MPT International 2/2017 (Apr)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

North Americaâ&#x20AC;&#x2122;s latest steel complex inaugurated at Big River Steel

April 2017

Intelligent data management powers staff to improve business

Leading partner in the world of metals

Secondary metallurgy: The fascination of stainless steel Aesthetic design and structural strength for brilliant façade cladding – that’s where our steel grades ﬁt the bill perfectly. Using our secondary metallurgy processes and plants, customers around the world supply the construction industry with innovative steel products. Included in our range are engineering, plant components, assembly supervision, commissioning, and training of operating personnel. Plus there are tailor-made service packages that ensure your plants run reliably and eﬃciently. SMS Mevac GmbH Bamlerstrasse 3a 45141 Essen, Germany

Phone: +49 201 6323-0 Fax: +49 201 6323-200

mail@sms-mevac.com

www.sms-mevac.com

SMS group is a global, leading partner for the metal industry. As a family-owned business headquartered in Germany, quality and innovation is in our DNA. We are committed to the success of our customers and strive to add value along the entire value chain of the global metal industry.

EDITORIAL

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Technical innovations give steel mills a competitive edge in FKHƂEWNV VKOGU In this issue we present a completely new steelworks, built as a greenfield project: Big River Steel has commissioned what is one of the world’s latest technology steelmaking facilities in Arkansas, USA. It is the first steel mill in North America to connect an electric arc furnace (EAF) to a Ruhrstahl Heraeus degasser. With the technology employed and the design of the facility, the mill will produce a range of product dimensions and strength levels never produced before in an EAF mill. In the first construction stage, Big River Steel is going to produce 1.6 million t of flat steel products annually. The commissioning of these latest production facilities is an extremely interesting topic to report about, especially from a technical point of view. However, the run-up is taking place in a very challenging business environment. U.S. crude steel output has decreased by 10 million t within four years since 2012. Reflecting on the global steel scale, the world crude steel capacity utilization ratio was 69.7% in 2015 and 69.3% on average (during the year) in 2016 (source: worldsteel). Stakeholders will have to bank on the future development.

Dipl.-Ing. Arnt Hannewald

Nevertheless, there are indeed good options for steelmakers to safeguard their competitiveness in terms of both quality and productivity. Product data management in the steel mill is one such option. Various articles in this issue deal with the topic of data management from different angles. For example, European steelmakers have developed a standard to log quality information directly on the steel strip. This will enable them to supply their customers with information on significant defects along with the coil. Another article describes how Nucor has implemented a centralized data repository able to correlate process information to the finished product. The implemented automation system has significantly changed reporting at the mill as manual data access has been dramatically reduced and a centralized real-time view of the production is available now. In a further article we learn how thyssenkrupp has implemented the first application in the Industrial Data Space, a new virtual data space within which companies can securely exchange information. The first case of use is an information system for truck logistics at thyssenkrupp Steel Europe. This application proves that the idea behind Industrial Data Space does work. Finally, we have two articles featuring innovative solutions for material tracking and integrated warehouse management along the value chain from billets/slabs down to the finished products. And there are actually more articles in this issue showing that technology in the steel industry is constantly being brought forward.

MPT International 2 / 2017

Since 1998, the patented Danieli spooler system has set a revolutionary way in spooled-bar-in-coil production, enabling the supply of high-quality ultra-compact heavy-weight coils made up of twist-free wound hot-rolled deformed bars.

Four main references out of total 56 spooler systems DONGKUK STEEL MILLS CO. POHANG WORKS REP. OF KOREA 37.8 m/s production speed: the fastest spooler line in operation producing deformed bars 10 to 19 mm dia in customized coils weighing up to 3.5 t.

Long product rolling mills

CELSA - COMPAÑÍA ESPAÑOLA DE LAMINACIÓN S.L. SPAIN Twin spooler line (90+90 t/h) for the production of deformed bars from 8 to 32 mm dia at 35 m/s in coils up to 3 t. Two lines supplied as single order.

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

DANIELI MORGÅRDSHAMMAR K-SPOOL SYSTEM TO PRODUCE PERFECT-SHAPE SPOOLED BARS > Twist-free bar winding into added-value ultra-compact coils up to 5 tons > Automated and safe downstream cold processing with “zero” scrap generation > Up to 18 Euro/ton production cost saving (up to 24 when combined to EWR system)

SN LONGOS PORTUGAL Twin spooler line (100+100 t/h) for the production of deformed bars from 8 to 25 mm dia at 35 m/s in coils up to 2.8 t.

DANIELI TEAM A CENTURY OF PARTNERSHIP EXPERIENCE

FERRIERE NORD ITALY Endless spooled production of 8 to 32 mm dia deformed bars in customized jumbo coils up to 5 t, the heaviest on the market.

www.danieli.com

››› CONTENTS

Events 30

AISTech 2017 will be the steel’s premier event in North America this year

Company profile 32

North America’s latest steel complex inaugurated at Big River Steel The facility, located in Osceola, Arkansas, is designed to produce the largest range of hot strip dimensions possible using the latest thin slab casting and rolling technologies Coverphoto: TML debricking machine UNIDACHS 850 at converter service. TML Technik GmbH, Monheim am Rhein, Germany Contact: www.tml-technik.com E-mail: info@tml-technik.com

Raw materials 36

Rotary discharge machines reduce dust emissions A rotary discharge machine with discharge wheel for extraction from silos can achieve a more precise blend of material

Continuous casting 38

Unique coating technology for superior mould wear resistance and product quality

A ceramic composite coating technology, XuperCOAT™, has been applied successfully on slab, bloom and billet moulds and proved to be the most efficient reliable alternative to electroplating solutions

Automatic testing system for temperature sensors of moulds A new system offers reproducible heating and testing for all types of thermocouples. Damage to copper plates is ruled out. Measured data can be saved for later use

Quality assurance 44

Zumbach has developed innovative online measurement, monitoring and control equipment since 1957

A pioneer of on-line measurement, Zumbach manufactures a comprehensive range of non-contact, online measuring and control instruments

“Quality Tracking” – logging quality information directly on the steel strip for later defect removal Barcode markings are applied to the steel strip at the exit zones of the cold rolling mill. The technology is to be established as a European standard

Automation 52

Intelligent data management powers staff to improve business Nucor Steel Darlington has implemented a centralized data repository able to correlate the process information to the finished products. The system has transformed reporting by delivering a centralized real-time view of the production

Material flow logistics 56

Integrated transport and warehouse management system for slabs and coils Salzgitter Flachstahl, Germany, has closed the existing gap in the material tracking system, establishing a seamless system from the slab cut-to-length cutting downstream the process chain to the packed coils ready for shipment

MPT International 2 / 2017

Central material tracking system for reliable and accurate management of product data A new technology has been developed for the global tracking of products from the arrival of material (billets) to the shipment of finished products (wire rods). All management procedures are centralized in a single digital system

44 66

Truck handling goes digital: thyssenkrupp UVGGN FKXKUKQP KU KPVTQFWEKPI C FKIKVCN VTCHÆ&#x201A;E management system

Materials 74

To achieve greater flexibility, Germanyâ&#x20AC;&#x2122;s biggest steel producer has introduced a solution that enables trucks en route to the company to continuously report their position in line with defined rules, for example using a smartphone app

Peculiarities in crystal structure of titanium alloys pave the way for new applications So-called gum metals exist but the mechanism behind this behaviour was still unsettled. Scientists from Germany have observed a new phase transformation within the crystal structure in a titanium alloy that clarifies the phenomenom

Surface treatment

Columns

70 ' EQPQOKECN ENGCPKPI CPF Æ&#x201A;PKUJKPI YKVJ C new generation of roller conveyor blasting systems

International industry news

Technical innovations

Cartoon

Literature service

In the next issue

Imprint

German manufacturer AGTOS has enhanced its machine concept with special emphasis on high blasting speed thanks to use of powerful turbines

72 #TEGNQT/KVVCN KPCWIWTCVGU YQTNF Æ&#x201A;TUV ,GV Vapor Deposition line for the steel industry The JVD technology coats moving strips of steel in a vacuum chamber by vaporizing zinc onto the steel at high speed. The new technology offers multiple advantages

Advertisersâ&#x20AC;&#x2122; index ABB Automation Technologies AB AIC Automazioni Industriali Capitano Srl ASMET Research GmbH Aumund FÃ¶rdertechnik GmbH BEDA-Oxygentechnik Armaturen GmbH BRAUN Maschinenfabrik GmbH BSE Badische Stahl-Engineering GmbH Castolin Eutectic Combilift Ltd. Danieli & C. Officine Meccaniche SpA DMT GmbH & Co. KG EREDI SCABINI SRL Fabris Inc. framag Industrieanlagenbau GmbH Friedrich Vollmer FeinmeÃ&#x;gerÃ¤tebau GmbH Getriebebau NORD GmbH & Co. KG Glama Maschinenbau GmbH GSB Group GmbH

79 27 24 17 65 54 69 35 71 45 16 37 29 51 84 68 25 54

Guild International Inc. 43 IMS Messsysteme GmbH 81, 82 Jasper Ges. fÃ¼r Energiewirtschaft und Kybernetik mbH 41 Kalugin Joint Stock Company 61 KELLER HCW GmbH 18 KIRO-NATHAUS GmbH 14 KÃ¶ppern GmbH & Co. KG Maschinenfabrik 76 KSK Kuhlmann-System-KÃ¼hltechnik GmbH 80 Maschinenfabrik Gustav Eirich GmbH & Co. KG 19 Messe DÃ¼sseldorf GmbH 77 MICRO-EPSILON Messtechnik GmbH & Co. KG 23 NOHMA GmbH 75 Paul Wurth S.A. 11, 12 Polytec GmbH 13 Polytec S.r.l. socio Unico 83

Primetals Technologies Austria GmbH 31 Redecam Group SpA 63 RUMP Strahlanlagen GmbH & Co. KG 84 Saar-Metallwerke GmbH 28 Schubert & Salzer Control Systems GmbH 18 SGL CARBON GmbH 88 SMS Mevac GmbH 2 STEIN INJECTION TECHNOLOGY GmbH 21, 22 TAMINI Trasformatori Srl 45 thyssenkrupp Uhde Engineering Services GmbH 47, 48 ThyssenKrupp Ind. Solutions AG 55 TML TECHNIK GMBH 78 TMT GmbH Tapping Measuring Technology 9 VELCO GmbH 78 Vishay Precision Group 75 Zumbach Electronic AG 15

››› INTERNATIONAL INDUSTRY NEWS

Africa Egypt EZDK to install quenching and self-tempering system. EZDK has contracted Danieli to replace the quenching waterboxes of the bar mill No. 2 at the Alexandria plant with a new QTB system (quenching tempering of bars). Quenching and self-tempering is a fast and cost-effective way of revamping bar mills to achieve improved mechanical properties without micro-alloying during melting. Designed for rolling speeds of up to 14.5 m/s, the new system will quench 3 x10 mm rebar at 12.9 m/s, and 12 mm rebar at 9 m/s. Danieli Automation will provide a stand-alone control package to avoid replacing the existing automation equipment with a tuned and dedicated solution. EZDK has already in operation a Danieli QTB system in its No. 1 bar mill.

The Americas Canada Iron Ore Company to proceed with Wabush 3 project. Iron Ore Company will proceed with the development of the Wabush 3 pit at its mine near Labrador City, Newfoundland and Labrador. Wabush 3 is a new pit that will be developed within IOC’s existing mine operations to extend the life of the mine, reduce operating costs and increase production of quality grade iron ore concentrate and pellets. Construction is expected to start in the second quarter of 2017. First ore from production mining is expected in the second half of 2018.

Mexico Tyasa orders production management solution. Tyasa has awarded Primetals Technologies an order to supply a production management solution (level 3) for its existing steelmaking plant, billet caster and new MPT International 2 / 2017

Castrip-based coil production line in Ixtaczoquitlan. The new production management solution will be based on the product PSImetals, which provides a comprehensive set of modules specifically developed for the metals industry. The solution steers the order-based production utilizing product routing information and corresponding process instructions for the individual processing units. A seamless material tracking along the entire production route from heat creation in the electric arc furnace down to the final coil product provides Tyasa with the genealogy information customers require for flat products. The project is due for completion by early 2018.

furnace designed to process 140 t/h of billets. The plan is to roll the billets into light sections and reinforcing bars from sizes #4 to #11 (12.7 mm to 35.8 mm), as well as corresponding round bars. The objective of the new reheating furnace is not only to increase productivity but also to significantly improve energy efficiency. The heating process will be optimized by the SMSPrometheus® software and extra low NOx burners that are digitally controlled to reduce emissions. The new finishing package includes all equipment starting from the outlet of the dividing shear up to the finishing area. Commissioning is expected to commence at the end of 2017.

