECHNICAL INNOVATIONS

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Large-capacity walking beam furnace FURNACE TECHNOLOGY In 2013, ArcelorMittal Gent decided to invest in a new walking beam furnace, replacing two of their four existing reheating furnaces. The new furnace is designed to handle the current yearly capacity of max. 5 million t/year. It is, however, foreseen to increase the initial furnace capacity of 225 t/h (stage 1) to 450 t/h in stage 2 of the project. While during stage 1, the furnace is exclusively equipped with conventional burners firing with mixed gas, in the second phase, CMI’s patented double regenerative burners (DRB) are to be installed, running either exclusively with low calorific blast furnace gas or with mixed gas when needed, thus considerably reducing operating costs. This project is co-funded by the European Life+ programme, the EU’s financial instrument supporting environmental, nature conservation and climate action projects.

CMI Metals was responsible for the engineering and supply, as well as the supervision, assembly and commissioning of the reheating furnace that had to be erected in an exist-

Furnace with a reheating area of 66 metres length

ing hall, with all of the related problems and constraints, mainly in terms of access and interference with the existing production. The furnace was unveiled in April 2016.

Contact: www.cmigroupe.com

© Utz Peter Greis, Düsseldorf

Cartoon

In mid-October, at its annual conference, the World Steel Association celebrates its 50th anniversary. The association was founded as the International Iron and Steel Institute on 19 October 1967 and changed its name to World Steel Association in 2008. Albeit VJG Æ‚GTEG EQORGVKVKQP COQPI UVGGN RTQFWEGTU VJGTG CTG OCP[ VCUMU VJCV ECP QPN[ DG EQRGF YKVJ KP C LQKPV GHHQTV HQT GZCORNG analysing and improving the economic, environmental and social sustainability of steel, developing the market for steel in the Æ‚GNFU QH CWVQOQVKXG EQPUVTWEVKQP CPF GPGTI[ ICVJGTKPI UVCVKUVKEU QDUGTXKPI UVGGN OCTMGV VTGPFU CEJKGXKPI KPLWT[ HTGG YQTMRNCEGU CPF RTQOQVKPI UVGGN CPF VJG UVGGN KPFWUVT[ VQ EWUVQOGTU VJG KPFWUVT[ OGFKC Æ‚PCPEKCN OCTMGVU CPF VJG IGPGTCN RWDNKE MPT International 5 / 2016

72

››› LITERATURE SERVICE Forging and handling technology 12 pages, English This brochure outlines the range of transport manipulators supplied by Dango & Dienenthal for handling operations in closed-die forges and ring rolling mills. The company offers railbound, stationary or mobile manipulators, depending on the application.

Contact: E-mail:

www.dango-dienenthal.de dds@dds-gmbh.com

Forging manipulators 16 pages, English, German, Russian, Chinese A brochure featuring the G-series of Glama handling and forging manipulators. The models of this series include mobile manipulators, furnace charging machines, heavy-duty robots as well as portal and dual-portal robots. The brochure includes descriptions and photos of machine details and of the machines in operation.

Contact: E-mail:

www.glama.de info@glama.de

Heat protection clothing 32 pages, English, German A catalogue of heat protection clothing and accessories offered by Jutec. This detailed and illustrative catalogue provides descriptions of products such as coats, jackets, trousers, aprons, hoods, helmets, masks and a wide range of gloves as protection against radiated or contact heat.

Contact: E-mail:

www.jutec.com info@jutec.com

Heating systems 16 pages, English A brochure summarizing the range of drying and heating systems offered by Mefkon. The products include ladle and tundish preheaters and driers, scrap driers, snorkel preheaters, multi-fuel, oxygen and flameless burners, combined oxygen burning/blowing lances, etc.

Contact: E-mail:

Wölfer moves the world

www.mefkon.com info@mefkon.com

AC motors as a replacement for DC motors 4 pages, English, German

DC Motor replacement with customized Mill Duty AC Motors by Wölfer

„Fine Craftsmanship from Germany“

MPT International 5 / 2016

Wölfer designs customized mill-duty AC motors as replacements for DC motors. This brochure presents the advantages of AC motors in terms of operational and life cycle costs, reduced energy consumption, lower maintenance, lower inertia, etc.

Contact: E-mail:

www.woelfer-motoren.com info@woelfer-motoren.com

IN THE NEXT ISSUE…

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Cold rolling – Modernization Salzgitter Flachstahl upgrades tandem mill to continuous operation For several years, Salzgitter Flachstahl has been operating a modern continuous pickling line and a five-stand tandem mill in addition to a push-pull pickling line. Recently, a smart and efficient solution was developed that will optimize coordination between those plants. A continuous entry section to the tandem mill has been successfully implemented.

Quality assurance – Automation Lasers replace diamonds: thickness measurement during cold strip rolling The new “VTLG” thickness measurement system has passed the acid test: It measures the strip thickness in the immediate vicinity of the roll gap under extreme conditions on a 20-roll cold strip rolling mill. Despite high strip temperatures and dense oil mist, it achieves a measuring precision of +/- 1 μm. It operates fully independently of the steel grade, protects the surface of the strip, allows the thickness profile to be measured at right angles to the rolling direction, significantly reduces maintenance and thus increases the availability of the mill.

Strip processing Exact setting of strip back-tension – at any position in the processing line Bridle units can build up strip back-tension exactly where and as high as needed. Also thick strips or high-strength steel strips can be handled with ease. Bridle units may be swiveled through their vertical axis, for example, in order to reduce strip camber and adjust the strip position during side trimming. At cut-to-length lines, they position the strip edge perfectly perpendicular to the shear. The result is an exact, rectangular cut.

Special equipment State-of-the-art water treatment plant to treat 35,000 cubic metres per hour of water critical to the steel production process Big River Steel, located in Osceola, Arkansas (USA), has ordered a water treatment plant for the new steel mill integrating a meltshop, hot strip mill and cold mill together. The water system will treat and supply the water for all the before mentioned systems, as well as the make-up water system, which treats the water originating from several deep wells, a purging system and the waste treatment of the cold emulsions mill. The complete water treatment plant design, supply, installation has been ready for start-up within 14 months.

This preview may be subject to change.

Metallurgical Plant and Technology

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

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MPT International 5 / 2016

Offering the highest quality of service in the graphite electrode industry we provide personalized consultations to maximize the total value for our customers.

We also manage individual partnership projects as ongoing support for your process improvement efforts. Mutually agreed projects, with defined targets and cost impacts, aim to reduce process variability using Six Sigma methodology.

Please visit our website to learn more about the types of services we offer and how we can add value to your operation.

See details under www.ge-competence.com

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