USA

CMC to build new steel fence post facility. Commercial Metals Company (CMC) will construct a highly automated steel fence post manufacturing facility on the site of its new micro mill in Durant, Oklahoma. The company will continue to operate its existing post manufacturing facilities in Cayce, South Carolina, San Marcos, Texas, and Brigham City, Utah. CMC’s steel fence post business, which operates as CMC Southern Post, supplies the agriculture, ranching and construction fencing markets. Shipments are expected to begin in the summer of 2018.

NLMK orders walking beam reheating furnace. Tenova Inc. has been contracted by NLMK Group to design and supply a 395 t/h walking beam furnace for reheating slabs at its Sharon, Pennsylvania plant. The new fuel-efficient furnace will be equipped with Tenova’s Flexytech® low NOx burners. Tenova will also design and supply the complete control and automation package that features an advanced thermal model-based level 2 control system. Start-up of the furnace is scheduled for 2018.

USA and Canada USA Steel Dynamics Roanoke orders reheating furnace and finishing equipment. Steel Dynamics has awarded the contract for an expansion at its Roanoke bar division, located in Virginia, to SMS group. The upgrade is to integrate a new reheating furnace and a new finishing area into the facility. With this investment, the Roanoke bar division plans to utilize its existing excess melting and casting capability to increase rolling capacity from the current 500,000 to over 600,000 t/year. The addition of the equipment will allow for multi-strand slitting. The supply package is comprised of a pusher-type high-capacity reheating

Zekelman Industries places orders for modernization of ERW tube lines. Atlas Tube, a company of Zekelman Industries, has placed several follow-up orders with SMS group for the 16-inch tube welding line which had been moved to Blytheville, Arkansas, in 2006 and which SMS had already extensively modernized and extended as part of that relocation. The line is now going to be equipped with a completely new sizing section to expand the product spectrum and improve productivity. Once the upgrading measures have been completed, the line will be able to roll structurals (round tubes with outside diameters up to 18 inches) as well as square and rectangular hollow sections with wall thicknesses of up to 17.3 mm.

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A joint company of DANGO & DIENENTHAL and PAUL WURTH

››› INTERNATIONAL INDUSTRY NEWS

News in brief Outokumpu has entered into an agreement according to which IMS Nederland and IMS Belgium will act as the exclusive distributor of Outokumpu Prodec high machinability round bars in the Benelux.

In Harrow, Canada, SMS group will install an additional pinch roll/breakdown stand in the 8 5/8-inch ERW line. This will allow higher grades and greater wall thicknesses to be produced in the future.

Asia

9-roll cassette for medium-thick plates up to 50 mm. The Danieli Multimotor drive concept will be adopted to carry out hydraulic gap control and multipoint bending. The scope of supply also includes electrical components and a level 1 and level 2 automation package. Production of the first plates is scheduled to take place by the end of 2018.

China Ovako, Sweden, officially inaugurated the new production process in operation at its Hofors plant. The new process makes it possible to produce bearing rings with diameters in excess of 4 m and up to 5 t weight.

NLMK, USA, has re-started its No. 2 hot-dip galvanizing line, located at Sharon Coating in Pennsylvania. The line has a capacity of approx. 226,000 t/year.

Saarstahl, Germany, has issued the FAC to SMS group for the upgraded high-capacity wire rod mill in Burbach. The upgraded mill was handed over to Saarstahl two months ahead of schedule.

MMK, Russia, has celebrated the 85th anniversary of the launch of the Magnitogorsk mill. The mill’s first blast furnace produced its first batch of pig iron on 1 February 1932.

Vallourec PTCT, Indonesia, has equipped its tube finishing plant with a state-of-the-art ultrasound control facility supplied by Olympus IMS.

Arvedi Tubi Acciaio, Italy, has successfully taken into operation a high-frequency tube welding line (ERW) upgraded by SMS group. The line can now handle tubes of up to 14” in diameter.

MPT International 2 / 2017

China Shandong Iron & Steel orders continuous caster. Shandong Iron & Steel Group, Rizhao, has placed an order with SMS group for the supply of a continuous caster for ultra-wide slabs. The single-strand caster will be designed for an annual production of 1.5 million t of steel slabs with up to 3,250 mm width and 150 mm thickness. The new caster will process structural steel grades and micro-alloy and low-alloy steel grades. SMS group will supply an HD moldTC (TC – thermocouples) and equip the narrow sides with HD moldFO (FO – fibre optical sensors). Also breakout prevention assist and mould temperature assist systems will be provided. The scope of supply will also include the entire X-Pact® electrical and automation systems for the continuous caster, the technological control systems (level 1) and the technological process models (level 2). Commissioning is scheduled for the end of 2018.

Shandong Iraeta to receive ring rolling machine for extra-large rings. Shandong Iraeta Heavy Industry (SIHI) has placed an order with SMS group for the supply of a newly developed ring rolling machine for the production of seamlessly rolled rings. The “RAW 2500/1250-16000/3000” radial-axial ring rolling machine will be the first to allow rings with a diameter of up to 16 m to be seamlessly rolled. With the new machine, to be installed in Zhangqiu in the Shandong province, SIHI is increasing the production capacities for rings that are made from blanks with a weight of up to 200 t. The maximum rollable ring height will be 3 m. The rings produced on the machine will be used e.g. for tower flanges of wind turbines and large shells as required in the construction of large pressure vessels for nuclear power reactors. Production is scheduled to start by the end of the 2017.

China

Shandong Rizhao orders plate levellers. Shandong Rizhao Iron & Steel has contracted Danieli to supply two new hot and cold levellers to be installed along the “Steckel Plate 3500” line in Rizhao. In order to maximize the production flexibility, multi-cassette configuration will be used for both machines. The hot plate leveller will operate with a cassette of eleven small-diameter rolls suitable for thin plates down to 4 mm, and a second cassette of nine rolls featuring a larger diameter for medium-thick plates up to 50 mm. Similarly, the cold plate leveller will operate with a 13-roll cassette for thin plates down to 4 mm and a

Hebei expands mill services contract. Harsco’s Metals & Minerals division has been selected by Hebei Iron and Steel Group to take over an increased range of onsite mill services at its Tangshan Stainless Steel works. Harsco already provides environmental services relating to the commercial sale of the mill’s slag co-products. With the new contract, Harsco now adds onsite slag handling, metal recovery and briquetting to its responsibilities. Included will be Harsco’s patented steam box technology for steel slag processing. This technology provides for faster cooling times, reduced water and energy consumption and more efficient

State-of-the-art Modernisation Concepts

We help you optimise your production facilities After a complete rebuild with modernisation and size increase by Paul Wurth, Jindal South West Steel’s N°1 Blast Furnace in Toranagallu, India, represents one of the largest capacity expansions ever seen from one single blast furnace rebuild. Fitting into the existing square tower, the entirely new blast furnace has a daily hot metal rate of 5 250 tonnes for a total yearly production of about 1.7 million tonnes, some 89 percent more then before the modernisation. After few months of operation, the production has already exceeded this design ﬁgure, reaching 5 900 HMt/d. 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

Inner volume increased from 1 250 m3 to 2 307 m3 Hearth diameter enlarged from 8 m to 10.4 m Number of hot blast tuyeres increased from 18 to 28 In parallel to building 16 brand new blast furnaces since the year 2000, Paul Wurth has executed 30 major BF plant modernisation projects for customers on 4 continents.

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 slag sizing than conventional methods. Its environmental benefits include the full capture of open atmospheric emissions, together with the opportunity to utilize the clean steam and heat generated from the steam box.

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others, with a straight cassette-type Smart Mold with LevCon mould level control, automatic breakout detection, inline width control, mould oscillator and an electromagnetic mold stirrer. The modernized casting plant is scheduled to come into operation in the first quarter of 2018.

China Xingcheng Special Steel places order for bar mill modernization. Jiangyin Xingcheng Special Steel Works has placed an order with SMS group for the modernization of its SBQ mill “Bar Mill No. 1”. The one-million-t/year mill will be expanded to include a 3-roll precision sizing mill (PSM®) of type 450/4. Thanks to the possibility of free-size rolling, all diameters in the range from 40 to 130 mm will be rolled from a small number of feed cross-sections. The hydraulic adjustment of the rolls, which permits roll gap control under load, allows dimensional deviations due to temperature or material behaviour to be equalized. A complete workshop for roll changing and adjustment in the cassettes, including an optical setting gauge, forms also part of the SMS group’s scope of supply.

China Yonggang orders billet caster for new SBQ products. Yonggang, based in Zhangjiagang, has awarded SMS Concast the order to supply a new four-strand SBQ billet caster. The project will involve replacing an old caster, while retaining part of the existing equipment, such as the ladle turret and the tundish. The new billet caster, which will be designed for a capacity of 540,000 t/year, is scheduled to be commissioned by the end of 2017. With the new four-strand billet caster, Yonggang will expand its range of SBQ grades by adding high-quality bearing and other engineering steel grades. With the support of SMS Concast’s dynamic mechanical soft reduction technology, the new caster will produce 150 mm and 220 mm square billets.

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China India Baosteel to modernize continuous slab caster. Primetals Technologies has received an order from Baoshan Iron & Steel to modernize continuous slab caster No. 3 in the company’s steel works No. 1 in Shanghai. The machine head and the complete strand-guiding system will be replaced. The caster has a machine radius of 10 m and a metallurgical length of 34.5 m. On completion of the modernization it will be able to cast slabs in thicknesses of 250, 300 and 357 mm in widths ranging from 1,200 to 2,300 mm. The range of products includes extremely low to high-carbon steels, micro and low-alloyed, peritectic and HSLA grades, structural steels, pipes and sheet steels. Primetals Technologies will be responsible for the basic and detail engineering of the caster, supervise manufacturing, installation and commissioning, and supply all technological components. The casting plant will be equipped, among

SAIL Bhilai to install coal injection system. Danieli Corus has signed a contract for a coal injection system to be installed at blast furnace No. 4 of the Bhilai steel plant operated by SAIL (Steel Authority of India Limited). The blast furnace has a working volume of 1,489 m³ and a nominal hot metal production capacity of 3,300 t/ day. The PCI system will be designed for injection rates of up to 150 kg/t hot metal through the 18 tuyeres currently available. The design of the injection system will provide for the addition of six more tuyeres in the future.

Non-contact Length and Speed Measurements Improve yield, reduce scrap, and increase profits. Polytec’s Laser Surface Velocimeters measure surface velocity and length from a safe distance without contact. Measure with Confidence!

India NFC orders second cold pilger mill. Nuclear Fuel Complex (NFC), producer of niche tubes for nuclear apMPT International 2 / 2017

Learn more: www.velocimeter.us

››› INTERNATIONAL INDUSTRY NEWS

plications, has ordered a second quarto cold pilger mill from Danieli W+K. The 50-Q-type mill will be designed to produce high-strength, high-temperature and corrosion-resistant stainless steel grade tubes, with outside diameters ranging from 10 to 35 mm and wall thicknesses from 0.4 to 5 mm. The mill stand configuration will allow the mill to achieve the extremely tight geometrical tolerances requested (±0.2% on outside diameters and ±3% on wall thicknesses). Also incorporated into the installation is a continuous shell feeding section, which adopts CNC machine technology and a vibration-free mass balancing system.

Kuwait United Steel upgrades electric arc furnace. United Steel Industrial Company, a private Kuwaiti joint venture company and sole producer of steel rebar and billets in Kuwait, operates its 150 t EAF with a complete MORE sidewall injection system (oxygen, carbon and lime injection) with 100% DRI/HBI

charge. To have the possibility to charge more scrap according to market conditions, United Steel contacted MORE to upgrade the sidewall injection system. During 2016, both companies agreed on the final injector layout which would provide the possibility to run the EAF with everything from 100% DRI/HBI to 100% scrap. MORE supplied three innovative M-ONE injectors for the combined supersonic oxygen and carbon injection, two JET burners, one LIMEJET for pneumatic lime injection, the valve stands upgrade and a system for the automatic inspection and sand filling of the EBT tap hole. Since October 2016, excellent results have been achieved. Thanks to the availability of better injection tools, EAF operations have improved both in terms of productivity and overall process control.

ing block. The new reducing block with four stand positions is to be installed in the roughing train of the wire rod and bar mill in Yenshui, Tainan, in southern Taiwan. The RB 500++/4 mill will be located between the planetary high reduction mill and the existing Kocks 500 intermediate block. With the implementation of the new reducing block, it will be possible for Walsin Lihwa to optimize the overall reduction in the high reduction mill according to the various material grades. With the additional reduction capability on an overall length of only approximately 5 m of the 3-roll reducing block, the rolling process can be flexibly harmonized for new and advanced special steel grades. Furthermore, larger billets can be used after the revamping leading to higher productivity, higher yield and subsequently improved mill economy.

Taiwan Vietnam Walsin Lihwa orders new reducing block. Walsin Lihwa has placed an order with Friedrich Kocks for a reduc-

Ton Dong A to build new coil coating line. Ton Dong A has contract-

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

Haus Füchteln 9 59399 Olfen

Tel: +49 25 95 / 38 77 00 Fax: +49 25 95 / 38 77 08

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

INTERNATIONAL INDUSTRY NEWS ed Danieli Fata Hunter to supply and install a 1,250 mm triple-coat continuous coil coating line at the new facility in Binh Duong province. With an operating speed of 120 m/min, the new line will process 120,000 t/year of hot-dip galvanized steel coils, mostly for the building and appliances industries. Strip size will be 1,250 mm (max. width) and 1.20 mm (max. thickness). The scope of supply will include a dry-in-place chemical coater and dryer to meet all the requirements of the various substrates and paints, as well as single slide coaters with a closedloop system for the paint thickness control. Also the printing section and tension levelling equipment are part of the supply. Low-maintenance and quick-change equipment will reduce maintenance time and increase line availability. Production of the first coil is scheduled to take place in the first quarter of 2018.

Vietnam Hoa Sen Group places follow-up order for reversing cold mill.

Cold strip producer Hoa Sen Group has awarded the Indian joint venture partner of SMS group, Esmech Equipment Pvt. Ltd., the order for the supply of a twin-stand reversing cold mill. This will be the second CCM® (compact cold mill) supplied by Esmech Equipment to Hoa Sen. The first mill is scheduled to go on stream in mid-2017. The recently ordered CCM® will be installed in the same bay as the first one. The two mills will be facing one another, an arrangement highly beneficial in terms of coil logistics. Included in the supply scope of the twin-stand CCM® are the pay-off reel and two reversing reels, allowing the finished coils to be removed from the entry or the exit side. The mill will be designed for rolling low carbon steel at a nominal annual capacity of 350,000 t. The minimum final gauge rolled by the mill will be 0.11 mm. SMS group will supply the quality determining components of the rolling technology from Germany. For example, both six-high stands will be fitted with CVC®plus technology. The mill will be equipped with a blow-off system at both the entry and

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exit for efficient removal of surplus lubrication from the strip surface. SMS India is supplying the complete electrical equipment and the automation system. This second CCM® is scheduled to go on stream by the end of 2017.

Europe Belgium ArcelorMittal Liège to install new surface inspection systems. ArcelorMittal Liège has ordered three surface inspection systems for three of its processing lines from Primetals Technologies. The systems will be installed on two continuous galvanizing lines and a continuous pickling line. Primetals Technologies’ scope of supply and services includes the complete hardware and software for three SIAS surface inspection systems, as well as commissioning, and training the operator’s personnel. The SIAS is able to detect surface defects on the top and

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bottom sides of the strip during production and classify them in relevant defect families in real time. In addition, the inspection systems will be fitted with coil grading, parallel classifier and DCR module functionalities. The improved quality control will optimize production costs and maintenance activities. The systems are scheduled to be commissioned by spring 2017.

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Silva Mash orders welded tube mill. Welded tube manufacturer Silva Mash has placed an order with Danieli W+K for the supply of an ERW line. The new line will be designed to produce round, rectangular, square, semi-oval and elliptical high-strength tubes with superior surface finishing. The main components of the plant will be an entry line with a double decoiler, strip joiner, horizontal accumulator, heavy-duty forming section, fin pass, welding and sizing stands. The outside diameters of the tubes will range from 10 to 45 mm and wall thicknesses from 0.5 to 2.5 mm. With a velocity reaching 150 m/min, the new line will be able to offer superior diameter/wall thickness ratio capability which along with quick product change-over time of less than 60 min will result in great product flexibility.

Czech Republic Tāinecké železárny plans major investment in plant modernization. Steelmaker Tāinecké železárny plans major investments in the modernization and renewal of equipment, including numerous environmental projects. A focus of the investments will be the automation of production. Key assets to be modernized or renewed include the blooming mill and the continuous casting facility. New cleaning billet equipment, renewal of a billet milling stand, purchase of a new drilling-sawing machine and the construction of annealing furnaces are other important activities planned. One of the environmental projects will be the desulphurization of sinter plant No. 1.

W E Czech Republic VÚHŽ to modernize special section mill. VÚHŽ, a subsidiary of Tāinecké železárny, has started a modernization project at its rolling mill for special sections. The contract for the supply, installation and commissioning of the core technology was placed with Primetals Technologies. The main goals of the modernization are the increase in production capacity by raising the profile weight from the current 21 kg/m to up to 30 kg/m and using heavier input stock of 150 mm x 150 mm. Another part of the renewal is the implementation of the industrial water recirculation system and scales separation. This investment phase is scheduled to be completed by the end of January 2018.

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Finland SSAB to modernize entry section of pickling line. Following the announcement of investing SEK 370 million to modernize the first section of the pickling line at Hämmeenlinna, SSAB has awarded SMS group the order to supply an X-Pro® laser welder with fibre laser and a high-performance tension leveller. The modernization will take place in two phases. In the first phase, the new entry section will be installed on part of the present coil storage area while pickling line production will be going on. The entry section will comprise two payoff reels, the X-Pro® laser welder and a horizontal six-fold looper. In the course of a one-week downtime, the new equipment will be connected to the pickling line by means of a bypass running across the existing entry section. In the second phase, also during ongoing production, the existing entry section will be removed and replaced by a new scale breaker and a recuperator tank. The recuperator tank will serve to pre-heat and pre-clean the strip with spent acid from the pickling process before the strip enters the actual pickling line. All new equipment will be supplied by SMS group including the electrical and automation systems. Integration of the new plant components is scheduled to take place during a twoweek downtime at the end of 2018.

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››› INTERNATIONAL INDUSTRY NEWS

Germany

out refurbishment work in the run-out area of the continuous caster in 2016.

Georgsmarienhütte to modernize continuous caster. Georgsmarienhütte (GMH) has awarded Primetals Technologies an order to modernize the company’s six-strand continuous bloom caster. Primetals Technologies will be performing the second stage of a multi-stage modernization project. Primetals Technologies will supply, install or modify the casting platform area, the machine head, the strand support, the withdrawal and straightening area, and the dummy bar system. Also included will be a system for measuring the thickness of the casting powder, a strand stirrer, secondary cooling, and a strand-guiding system with dynamic soft reduction. Modification of the machine control sections (level 1) and the process automation (level 2) is also part of the supply scope. This project stage will be completed in the summer of 2017. As part of the first stage, Primetals Technologies already carried

product mix will include low and medium carbon steels for concrete reinforcing and cold drawing applications.

Germany Russia Elbe Stahlwerke Feralpi completes first modernization stage. The wire rod mill at Elbe Stahlwerke Feralpi in Riesa is back to production. Danieli has completed the first stage of the modernization plan, involving the replacement of the old loop laying head and part of the cooling line with a new, high-tech oil film bearing unit and controlled cooling equipment. The next stage of the modernization will be the installation of a three-stand compact sizing block featuring multiple drive technology. The overall modernization is expected to be completed by January 2018. Then the plant will roll 5.5 to 16 mm dia. plain and deformed wire rod into 2,400 kg coils, at rolling speeds of up to 115 m/s. The

Ural Steel to revamp continuous caster. SMS Concast has been awarded a contract by Metalloinvest to modernize a four-strand continuous casting machine CCM-1 at Ural Steel. The aim of the upgrade is to enable the casting of round billets of 455 mm diameter for downstream manufacturing of railway wheels and the casting of rectangular billets of 300 mm x 330 mm for the production of rails. Apart from foot rollers, segments, spray rings, needed for the new billet size, SMS Concast will supply CONVEX® mould technology, CONFLOW stopper control and CONSTIR, a new system of electromagnetic final stirrers. Electrical and automation systems will

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Russia Evraz NTMK orders automation and electrics for new blast furnace. Evraz Nizhniy Tagil Metallurgical Plant has awarded Primetals Technologies an order to supply the automation, electrical equipment and instrumentation for the new blast furnace No. 7. The basic automation (level 1) and the process optimization (level 2) will be installed as a virtualized automation system on central, redundant servers, which will drastically reduce service costs, especially those for future upgrades. The new process automation will also optimize coke consumption. The new blast furnace is scheduled to be commissioned at the end of 2017.

Sweden Ovako invests in increased heat treatment capacity. Ovako has decided to invest in increased production capacity at its plant in Smedjebacken. The investment is part of the companyâ&#x20AC;&#x2122;s strategy to broaden operations at the plant and relates to a furnace that, together with the recently installed heat treatment capacity, will create coordinated, efficient and flexible production of heat-treated steel in Smedjebacken. The investments now being made in Smedjebacken will reduce lead times in production and delivery of heat-treated steel for Ovakoâ&#x20AC;&#x2122;s customers from weeks to one day or a few days, while considerably reducing the number of material movements within the group. The facility at Smedjebacken already has a materials laboratory and other technical functions that help to assure the highest quality. Like the furnace installed in Smedjebacken during the second and third quarters of 2016, the new furnace comes from Ovakoâ&#x20AC;&#x2122;s plant in Forsbacka. The furnace is expected to be operational in April 2017.

››› INTERNATIONAL INDUSTRY NEWS

Companies Outokumpu to divest quarto plate mill in New Castle, USA. Outokumpu is going to divest its quarto plate mill in New Castle, Indiana, USA, to D’Orazio Capital Partners, a US-based private equity company, and to the mill’s current management, as it serves Outokumpu’s financial and operational interests. Outokumpu’s other American operations remain unchanged.

Vallourec and Asco Industries to create Ascoval. Vallourec and Asco Industries have finalized the acquisition of a majority shareholding by Asco Industries in the Saint Saulve steel mill. Ascoval S.A.S., 60% owned by Asco Industries and 40% by Vallourec, will own all the assets of the steel mill. The creation of Ascoval is based on a solid industrial and commercial project that includes a major investment programme as well as commercial commitments for the purchase of steel by both partners. The mill should reach an annualized production level of 275,000 tonnes from the end of 2017.

ArcelorMittal Brasil and Votorantim to combine their Brazilian long steel businesses. ArcelorMittal Brasil S.A. and Votorantim S.A. have signed a definitive agreement, pursuant to which Votorantim’s long steel businesses in Brazil, Votorantim Siderurgia, will become a subsidiary of ArcelorMittal Brasil. Votorantim will hold a minority stake in ArcelorMittal Brasil. Votorantim’s long steel operations in Argentina (Acerbrag) and Colombia (Paz del Río) were not included in the transaction. The combination of the businesses will result in a long product steel producer with annual crude steel capacity of 5.6 million t and annual rolling capacity of 5.4 million t.

Owen Steel to acquire recycling facilities from OmniSource. Owen Steel Company of South Carolina, a subsidiary of Commercial Metals Company MPT International 2 / 2017

(CMC), has signed a definitive asset purchase agreement to acquire certain assets from OmniSource Corporation, a wholly owned subsidiary of Steel Dynamics. These assets consist of seven recycling facilities located in the southeast United States in close proximity to CMC’s minimill in Cayce, South Carolina. These facilities purchase, process and sell ferrous and non-ferrous scrap metal and other related products throughout the southeastern United States.

Vallourec to restructure organization. Vallourec is going to adapt its organization to enable the company to benefit fully from its transformation plan. The four regions – North America, South America, Europe/Africa and the Middle East/Asia – in charge of sales and industrial operations within their geographies, will be headed respectively by Nicolas de Coignac, Alexandre Lyra, Hubert Paris, and Edouard Guinotte. There will be two new central departments – Technology and Industry (T&I) and Development and Innovation (D&I). The first will design and implement the development strategy of the product lines and be responsible for innovation and R&D. The latter will design the group’s industrial strategy, aiming to continue to improve its cost base. It will also be responsible for technology, group sourcing, and global planning. The new organization aims to strengthen the group’s customer focus in each of its regions to optimize the use of its global resources and to boost its development.

Tenova TAKRAF acquires USbased material handling business. Global mining and bulk material handling equipment supplier TAKRAF has acquired the assets of FMC Technologies’ Material Handling Systems business unit based in Lansdale, Pennsylvania, USA. For over 100 years, FMC MHS has been a global leader in providing material handling solutions to a variety of industries including mining, minerals, power and food. The business provides systems expertise by engineering, procuring, and construction assistance of complete material handling systems, including a line of proprietary equipment for ro-

News in brief Thyssenkrupp, Germany, has modernized the pickling line for hot-rolled steel at its DuisburgHüttenheim site. The pickling baths including ancillary equipment have been upgraded and are now all-plastic. MMK, Russia, produced 5,948,000 t of metal in its hot-rolled products Mill 2000 in 2016 – an all-time record for annual output since the mill was commissioned. Saarstahl, Germany, has successfully rolled the first bar on the single-strand wire rod outlet at its Neunkirchen works. The outlet equipment was supplied by SMS group. Rihzao Steel, China, has issued the FAC for the continuous pickling line supplied by Primetals Technologies. The line is designed to produce around 2 million t/year of hot strip. Tata Steel, India, has put into operation its new greenfield ferro-chrome plant built at Gopalpur and produced ferro-chrome in compliance with all technical parameters.

tary drying and cooling of various materials. The business unit is being integrated into TAKRAF’s USA business, located in Denver, Colorado, and will retain its office presence in Lansdale.

Klöckner sells Spanish activities to Hierros Añon. As part of the One Europe strategy to further concentrate on its core markets, Klöckner & Co SE is selling its Spanish activities to Hierros Añon S.A. based in A Coruña, Spain. An agreement on the sale and purchase of Klöckner & Co’s Spanish subsidiaries, including the operating business unit Kloeckner Metals Ibérica S.A., has been signed by the two companies.

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INTERNATIONAL INDUSTRY NEWS EU steel market report. Having grown 3% year-on-year in the first half of 2016, the second half of the year saw EU apparent steel consumption stabilize relative to the same period in 2015. Distributors trimming stocks weighed on a still positive trend in real steel consumption. On balance, the EU steel market expanded by 1.8% in 2016. According to Eurofer director general Axel Eggert, total imports rose by more than 9% in 2016, hitting a multi-year peak. For the fourth year in a row, imports grew more strongly than the actual steel market in the EU and yet again absorbed the modest increase in demand. In the second half of 2016, imports accounted for 25% of the EU market. In 2017 and 2018, apparent steel consumption is forecast to continue to grow, albeit at a modest rate. Eurofer’s key concern is that the gradual recovery of steel demand in the EU market is being hampered by unfair trade. In the absence of structural solutions for excess global capacity and state subsidization, overproduction will persist and will continue to severely distort world trade in steel. Therefore the European Commission is urged to continue to vigorously implement trade defence measures against dumping into the EU. Having grown relatively strongly in the first half, activity in steel-using sectors gained only a little momentum in the third quarter of 2016. Prospects for 2017 and 2018 are again mildly positive. EU economic momentum gained some strength in the final quarter of 2016, following rather modest growth in the two preceding quarters. This implies that the economic recovery continued despite concerns regarding Brexit, the outcome of the US presidential elections and other internal and external risks and uncertainties. Private consumption remained the key driving force of economic growth during 2016.

Outokumpu returns to profitability in 2016. Outokumpu’s profitability for the full year 2016 improved significantly with positive underlying EBIT of EUR 45 million compared to EUR -101 million in 2015. This was driven by significant reduction in costs, as well as higher delivery volumes particularly in the Americas. The recognition of deferred tax income

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of EUR 189 million related to losses from prior years turned the full-year net result EUR 144 million positive. In line with typical seasonality, the stainless steel market is expected to be strong in the first quarter of 2017 with healthy underlying demand in both Europe and the USA. The cost saving initiatives are expected to continue according to plans and contribute positively in the first quarter. In addition, the higher ferrochrome contract price will have a significant positive impact on business area Europe’s profitability.

2016 world crude steel output. According to data released by the World Steel Association, world crude steel production reached 1,628.5 million t for the year 2016, up by 0.8% compared to 2015. Crude steel production decreased in Europe, the Americas and Africa, while it increased in the CIS, the Middle East, Asia and Oceania. Crude steel production by regions was as follows: annual production for Asia was 1,125 million t in 2016, an increase of 1.6% compared to 2015. China’s crude steel production in 2016 reached 808 million t, up by 1.2% on 2015. China’s share increased from 49.4% in 2015 to 49.6% in 2016. In 2016, the EU (28) produced 162 million t of crude steel, a decrease of -2.3% compared to 2015. 2016 crude steel production in North America was 111 million t, the same amount as in 2015. In the CIS it was 102 million t, 0.8% higher than in 2015. Annual crude steel production for South America was 39 million t in 2016, a decrease of -10.6% on 2015. Brazil produced 30.2 Mt in 2016, down by -9.2% compared to 2015.

Nucor Grating to acquire AMICO bar grating assets. Fisher & Ludlow, Inc., a subsidiary of Nucor Corporation, is acquiring the assets of Alabama Metal Industries Corporation’s (AMICO) bar grating facility located in Bourbonnais, Illinois, as well as the bar grating equipment and related inventory at three other AMICO locations. Fisher & Ludlow fabricates steel and aluminium bar grating products that are sold under the brand name Nucor Grating. MPT International 2 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

JFE acquires shares in coated steel manufacturer. JFE Shoji Trade Corporation has invested in Ton Dong A Corporation (TDA), manufacturers of cold rolled steel and coated steel products in Vietnam, by acquiring shares of the company. JFE Shoji and TDA have already shared sales strategy in the past. The new relationship will enhance the existing business of both companies.

Thyssenkrupp sells Brazilian steel mill to Ternium. Thyssenkrupp has reached agreement with Ternium on the sale of the CSA Siderúrgica do Atlântico (CSA) steel plant in Brazil. With the closing of the transaction thyssenkrupp will receive a clear cash inflow which will significantly reduce the group’s net financial debt. The sale is subject to the approval of the competition authorities. The two parties aim to close the transaction by 30 September 2017. The sale will take economic

effect retrospectively at 30 September 2016. With the sale of CSA, thyssenkrupp is bringing its loss-making chapter of steel in the Americas to an end. Ternium is a leading Latin American steel producer with production facilities in Mexico, Argentina, Colombia, the southern United States and Guatemala. With shipments of 9.8 million t of finished steel products, Ternium purchased approximately 3.7 million t of steel slabs from third parties in 2016. With the purchase of CSA, Ternium will acquire additional production capacities of up to 5 million t of slabs per year. Under a slab supply contract agreed up to 2019, CSA will continue to deliver an annual 2 million t to the ArcelorMittal/Nippon Steel plant in the USA.

Eurofer comments on ETS deal. Eurofer considers the deal on the Emissions Trading System (EU ETS) post 2020 agreed by the Environment

3rd ESTAD

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Council as inadequate to protect the European steel industry’s global competitiveness or prevent carbon leakage. According to Axel Eggert, director general of Eurofer, the package put together by member states unfairly penalizes even the most efficient players in the market. Member states concluded an arrangement that reduces the auctioning share by just 2%, meaning that there will not be enough free allowances for even the 10% best performing plants as the EU ETS post 2020 rolls on. Among others, Eurofer criticizes that the environmental benefits of the use of recovered waste gases in electricity production were not fully considered, and there was no solution found to protect sectors at high risk of carbon leakage by preventing the application of the Cross Sectoral Correction Factor (CSCF). “On 15 February the European Parliament reached an agreement that included a 5% reduction of the auctioning share, a method for shielding sectors at high risk of carbon leakages from the application of

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INTERNATIONAL INDUSTRY NEWS the CSCF, and strengthened the provisions on recovered waste gases used for electricity production,” added Mr Eggert. “These solutions would have gone some way to protecting the climate and more carefully underpinning the ability for European industry to invest in the innovation needed to reduce emissions.”

NSSMC acquires Nisshin Steel. Nippon Steel & Sumitomo Metal Corporation (NSSMC) has acquired Nisshin Steel Co. with effect of 13 March 2017. Naoki Konno has retired as managing executive officer of Nippon Steel & Sumitomo Metal Corporation and taken office as advisor of Nippon Steel & Sumitomo Metal Corporation from 1 April. From the same date, Naoki Konno has been nominated as managing executive officer of Nisshin Steel Co., Ltd. In late June he will assume the position of direc-

tor, member of the board and managing executive officer of Nisshin Steel Co., Ltd., at the same time retiring as advisor of Nippon Steel & Sumitomo Metal Corporation.

Andritz reports solid business development in 2016. In spite of a slight decline in sales, Andritz achieved the highest earnings and profitability figures in the company’s history. EBITA increased to EUR 442.1 million, a +3.1% versus 2015. Net income (without non-controlling interests) increased to EUR 274.6 million (2015: EUR 267.7 million). Sales amounted to EUR 6,039 million and thus remained 5.3% below the all-time high of the previous year. All four business areas noted a project-related decline in sales in the capital segment. Service business saw very positive development, rising to a share of 32% of total sales with increases in all four business areas.

GFM up to 150 t capacity

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Personalities New chairman of Tata Sons. The board of directors of Tata Sons has appointed N. Chandrasekaran as executive chairman. N. Chandrasekaran has been chief executive officer and managing director of Tata Consultancy Services since 2009. In October 2016 he was appointed as a director on the board of Tata Sons.

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››› INTERNATIONAL INDUSTRY NEWS

New executive vice president at Ovako. Phetra Ericsson, currently HR manager for Ovako’s Hällefors business unit, has been appointed as the new executive vice president HR, communication & safety, health and environment for the group. Phetra Ericsson has been at Ovako since 2011, and has 16 years of experience in the field of human resources and leadership from several different industries, as well as operational experience, including as acting site manager at Ovako in Hällefors since the summer of 2016.

New chief financial officer at Andritz. Mark von Laer has been appointed as head of the group functions controlling, treasury, order and project financing, legal, and compliance. Wolfgang Leitner, president and chief executive officer of Andritz, will continue to be responsible for manufacturing, information technology, human resources, internal auditing, investor relations, and corporate communications. The executive board of Andritz AG will in the future consist of five members: Wolfgang Leitner, Humbert Köfler, Mark von Laer, Joachim Schönbeck and Wolfgang Semper.

Phetra Ericsson

Management appointments at Outotec. Adel Hattab has been appointed as executive vice president strategic customers and business development of Outotec. In his new position, he will lead the development of strategic customer relationships, sales processes and customer experience as well as marketing and market intelligence operations globally. Olli Nastamo, currently responsible for Outotec’s strategy, marketing and operational excellence, will become head of the operational excellence organization.

Changes in Outokumpu’s leadership team. Outokumpu has appointed Reeta Kaukiainen as executive vice president, communications and investor relations. She will join the Outokumpu leadership team and report directly to Outokumpu CEO Roeland Baan. Pekka Erkkilä, Outokumpu’s chief technology officer, has decided to retire from his position. He will continue to support the company in selected key areas and represent Outokumpu’s interest in, for example, Fennovoima and the Association of Finnish Steel and Metal Producers. MPT International 2 / 2017

Executive appointments at United States Steel. David B. Burritt, who currently serves as executive vice president and chief financial officer, has been elected president and chief operating officer. Mario Longhi, who has served as president and chief executive officer since September 2013, will remain U. S. Steel’s CEO and continue to serve on the board of directors. Two other executive appointments have been made at U. S. Steel: James F. Dudek has been named vice president – asset revitalization & manufacturing excellence, and Pipasu H. Soni will serve as vice president – finance. They will both continue to be based at the company’s Pittsburgh headquarters and join the company’s executive management team.

New managing director sales & marketing at Kocks. Günther Schnell has taken on the role of managing director sales & marketing at Friedrich Kocks. He takes over from Sergio Filippini, who left the company to retire. Günther Schnell had previously served as Kocks’ general manager sales/ chief representative China. He has 20 years of experience in sales of metallurgical plants and wire rod, bar and merchant bar mills.

New managing director of PSI Metals. Detlef Schmitz, manager at PSI for 29 years, resigns as managing director of the PSI Metals Group and will serve the company further on in business development. He has led PSI Metals together with his co-managing director Sven Busch. Detlef Schmitz will be succeeded by Thomas Quinet, former CFO, who has now been appointed as the new managing director. Thomas Quinet will keep responsibility for finance, controlling, legals, IT and services. In addition, he will be managing all topics related to the product PSImetals. Sven Busch will be responsible for all customer needs covered by four divisions which are directly responsible for sales and delivery in dedicated markets.

Nucor appoints lead director of the board of directors. The independent directors of Nucor’s board of directors have appointed John H. Walker to serve as lead director. John H. Walker has served as a member of the board since 2008 and has more than 30 years of experience in metal-related manufacturing and fabricating industries.

David B. Burritt

British Steel appoints new CEO. British Steel has appointed Peter Bernscher as the company’s new chief executive officer. He has thirty years of experience in the steel industry, having held numerous board and director positions with global leading technology and capital goods group voestalpine.

New head of BASF’s global business unit Surface Treatment. Martin Jung, senior vice president, has been appointed head of the global business unit Surface Treatment of BASF’s Coatings division which comprises the Chemetall business acquired from Albemarle in December 2016. Martin Jung succeeds Joris Merckx, who led the Chemetall business since 2007.

INTERNATIONAL INDUSTRY NEWS

Events ›

22 – 25 May 2017 Singapore Organizers: South East Asia Iron and Steel Institute (SEAISI) www.SEAISI.org

SEAISI 2017. This year’s conference and exhibition will be staged under the theme “Realizing the value within ASEAN steel industry through technology development, capacity optimization and digitization.”

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5 – 8 June 2017 Moscow, Russia Organizers: Messe Düsseldorf www.wire-russia.com, www.tube-russia.com, www.metallurgy-russia. com, www.litmash-russia.com

Tube Russia, wire Russia, Metallurgy Russia, Litmash Russia. This fair quartet will provide numerous synergies for visitors from the fields of industry covered by the individual exhibitions. The event will serve as a forum for intensifying business relations and meeting new contacts from Russia, other CIS countries and neighbouring European countries.

›

13 – 16 June 2017 Shanghai, China Organizers: CFA, CISA, MC-CCPIT, CMES www.mm-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.

›

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

SCT 2017. The use of steel in vehicle construction is the focus of the International Conference on Steels in Cars and Trucks. Four main topics will be covered: steel components in cars and trucks, man-

‹‹‹

ufacturing and components, new steels, and modelling, simulation and testing.

›

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

3rd ESTAD and 9th ECCC. European Steel Technology and Application Days (ESTAD) will be held in conjunction

››› INTERNATIONAL INDUSTRY NEWS

with the European Continuous Casting Conference (ECCC) at the Austria Center Vienna. Both conferences together will be the biggest steel technology event in Europe in 2017. Being the leading European technical conference for the steel industry, ESTAD is jointly organized by ASMET, AIM, A3M, Steel Institute VDEh and Jernkontoret. A technical exhibition is held during the event for equipment and service suppliers, steelmakers and media.

›

27 – 28 June 2017 Düsseldorf, Germany Organizers: Messe Düsseldorf www.itps-online.com

ITPS 2017. The International Thermoprocess Summit will provide a highquality programme for stakeholders in the automotive, aviation and metals industries. High-profile speakers, including Professor von Weizsäcker, president of the Club of Rome, and experts from different technological and economic fields will ensure that the programme will cover not only scientific and practical aspects but also general global issues such as the impact of digitization on industry.

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8 – 10 September 2017 Mumbai, India Organizers: International Trade and Exhibitions India www.ite-exhibitions.com

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5 – 8 December 2017 Tehran, Iran Organizers: Messe Düsseldorf www.iranwire-expo.com

World of Metal. This event combines various sectors of the metals and metallurgical industry in India within one common venue. Co-located will be four exhibitions: for machine tools, cutting and welding equipment, hand tools and fasteners, and the engineering and manufacturing industry.

Iran Wire 2017. This exhibition maps the entire spectrum of wire and cables, but also tubes, pipes, sections and related industries. International exhibitors will showcase their products on this attractive entry point into the emerging Iranian market. The exhibition is jointly organized by Aria Group, Tehran and Messe Düsseldorf.

›

6 – 9 November 2017 Chicago, USA Organizers: Messe Düsseldorf www.fabtechexpo.com

Fabtech 2017. This key industry event is held every two years, mapping the entire spectrum of metalworking and processing. For the first time, in 2017, Fabtech, in a joint venture with Messe Düsseldorf, will also feature an expanded Tube & Pipe pavilion showcasing tubes, tube end products and the tube trade.

17 – 19 December 2017 Dubai, UAE Organizers: Al Fajer Information & Services www.metalmiddleeast.com

Metal Middle East Dubai. This international trade fair will host four exhibitions under one roof: Tube Middle East, Wire & Cable Arabia, Welding & Cutting Middle East, and Tekno 2017. Visitors will benefit from the comprehensive spectrum of technology showcased.

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 2 / 2017

››› EVENTS

AISTech 2017 will be the steel’s premier event in North America this year AISTech 2017 – the Iron & Steel Technology Conference and Exposition – will take place at the Music City Center in Nashville, Tenn., USA on 8 – 11 May 2017. The industrial leader town hall forum and the president’s award breakfast are the two most exciting events planned for AISTech 2017. AISTech 2017 – the Iron & Steel Technology Conference and Exposition – will incorporate North America’s biggest steel event of the year. More than 8,000 attendees are expected to attend this global event, which will feature technologies from the world over, allowing steel producers to compete in today’s global market. The 2017 exposition is slated to be one of the largest yet, with more than 500 exhibitors. The AISTech 2017 exposition is an opportunity to meet face-to-face with the individuals who specify, design, deliver and commission plants and facilities associated with the production and processing of iron and steel. The exhibition will feature more than 500 U.S. and international companies for an unrivaled display of steel technology. The exposition will be available for all attendees to explore.

Conference schedule The technology conference will showcase more than 550 presentations on aspects of iron and steel manufacturing technology. Highlights include the latest environmental technologies throughout the iron- and steelmaking process; safe work practices and procedures for projects, production, and maintenance; cutting-edge research and advancements in the processing, product development, and application of steel; and discussions on efficient material movement both within the facility and to the customer.

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

MPT International 2 / 2017

The three day technical program will kick off on Monday with the Howe memorial lecture. The 2017 Howe memorial lecturer is Harry Bhadeshia, Tata Steel professor of metallurgy and director, SKF Steel Technology Centre, University of Cambridge. His lecture is titled “Extremely strong steels – the mechanism and prevention of hydrogen embrittlement.”

President’s award breakfast and town hall forum The AIST president Wendell Carter, vice president and general manager of ArcelorMittal Indiana Harbor, will host the president’s award breakfast on Tuesday, 9 May, in the Karl F. Dean Grand Ballroom of the Music City Center. The breakfast program will consist of the presentation of several prestigious association-level awards, including AIST’s steelmaker of the year. David Stickler, chief executive officer of Big River Steel, will address a keynote entitled “A technology company that just happens to make steel”. He’ll discuss how Big River is successfully applying new and advanced technology to steelmaking at its newly opened mill in Arkansas. Once again, a major highlight of the event will be the town hall forum, which will be held on Wednesday morning, 10 May, at the Music City Center. Five of North America’s most influential steel executives will discuss the future of steelmaking under the Donald Trump presidency. As part of AISTech’s annual town hall forum panel discussion, the panelists will look at this most unconventional American president and what his policies and administration might mean for steelmakers throughout North

America and the impact it may have around the globe. 2017 town hall forum panelists are the following VIPs: ▪ John L. Brett, president and chief executive officer, ArcelorMittal USA, Chicago, Ill., USA, ▪ James E. Bruno, senior vice president – Automotive Solutions, United States Steel Corporation, Troy, Mich., USA, ▪ Theodore F. Lyon, managing director – Metals, Hatch Associates, Pittsburgh, Pa., USA, ▪ Randy C. Skagen, vice president and general manager, Nucor Steel Tuscaloosa Inc., Tuscaloosa, Ala., USA, ▪ Barbara R. Smith, president and chief operating officer, Commercial Metals Company, Irving, Texas, USA.

Activities for students and young professionals Young professionals and students with a technical interest in the iron and steel industry can benefit from attending AISTech. The student schedule includes a plant tour, an undergraduate student project presentation contest, and a graduate student poster contest. At the “Steel to students reception”, students from various universities meet for a brief orientation and reception with representatives from a number of steel companies.

Plant tours Four plant tours will be held in conjunction with AISTech 2017. Nucor Steel Decatur LLC, Bridgestone LaVergne, Bridgestone Warren and Gerdau Nashville Construction Products will host the respective industry tours. The plant tours are on a first-come-first-served basis and are limited.

AS ONE We are stronger

Two powerful companies in the metals industry have forged together. Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies have united to become the new global force in metals technologies. Creating the future of metals as one. primetals.com

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

Grand opening of the steelworks complex at Big River Steel

North Americaâ&#x20AC;&#x2122;s latest steel complex inaugurated at Big River Steel %LJ 5LYHU 6WHHO KDV EXLOW WKH ZRUOGĹ&#x2019;V Ć&#x201A;UVW )OH[ 0LOOĹĄ D VWHHO PLQLPLOO IRU WKH SURGXFWLRQ RI D ZLGH SURGXFW VSHFWUXP LQFOXGLQJ DGYDQFHG DXWRPRWLYH VWHHOV DQG HOHFWULFDO VWHHOV 7KH IDFLOLW\ ORFDWHG LQ 2VFHROD $UNDQVDV LV GHVLJQHG WR SURGXFH WKH ODUJHVW UDQJH RI KRW VWULS GLPHQVLRQV SRVVLEOH XVLQJ WKH ODWHVW WKLQ VODE FDVWLQJ DQG UROOLQJ WHFKQRORJLHV IURP 606 JURXS Big River Steel has commissioned what is one of the worldâ&#x20AC;&#x2122;s latest technology steelmaking facility. Construction of the facility had started in July 2014. Big River Steel is going to recycle approximately 2 million t/year of scrap metal and other metallics to produce 1.6 million t of flat steel products annually. This is the first steel mill in North America to connect an electric arc furnace (EAF) to a Ruhrstahl Heraeus degasser. Based on the technology being employed and the design of the facility, the mill will produce a range of product dimensions and strength levels never produced before in an EAF mill.

Big River Steel, Osceola, Arkansas, USA Contact: www.bigriversteel.com E-mail: salesinfo@bigriversteel.com SMS group, DĂźsseldorf, Germany Contact: www.sms-group.com E-mail: thilo.sagermann@sms-group.com

MPT International 2 / 2017

Enthusiasm all around On 1 March 2017, Big River Steel (BRS) officially opened its new steelmaking plant in Osceola in the U.S. State of Arkansas. Numerous guests from the steel industry, politics and economy attended the grand opening, among them Asa Hutchinson, Governor of the State of Arkansas. With the new plants supplied and commissioned by SMS group, Big River Steel will produce, at its Arkansas site, grades for pipelines, silicon steels and advanced high-strength grades for the automotive industry in the U.S.A. As a systems provider, SMS group supplied all equipment and process know-how required for the steel mill complex and supported BRS during the commissioning phase. The company has seen a steep ramp-up curve in the production of hot strip which is at record level. During the grand opening, David Stickler, chief executive officer at Big River Steel, said: â&#x20AC;&#x153;We are very satisfied with the progress of our new steel mill

complex. Having SMS group by our side we are sure to achieve our ambitious project targets.â&#x20AC;? Burkhard Dahmen, chairman of the managing board of SMS group, added: â&#x20AC;&#x153;The good production start is the result of a strong and trusting partnership. Since SMS group supplies technology for the complete process chain, we were able to meet the challenge of supplying this complex complete with all required mechanical equipment, and the electrical and automation systems. Harmonized process sequences and the use of cutting-edge technology are basis and proof of the very good ramp-up curve. This is the first project for which SMS group has supplied the know-how for the entire process chain to produce the latest generation of steel grades.â&#x20AC;?

Steelmaking, hot rolling and strip processing facilities The Big River Steel complex is North Americaâ&#x20AC;&#x2122;s most modern steel-

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works. It covers an area of 567 hectares. In the first construction stage, the mill is going to produce 1.6 million t/year of steel. Increasing the annual output to nearly 4 million t will be accomplished stepwise by several expansions. The SMS group supplies comprised the mechanical equipment and the electrical and automation systems for all plant units. The steelworks was commissioned in December 2016 together with the CSP® plant. Com-

missioning of the RH-TOP facility is to follow in June this year. Once the equipment of the planned second construction phase will have been in operation, the steelworks will consist of two electric arc furnaces and two twin-ladle furnaces. The installed gas cleaning system has been designed to meet the applicable high environmental standards. The CSP® plant comprises a thin-slab CSP® caster, a tunnel furnace, a lami-

nar cooling system and a downcoiler. With a maximum strip width of 1,930 mm, Big River Steel operates the widest of all CSP® plants in North America. The hot strip leaving the CSP® plant will be processed to high-quality cold strip on the downstream combined pickling line/tandem cold mill that will go on stream soon. In combination with the two downstream strip processing lines, the tandem cold mill supplies a wide range MPT International 2 / 2017

››› COMPANY PROFILE

of products. Hot-dip galvanized cold strip is produced on the continuous process route via the annealing and galvanizing line, and an inline skinpass mill. The offline skin-pass mill stand installed downstream the batch annealing furnace stands out for its

The QR links to a video showing the BRS production facilities

high rolling force. Big River Steel can produce strips ranging from 914 to 1,880 mm wide and 1.4 to 0.28 mm thick.

First production record in January 2017 The first hot rolled coil was produced in December 2016 concluding commissioning of the melt shop and the hot strip mill. BRS immediately produced a coil of commercial quality. It was purchased by Zekelman Industries and sent to Atlas Tube, one of the company’s structural tube mills in Blytheville, Arkansas. Zekelman Industries purchased the coil for US$ 100,000 with the entire amount jointly contributed by Big River and Zekelman Industries to Wounded Warrior Project and Arkansas Northeastern College (ANC). Dave Stickler, chief executive officer of Big River Steel, said, “We are thrilled to be commemorating this milestone alongside Zekelman Industries. Having spent over US$ 1 million on training services provided by ANC over the past 18 months, we have an extremely strong relationship with the college and we look forward to expanding this relationship.” Big River Steel established a first production record in terms of tons of steel produced during the first full month of operation. With over 63,000 t of hot rolled steel produced in January, the first full month of production, Big MPT International 2 / 2017

First coils produced leaving the downcoiler area of the hot rolling mill

River topped the previous first month production record according to data maintained by SMS group. “Starting up a mill such as Big River’s takes a team effort and all of us at Big River take pride in this accomplishment as we work to meet the demands of our customers,” said Dave Stickler. Axel Sprenger, project manager for SMS group, stated, “The Big River

Steel team is extremely impressive and SMS is proud to be working alongside so many experienced operators and managers. This start-up record is just one of many milestones that the Big River Steel and SMS teams have already achieved.” © All pictures by courtesy of SMS group and Big River Steel

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AISTech 2017, 8-11 May, Nashville, USA / Booth NÂ°2437 ECCC 2017, 26-29 June, Vienna, Austria www.castolin.com

info@castolin.com

››› RAW MATERIALS

Rotary discharge machines reduce dust emissions 7KH $XPXQG URWDU\ GLVFKDUJH PDFKLQH RIIHUV YDULRXV DGYDQWDJHV IRU HIƂFLHQW KDQGOLQJ RI UDZ PDWHULDOV 'XVW HPLVVLRQV FDQ EH UHGXFHG E\ FRQYHUVLRQ RI RSHQ VWRFNSLOHV LQWR DQ HQFORVHG VLOR V\VWHP $ URWDU\ GLVFKDUJH PDFKLQH ZLWK GLVFKDUJH ZKHHO IRU H[WUDFWLRQ IURP VLORV FDQ DFKLHYH D PRUH SUHFLVH EOHQG RI PDWHULDO

Aumund rotary discharge machine, type BEW (picture by courtesy of Aumund)

Raw materials for ironmaking (metallurgical coal, iron ore, limestone etc.) are usually delivered to spacious outdoor stockyards located close to the coking and ironmaking facilities. The raw materials are stored at stockpiles, but space is always limited, especially in case the material is provided from different sources (suppliers). Problems can arise if production capacity increases and more space may be necessary. Mixing and blending results have their limitations in an outdoor stockyard, anyway. A certain average blend can be achieved, for example with the chevron method, but both stacking and reclaiming generally cause dust emissions. Advanced technical solutions have to be implemented to combat dust emissions and reduce the environmental impact. The following case studies demonstrate how performance requirements can be fulfilled successfully.

Circular silos save storage space The capacity of a stockyard near Shanghai was to be increased, but the space

Aumund Fördertechnik GmbH, Division Metallurgy, Rheinberg, Germany Contact: www.aumund.com E-mail: metallurgy@aumund.de

MPT International 2 / 2017

available was limited. The solution was to replace the outdoor storage with eight circular silos. Extraction from the circular silos is now carried out by an Aumund rotary discharge machine. This has resulted in more options for blending the material, and problems with solidification and bridging no longer exist. Additionally, the rotary discharge machine helps to be in compliance with the safety regulations relating to explosion protection, by respecting the first in first out principle. In effect, this has led to an enclosed storage system which emits no dust. This option was able to accommodate the highest storage volume whilst taking up the least space. A further advantage is that various types of coal can be stored in separate bunkers. The discharge wheel can extract material from the silo by itself whilst in a stationary position. An alternative discharge plough would need to be in movement, which is why it is suitable for longitudinal storage but less so for silos where there is a requirement for continual discharge. With a discharge plough the extraction process has to be interrupted in order to switch direction. The rotary discharge machine combines a discharge wheel with its own drive unit, therefore making a continuous flow of extracted material possible. In this way an exactly blended mixture of various coal types can be achieved, which is not possible in a longitudinal storage.

Discharge of coke from underneath the stockpile In an application in Australia coke is now taken directly to ship by an Aumund rotary discharge machine and belt conveyor, eliminating the requirement for transfer by truck or railway wagon, along with the dust emissions that this usually entails. BlueScope Steel in Wollongong (New South Wales), the main steel producer in Australia, is operating a coke oven

battery which today produces coke not only for their own consumption but also for the market. As an intermediate storage the coke is piled on large stockpiles (total storage capacity of 90,000 t), with 50,000 t built up on top of the discharging gullet. The coke is automatically reclaimed from underneath the stockpile for further transport. The Aumund rotary discharge machine travels inside a tunnel under which a discharge wheel reclaims the bulk material from one side of the gullet bottom. Such applications are widely used worldwide also in case of closed storage systems further reducing potential dust emissions. The rotary discharge machine has already been commissioned as a star performer in the overall raw material handling project of BlueScope Steel. Such applications are becoming more and more popular worldwide also in case of closed storage systems further reducing potential dust emissions.

Conclusion Aumund offers three types of rotary discharge machines: ▪ the block model type with high extraction capacity and low width dimension, ▪ the low profile model type with easy access whilst in operation, and ▪ the block model frame type for a more economical alternative to the block model, with explosion protection to ATEX 21. Dust emissions can be reduced by conversion of open stockpiles into an enclosed silo system. The space requirement of silos is lower than open stockpiles for the same volume. The Aumund rotary discharge machine with discharge wheel for extraction from silos can achieve a more precise blend of material. With the first in first out principle, material solidification is avoided and safety is enhanced.

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş CONTINUOUS CASTING

Unique coating technology for superior mould wear resistance and product quality Mould coatings play a crucial role in improving product quality and reducing operating costs in continuous steel casting. Monitor Coatings, a UK based Castolin Eutectic company, has developed a unique, ceramic composite coating technology, XuperCOATâ&#x201E;˘, which has produced best-in-class results in terms of mould life, cast product quality and caster operating costs. The technology has been applied successfully RQ VODE EORRP DQG ELOOHW PRXOGV DQG SURYHG WR EH WKH PRVW HIĆ&#x201A;FLHQW UHOLDEOH DOWHUQDWLYH to electroplating solutions. In the late 1980s, Davy Distington, Workington (UK), commissioned the second slab caster for British Steelâ&#x20AC;&#x2122;s Port Talbot facility. The new caster featured a split mould enabling parallel casting of two strands using a central divider. However, due to the harsh environment the divider was worn far earlier than the rest of the mould even though it was being protected by an electroplating layer. It was then, that British Steel and Monitor Coatings came together to develop the very first wear protection coating for casting

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Product quality and wear issues in the steel casting process Continuous caster components are exposed to high temperatures, corrosive environments and wear. The primary function of the mould is to control the rate of solidification and the shape of the strand. 60% of the heat exchange from the solidifying steel occur in the top half of the mould and controlled heat transfer is critical to the rate and homogeneity of steel solidification. Friction developed between the mould wall and the solidifying steel shell is minimized by

the combined effect of molten flux or lubricant addition and oscillating mould vibration. Despite this, wear by the solid steel shell can still be significant and may result in deteriorating product quality: â&#x2013;Ş Deteriorating coating layers lead to pick-up of copper from the mould wall which is then trapped on the hot liquid metal surface and forms star cracks [2] which may result in costly coil breaks in the following rolling processes. Manual inspection on cooled slabs is required to detect these cracks, followed by surface scarfing as required. This leads to increased costs through delays, yield losses and the energy needed for slab reheating. In the case of a continuous casting/rolling process, manual inspections may not even be possible. â&#x2013;Ş As mould wear typically appears first in the corners, the slab transforms increasingly into a W-shape which leads eventually to rejections

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machine components such as mould plates, dividers and grid plates. Over those last 30 years, Monitor Coatings and its customers in the steel industry have constantly worked together on enhancing this solution which is now available worldwide for all caster types and proving its superior performance.

spray

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the applied load)

MPT International 2 / 2017

CONTINUOUS CASTING due to mismatch with required shape standards. It may also cause longitudinal corner cracks which bear the risk of coil breaks in downstream rolling processes. ▪ Mould wear can be one reason for improper heat exchange causing the steel shell to stick to the inner copper mould surface and to tear. This results in transversal and edge cracks and in the worst case in a sticker breakout. This most detrimental incident is not only very costly but also a serious safety hazard for the operators.

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Uniformly distributed phases 1. No amorphous phase formation and minimum lattice distortion resulting in higher thermal conductivity compared to other HVOF sprayed WC based coatings. 2. High WC% and uniform distribution ?JJMUGLE DMP FGEFCP UC?P PCQGQR?LAC compared to other HVOF carbide based coatings.

XuperCOAT™ technology – cure to the disease XuperCOAT™ is the next generation hard-metal composite coating using HVOF (high velocity oxygen fuel) techniques [3] capable of manipulating the coating composition to give an optimum microstructure design [4]. The process capabilities go beyond the simple dual-phase alloys of tungsten carbide and cobalt to composite architectures. Significant performance improvements in coating properties have been achieved by changes in size, shape and distribution of the phases to produce ultra-fine-grained materials showing very dense structure with uniform distribution of carbides and minimum in-flight particle decarburization. Despite being very dense, coatings – even tungsten-based hard-metal ones – do not ultimately meet the corrosion and abrasion requirements of specific steel industry applications. Micro-porosity (pore size smaller than 5 μm) in the coatings can lead to crack initiation. So, to combat this phenomenon, specialist coatings are also used to densify the underlying coating, forming a physical barrier between the component and the working environment. Unique, thermo-chemically formed ceramic coatings are subsequently

‹‹‹

500x Typical XuperCOAT™ microstructure

on high casting speed, customers have identified additional benefits of the application of XuperCOAT™ coatings, such as improved product quality: ▪ fewer star and corner crack defects, ▪ fewer strand shape issues, ▪ fewer stickers and sticker breakouts, and lower operating cost: ▪ reduced consumption of copper moulds, ▪ reduced consumption of mould flux powder, ▪ better economy of scale due to less wear-related enforced stoppages.

formed, where a metal oxide bond is established not only between the particulate materials, grains or powders used to form the coating, but also between the coating and the substrate. Monitor Coatings’ customers have reported two to eight-fold cast steel yield increases on the same mould compared to electroplating solutions. The actual mould life increase varies dependent on the mode of operation and the nature of the product. Some plants operate thin slab casters or produce stainless steel, which tend to run with higher casting speeds and which require different coating setups compared to the lower speed traditional slab casters. In addition to increased yield with no operation disturbances noted, even

Alternative thermal spray solutions For many years, hard chrome plating was an industrial standard process for

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100% Dr. Spyros Kamnis, Stephen Shepherd, Monitor Coatings, Newcastle, UK Thilo Krah-Tomala, Castolin Eutectic, Bad Soden, Germany Contact: www.castolin.com E-mail: thilo.krah-tomala@castolin.com

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The successfully established XuperCOAT™ technology for slab mould plates has raised the interest of long product steel producers who wish to similarly benefit in bloom and billet moulds. In conjunction with its partners and customers in the UK steel industry, Monitor Coatings has suc-

XuperCOAT™ applied on billet moulds MPT International 2 / 2017

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cessfully developed the XuperCOAT™ technology for application inside of one-piece mould tubes used in long products casting. The same benefits for producers of blooms and billets have been reproduced as established for slab casters.

Industrial experiences Recent developments for long product casting

Coating thermal conductivity (W/mK)

wear and corrosion protection. However, due to amendments to the European Registration, Evaluation, Authorization and restriction of Chemicals (REACH) regulations coming in force in September 2017, the application of hard chrome plating will be considerably restricted in Europe for health and safety reasons. This is not just a European trend, and combined with the relatively low wear protection and cracking has prompted the development of other thermal spray coating solutions such as WC-Co blended powder, Ni-based alloys, Ni alloy plus oxide cermets and functional gradient coatings combining layers of Ni-rich alloys and WC-Co. The friction characteristics of such coatings were superior to those of electroplated chromium under simulated mould wear conditions [5]. Findings confirm the superior performance of the XuperCOAT™ technology over alternative thermal spray coating systems from other casting technology suppliers in terms of coating hardness, thermal conductivity and mould life extension.

Coating vickers hardness (HVC.3)

››› CONTINUOUS CASTING

Average lifetime factor

Stainless flat steel plant. In service, the XuperCOAT™ coated slab mould life is four times that of the conventional copper mould at 100,000 t of stainless steel cast. Little mould wear and no detrimental effects were observed. Early successes have now been translated into fully XuperCOAT™ protected moulds being used as standard on all mould sizes in the fleet. The an-

nual savings in mould maintenance costs alone are approaching 25%. Carbon flat steel plant. With XuperCOAT™ it has been possible to replace the mould’s CuCrZr base material with plain CuAg, achieving net savings in annual copper costs of 30%. This has not only created increased caster availability and reduced mould maintenance costs, but has also resulted in improvements in surface quality on specific grades that were particularly susceptible to off-corner wide side cracks. The level of scarfing has reduced dramatically because of the improved integrity and management of narrow face taper, with little or no wear occurring on the narrow faces. The XuperCOAT™ technology is now the standard coating on all four mould faces.

CONTINUOUS CASTING Carbon long steel plant. The plant operates a twin-strand large bloom caster (560 x 400 mm). All four faces of a mould were coated with XuperCOAT™ and achieved 100,000 t of steel cast – already three times the previous best performance. The plant has now the whole mould fleet coated with XuperCOAT™. Previously, with the conventional mould there would be a significant loss of taper after approximately 200 heats (~ 16,000 t of steel per mould) leading to longitudinal corner cracking of the blooms. Mould taper is now sustained throughout the mould campaign and there has also been a general improvement in overall bloom surface quality. Carbon long steel plant. The plant applies XuperCOAT™ technology in casting blooms from 230 x 283 mm up to 305 x 483 mm for a variety of applications. This has achieved a life of three to four times the previously used chrome-plated moulds.

Summary Castolin Eutectic’s UK-based Monitor Coatings was the first company to

introduce high performance ceramic composite coatings to caster copper moulds and has continued to lead the field in innovation and performance,

‹‹‹

significantly lower mould wear rates than conventional coatings, leading to lower operating costs and technical and commercial advantages.

References [1] Thomas B.G., Modeling for casting and solidification processing, chapter 15, Marcel Dekker, NY, 2001, pages 499540. [2] Brimacombe J. K. and Sorimachi K. , Crack formation in the continuous casting of steel. Metallurgical Transactions B, 8B, 1977, pages 489-505. [3] Kamnis S., Gu S., 3D modelling of kerosene-fuelled HVOF thermal spray gun, Chemical Engineering Science 61 (16), 2006, pages 5427-5439. XuperCOAT™ applied on a bloom

[4] Kamnis S., Gu S., Lu T.J., Chen C., Com-

mould; coating condition after 600 heats

putational simulation of thermally sprayed WC–Co powder, Computation-

bringing extended benefits to its customers by tailoring the application to their specific requirements. XuperCoat™ coatings function in extreme environments of temperature, abrasion, fatigue and friction and generate

al materials science 43 (4), 2006, pages 1172-1182. [5] Matthews S., James B., Review of Thermal Spray Coating Applications in the Steel Industry, JTTEE5 19, 2010, pages1267–1276.

Setting The Standards For Highest Efficiency In Thermal Processing

EcoMelter©, 105t per day, content: 35t PulsReg® Medusa Regenerator JASPER Gesellschaft für Energiewirtschaft und Kybernetik mbH / Bönninghauser Str. 10 / D-59590 Geseke Telefon: +49 2942 9747 0 / Fax: +49 2942 9747 47 / www.jasper-gmbh.de / info@jasper-gmbh.de

MPT International 2 / 2017

››› CONTINUOUS CASTING

Automatic testing system for temperature sensors of moulds The new system developed by Primetals Technologies offers reproducible and standardized heating and testing for all types of thermocouples. Damage to copper plates is ruled out. Defective thermocouples and poor contacts can be reliably detected with the system. Measured data can be saved for later use, for example in quality management. Temperature distribution in the mould is measured with the aid of thermocouples. It is important that knowledge about this distribution is as precise as possible in order to ensure that any sticking in the mould is detected quickly enough. Such stickers can lead to openings in the cast shell, resulting in damage averaging 100,000 euros. Until now, thermocouples have been tested by various manual methods, for example with the aid of gas torches. In doing so, the individual thermocouples are heated up to different extents, which makes interpretation of the measured results difficult. Moreover, heating of thermocouples can damage the copper plates of the moulds. In contrast with conventional test methods, for example with the aid of gas torches, use of the Automatic Thermocouple Checker rules out damage to copper plates. Alternatively, blow heaters can also be used, but the measurment takes longer then. The drawback of all manual methods, moreover, due to imprecise positioning or an unequal distance heating up of the copper plate is not reproducible and is not identical for all measurement positions. The Automatic Thermocouple Checker reliably detects defective thermocouples and poor contact between the thermocouple and the copper plate. The computer-aided test process supports optimum installation of thermocouples. This reduces to a minimum the replacement of moulds due to defective thermocouples, thus reducing

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

MPT International 2 / 2017

Heating arm of the Thermocouple Checker while measuring functioning of the thermocouples belonging to the broad side of a mould in the installed state

the need for maintenance. For quality management, the measured data gathered can also be stored for later evaluation. The system’s measurement arm is moved to a defined thermocouple column for testing. Then, one thermocouple after the other is heated automatically and the temperature that is reached is measured. Once testing of the complete copper plate is completed, a report is generated to indicate correct or defective functioning of the thermocouples. Narrow and broad sides of moulds can be equally tested with the system. It can be used both

to test one single mould plate in the workshop and also to check the complete mould. The Automatic Thermocouple Checker is delivered as a transportable unit. The basic system, which is connected to the thermocouple connectors on the mould, consists of a heating arm that is mounted on a linear guide and a measuring and evaluation unit. With the Automatic Thermocouple Checker, Primetals Technologies offers operators of continuous casting plants a solution for standardized and reproducible heating and testing of thermocouples in the copper plates of mould.

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Zumbach has developed innovative on-line measurement, monitoring and control equipment since 1957 A pioneer of on-line measurement, Zumbach manufactures a comprehensive range of non-contact, on-line measuring and control instruments. The technology is in use worldwide for such dimensional parameters as diameter, thickness, eccentricity, out-of-round and for physical or electrical parameters like expansion, capacitance, dielectric strength, and more. Zumbach technology is used successfully for quality assurance in various industries by thousands of customers around the world who rely on the quality and reliability of the instruments and systems, for example in the cable industry, in the plastic industry, in the rubber industry and last but not least in the steel and metal industry â&#x20AC;&#x201C; on hot rolling mills as well as in cold processes for steel and other metals.

How it all began It was in Biel (the centre of the Swiss and worldwide watch industry), Switzerland, on 1 May 1957. There was Bruno Zumbach, a young electrical engineer, not even thirty. He had come up with the idea of starting his own electronics company because he wanted to build something independently. Electronics were still in their infancy, relay and vacuum tubes were still the main elements. The transistor was something almost unbelievable; all integrated circuits and microprocessors, the stuff of the future. However, economic development in Switzerland at that time was good and there were many thriving machine factories in Biel. By and by, the first orders, individually or in small quantities, were re-

Bruno MĂźhlheim, Zumbach Electronic AG, Orpund, Switzerland Contact: www.zumbach.com E-mail: sales@zumbach.ch

MPT International 2 / 2017

ceived for drive systems in any kind of machine. They concerned machines for watches, optics, sterilization and instruments of all kinds. Probably the biggest and â&#x20AC;&#x153;most daringâ&#x20AC;? order at the initial stage was automating the butter centre in Gossau near St. Gallen (Switzerland). The whole butter production and distribution system was automated with a completely non-contact drive â&#x20AC;&#x201C; at that time still a brand new technology. It was the first such drive in Switzerland. For cost reasons, all control elements, the so-called logic blocks, were developed and mass-produced at the companyâ&#x20AC;&#x2122;s own factory. Even drives, light barriers and other items were manufactured in-house in Biel.

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The vision of a new kind of DC motor drive At the time, there were many manufacturers of cylindrical grinding machines in that region who required low-vibration and finely adjustable drives. Bruno Zumbach quickly realized that this was a major market. The problem was that a satisfactory solution was not possible with the thyratron technology of the time. Zumbachâ&#x20AC;&#x2122;s vision involved developing and building a small and affordable â&#x20AC;&#x153;Ward Leonardâ&#x20AC;? drive with a monoblock inverter and a matching DC motor and controller. This technology was only practicable and affordable for far higher drive outputs at the time. The â&#x20AC;&#x153;Ward Leonard visionâ&#x20AC;? would soon become the basis Zumbach technology for many years. The first production orders soon arrived. The new kind of drive proved its worth and became established. Leading grinding machine companies such as Tripet, Charmilles, Kellenberger, Tschudin, Studer and others became regular customers. As a result, hundreds if not thousands of Zumbach drives found their way to the four corners of the earth. Many of them are still in operation today. The workforce had since grown to around 20, and new premises were required. A small factory building was built in a few months and today (with new cladding) still forms the heart of the companyâ&#x20AC;&#x2122;s main building in Orpund.

Changing times and new XKUKQPU s VJG Ć&#x201A;TUV QRVKECN diameter measuring device In the early 1960s, Zumbach realized that its business with drives could not guarantee a viable future for the company. The field was marked by new technical possibilities and thus growing numbers of competitors, who began to force down prices and margins. The machine tool industry would also soon begin its process of decline. Around 1972, a plan was developed to produce an eccentricity tester for electrical cables. In 1974, Zumbach was granted a patent for the new inductive EX-TEST 7 device. It became the first major success in what was then the new field of in-line measuring equipment. MPT International 2 / 2017

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The optical diameter measuring devices became Zumbachâ&#x20AC;&#x2122;s most successful products. The analogue ODC types were created around 1975, the absolute measuring ODACÂŽ gauges from 1977. The ODACÂŽ 24 was the first gauge with absolute measurement to be sold in large quantities. â&#x20AC;&#x153;ODACÂŽâ&#x20AC;? became a registered trademark; over 80,000 ODACÂŽs of all types and for a huge range of applications have been sold since then. Zumbach has become a clear global leader in the field for many years.

1994 â&#x20AC;&#x201C; generation change In 1994 Bruno Zumbach handed the management of the Zumbach group over to his son Rainer. In the following years the group has been expanded and founded further subsidiaries, amongst others in Asia. Besides these own Zumbach companies, also additional representatives have been contracted. Consequently, one of the objectives of Zumbach, the proximity to customers, could be strengthened to a maximum and local services have consistently been expanded over the last 20 years.

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

QUALITY ASSURANCE ing rise to special devices using other technologies such as ultrasound etc. Profiles also became a relevant market segment and can be measured and monitored in real-time today with devices equipped with light-slit method and image processing capabilities. In the late 1980s, Zumbach also ventured into a completely new field, the steel industry. This concerned the measurement of huge, red-hot steel pipes for the oil and gas industry. They were later joined by rods and wire rod that must be measured at speeds of up to 400 km per hour! Although the established ODAC® measuring heads could be used, complex systems for cooling and mechanical protection needed to be developed. The first systems were sold in Italy, France and Spain. These steel systems were subjected to ongoing development and upgrades, and today are responsible for a / * KPVGTHCEG YKVJ KPVGITCVGF 12% 7# UQHVYCTG KP good proportion of overall sales. Zumbach has now be<WODCEJ KPUVTWOGPVU come one of the undisputed market leaders in the field. the most ideal price-performance ra- At the time, it was a daring decision tio. with many unknowns; the result, howIt was necessary to serve all the mar- ever, shows that Zumbach was right. kets at the same time, so work began to find representative offices for the most important countries. Specialist knowlOutlook: Industry 4.0 edge and local service are essential for These days, everyone is talking successful sales of these products, and about Industry 4.0. In actual fact, the only very few trading companies could technologies involved in Industry 4.0 offer this expertise. are well-known; the concepts are viAs a result, sales and service offices sionary but not new. Zumbach has recand later registered companies were es- ognized the importance of data to its tablished from 1970 in many different customers, from acquiring, combining countries. The first was in the USA in and displaying measured values from 1979, followed by England, Germany, different instruments, via transmisFrance, Spain, Italy, India, Taiwan and sion of the data to a customer server, in 2001 China. Over 20 sales engineers to the preparation of statistics and rein Orpund and the foreign companies ports. now ensure the success of the products Industry 4.0 introduces further chalon the global market. lenges, understood as follows by Zumbach: communication (ma▪ M2M 'ZRCPUKQP KPVQ PGY ƂGNFU QH chine-to-machine communication) based on established standards, application The plastics industry is a large, ▪ M2H communication (machine-to-hugrowing market. Tubes and hoses of man communication) based on platall types need to be tested for their form-independent display devices and diameters and wall thicknesses, givstandard software. Numerous, market-driven and innovative developments have been realized, e.g. the non-contact profile and shape measuring systems or the rotating measuring units with the revolutionary, non-contact transmission of both, signals and energy as well as the use of modern technologies (e.g. linear sensor technology and many others). Thus, a further aim of the Zumbach group could be met: offering the customer always the best solution with

‹‹‹

In the field of M2M, customer fieldbuses are particularly supported, in compliance with standards and the measures required for certification. Beyond this, OPC UA integrated in USYS processors as well as in many Zumbach products are available to customers. Using the new OPC server gateway software, the majority of terminal devices can also receive data via OPC UA. OPC UA is a key element of Industry 4.0 and the Internet of Things (IoT). It enables horizontal and vertical integration across various levels of the automation pyra mid, from the sensor to the ERP system.

Conclusion Zumbach systems, integrated into the manufacturing process, enable users to increase the output with lower material costs; they also reduce downtime, allow for safer operation of equipment and provide for flawless quality control. In addition, they also allow for an immediate quality improvement in cable manufacture through tighter tolerances, better transmission capabilities, easier subsequent manufacture, and simple pairing of conductors, as typical examples. Today, in-line measurement is a fundamental part of many production lines. Investment in Zumbach systems pays for itself practically in every manufacturing process. Continuous direct material savings and scrap reduction, mean these high-performance controls are amortized in a few months. In addition, the user benefits from substantial quality improvements and greater customer satisfaction, factors which cannot be expressed in numbers alone. Thanks to extensive research and development activities, Zumbach is in command of important technologies such as lasers/optics, ultrasonic, x-ray, high-voltage technology, computer hardware and software, including OPC UA and many others. This enables the company to apply to each application the most appropriate technology, and allows to develop new and unique solutions. Numerous patents obtained around the world demonstrate the strength in innovation. MPT International 2 / 2017

››› QUALITY ASSURANCE

“Quality Tracking” – logging quality information directly on the steel strip for later defect removal The newly developed Quality Tracking process permits information on defects to be supplied digitally along with the coil and thus enables steel processors to remove damaged sheets or coil sections at the start of their production process. Barcode markings are applied to the steel strip at the exit zones of the cold rolling mill. Quality Tracking is to be established as a European standard under the auspices of the European Steel Association EUROFER.

The barcode is printed continuously over the entire length of the coil

Manufacturing steel is a complex process. So kilometre-long steel strips – wound into coils – frequently have a few typical surface defects. For car manufacturers, however, it is extremely important to know about such irregularities and exactly where they are.

EUROFER, the European Steel Association, Brussels, Belgium Contact: www.eurofer.be E-mail: C.Liu@eurofer.be thyssenkrupp Steel Europe AG, Duisburg, Germany Contact: www.thyssenkrupp-steel.com E-mail: erik.walner@thyssenkrupp.com

MPT International 2 / 2017

To meet this requirement, the Quality Tracking process was developed, which permits information on defects to be supplied digitally along with the coil and thus enables customers to remove damaged sheets or coil sections at the start of their production process. The equipment required to apply the barcode markings to the steel strips was installed in the exit zones of cold rolling mills. In the future, European steel producers intend to offer the Quality Tracking system to their European customers to further improve quality and service and as an important contribution for Industry 4.0 applications. Quality Tracking is to be established as a European standard under the auspices of the European Steel Association EUROFER.

Proven process suitable for industrial use The three European steelmakers thyssenkrupp Steel Europe, ArcelorMittal and Tata Steel formed a research R&D cooperation in 2011 to develop a European standard that will enable them to supply their customers with information on significant defects along with the coil. Customers such as automotive OEMs and suppliers are informed about the exact position of the defects. To locate the damaged sections on the steel strip, which can be up to three kilometres long, defects identified by automatic inspection during the production process are assigned to the one-dimensional barcodes on the steel strip. These barcodes are printed onto the strip at roughly

QUALITY ASSURANCE 50 centimetre to two metre intervals and contain information on position, manufacturer and coil number. The quality information on the position of a possible defect is provided to the customer via a separate dataset. The process has been trialed with a customer to validate its suitability for industrial-scale use. The company was supplied with coils from the three steelmakers with Quality Tracking information. The trial was a success: Test runs showed that the Quality Tracking system allowed all identified defects to be rejected reliably. Thorsten GrĂźnendick, Quality Management, thyssenkrupp Steel Europe, explains, â&#x20AC;&#x153;The customers were able to read the barcodes with their scanning devices. It proved accurate to the metre.â&#x20AC;? The barcodes were read with an accuracy of over 99.5 percent. These results confirmed that the process is suitable for industrial use. It provides enormous advan-

tages both to suppliers and to automotive end customers. Five steel manufacturers have now come together under the roof of the European Steel Association EUROFER, with voestalpine und Salzgitter Flachstahl joining ArcelorMittal, Tata Steel and thyssenkrupp Steel Europe to drive the technology and implement it as an open European standard. Several other companies, including suppliers of blanking equipment and system suppliers, have now also signed up to the Quality Tracking project. The steel division of thyssenkrupp is currently converting the first production lines to enable them to manufacture Quality Tracking coils. â&#x20AC;&#x153;Only in this way can we move closer to the OEMsâ&#x20AC;&#x2122; goal of zero-defect deliveries. Many of our customers will benefit greatly from the development of this process, so we are confident that Quality Tracking will meet with a positive response,â&#x20AC;? it states.

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

The barcode provides information on the production site, manufacturing machine, coil number, material quality, and the exact position on the coil

framag Industrieanlagenbau GmbH /FVLJSDIOFS 4USBÂ&#x2022;F " 'SBOLFOCVSH 5FM & .BJM TBMFT IU!GSBNBH DPN www.framag.com

framagâ&#x20AC;&#x2DC;s torch cutting technology t T t TNBMM DVUUJOH HBQ t NJOJNJ[FE MPTT PG t N NBUFSJBM N t QFSGFDU DVUUJOH RVBMJUZ t Q t IJHI DVUUJOH TQFFE t I t T t TIPSU DZDMF UJNF t MPX HBT BOE PYZHFO t MP DPOTVNQUJPO D MPT International 2 / 2017

››› AUTOMATION

Intelligent data management powers staff to improve business Nucor Steel Darlington has implemented a centralized data repository able to correlate WKH SURFHVV LQIRUPDWLRQ WR WKH ƂQLVKHG SURGXFWV 7KH 'DQLHOL $XWRPDWLRQ 4 ,QWHOOLJHQFH system has transformed reporting by reducing manual data access and by delivering a FHQWUDOL]HG UHDO WLPH YLHZ RI WKH SURGXFWLRQ Nucor Steel Darlington is a premier producer of angles, channels, flats, rounds, rebar and hexagons. Nucor also produces rod, bar, and hex in coil. The facility is located in Darlington, South Carolina, USA. Since the beginning of operations in 1969 as Nucor’s first bar mill, the Darlington steel mill has grown to become the largest bar producer in the Southeast. Today, Nucor Steel Darlington’s facility consists of two highly efficient bar rolling mills that produce special bar quality, merchant bar quality, and reinforcing bar products in over 600 distinct steel grades.

As the quality of the rolled products has top priority, it became essential to have a centralized repository able to correlate the process information to the finished products and make it possible to use analytical tools to support the mill output. The Q3Intelligence system from Danieli Automation accomplished the need to merge heterogeneous sources into a single data warehouse, transforming data streams into useful information to optimize the overall process.

Information delivery systems become an intelligent decision platform The Business Intelligence (BI) vertical solution for the metals industries developed by Danieli Automation is a real-time data monitoring system and

Danieli Automation, Buttrio, Italy Contact: www.danieli.com E-mail: info@danieli.com

Q3Reports

Reporting Web based reports distributed across the company

Data Sources

> Web Portal > Real Time > Automated Delivery

> Process Variables > Production Times > Consumptions > Chemical Analysis > Laboratory > Quality Inspection > Final Products

PCS and Laboratory

Plant Process Automation

data analysis platform. Q3Intelligence business-user data analysis needs are delivered by the web dashboards and through Microsoft Excel via the custom Q3Intelligence data analysis templates and the exhaustive library of key performance indicators (KPI). Q3Intelligence extends information delivery systems towards being complete decision platforms by combining operational data streams with advanced analytical tools. Danieli Automation’s Level 2 system comprises the following modules: ▪ the Production Module, which manages the flow of data from the time billets are charged into the reheat furnace up to the end of the mill lines; ▪ the Downtime Module, which tracks and categorizes scheduled and unscheduled downtimes;

Q3Dashboards

Monitoring KPIs and metrics, evaluating the single heats or product details

Analyzing Advanced templates to evaluate process performances

> Self Service BI > Unified Data Models

Q3Analytics

Conceptual scheme of the Q3Intelligence system implemented at Nucor Steel Darlington MPT International 2 / 2017

> Web Dashboards

AUTOMATION ▪ the Quality Control System Module, which aims to automatically identify the quality level of the rolled products on the basis of measurements collected during the process and the application of a set of pre-defined quality evaluation rules; ▪ the Roll Shop Module, which provides regular and timely roll and setup shop management information to operators. Through automated tasks, all this data is centralized into the Q3Intelligence system data warehouse, which thanks to the predefined and built-in interfaces towards Danieli Automation’s Level 2 system, makes it a plug & play application.

Q3Intelligence set up and methodology The software commissioning was carried out in different steps by means of several visits on site, in which the integration of new modules and system tuning were performed gradually according to Nucor’s standards. Each phase involved specific Nucor personnel to properly configure the system. Due to the needs to centralize and correlate Level 2 data with the laboratory system data, an interface to exchange data was designed to import the laboratory test results into the Q3Intelligence centralized repository. Finally, the Q3Intelligence modules were integrated into Nucor’s SharePoint portal, leveraging the usage of the centralized data model thanks to its native compatibility with such environment. Gigabytes of information that were previously stored across several independent relational databases are now inserted into a custom-tailored data warehouse and analysis data models. One-click access to process data which had previously taken hours to track down is now instantly available. “The role-based access to the data makes it simple for our team to use Q3 Intelligence,” says Ben Souther, rolling mill supervisor at Nucor Steel Darlington.

Enhanced real-time production monitoring and data analysis Real-time data visualization tools, showing graphical snapshots and historical trends, enable end users to be

instantly informed about the status of both production lines. The web dashboards are entirely configurable, allowing to monitor specific production KPIs and metrics according to single user’s needs. Visualization is enhanced with the adoption of a top down dashboard design that starts with the automatic evaluation of individual key performance indicators and then tracks down the production to single day/ shift details or to production order details, with ready access to specific custom reports. Analytical data structures and data models are constantly updated with production data, in line with the need to easily and immediately correlate any information, from timings to quality and process variables, and from different perspectives, aiding decision-making activities. This data structure architecture permits to log the information, giving the ability to compare production trends and performances over time as well to correlate the product’s quality to any process of its process variables. All this information can be accessed from the company’s intranet through the readyto-use Excel dynamic analysis templates or through the SharePoint portal by means of various features such as Excel Web Services.

Role-based access to data The need to securely restrict access to certain information is easily fulfilled using the Q3Intelligence integrated security functionalities, integrated with customers’ Active Directory. For both systems, the web dashboards and Excel analysis workbooks, it is possible to rapidly set up roles with customizable privileges, thus preventing unauthorized access. Finally, any configured security role is automatically inherited by SharePoint, making it simple to handle security accesses. “The power of the Q3Intelligence data analysis system has made it a true tool for us to use; not just another piece of software,” says Ben Souther. Nucor Steel Darlington recognizes the additional value Q3Intelligence brings to its users. This is guaranteed thanks to the use of a wide-ranging data analysis platform comprising multiple data analysis tools for different needs, ensuring correct analyses

‹‹‹

Nucor Steel Darlington has grown to become one of the largest wire rod and bar producer in the Southeastern USA

of the gathered data. It is a powerful tool for production teams, quality assurance, process engineers and other key users of business processes, allowing them to focus on the monitoring and analysis of process data and reduce the time otherwise needed to identify the causes for production anomalies.

Conclusion Q3Intelligence leveraged the value of the existing process data to achieve a real-time and unified view of actual and historical plant performances. All users from both mills have now the possibility to readily browse production information thanks to a centralized repository of integrated data

Q3Intelligence system has transformed reporting at Nucor by reducing manual data access and by delivering a centralized real-time view of production MPT International 2 / 2017

››› AUTOMATION

from multiple sources. Q3Intelligence includes fully customizable advanced statistical tools which offer short learning curves for first time users. Q3Intelligence has transformed reporting at Nucor by reducing manual data access and by delivering a centralized real-time view of production. The system is characterized by a variety of benefits as follows: ▪ centralized production data generated from multiple process control systems, ▪ ordinary front-end tools (web browser and Excel) shortening learning curves, ▪ improved ease of access to data in terms of front-end analyses, system performance and maintenance by internal IT personnel, ▪ significantly decreased time to access internal data streams, via a unified methodology, ▪ real-time monitoring of plant production data together with the integration of existing reporting tools, ▪ customization of advanced dynamic data analyses,

Rolling mill day report: general overview of the analyzed period with gauges and KPIs displaying the most useful rolling mill information

▪ self-service BI that permits users to query data independently without needing extensive IT skills, ▪ extranet access to information thanks to the native integration with Microsoft SharePoint long time storage of all production data in a centralized data warehouse for advanced data analysis,

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MPT International 2 / 2017

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Coil store at the SZFG cold rolling mill – real picture (courtesy of SZFG) and 3D visualization by the warehouse management system (courtesy of 3tn)

Integrated transport and warehouse management system for slabs and coils Salzgitter Flachstahl GmbH, Germany, has awarded 3tn the order to supply a warehouse and transport management system for slabs. With the new system, the steel company is closing the existing gap in the material tracking system at its Salzgitter works, establishing a seamless system from the slab cut-to-length cutting downstream the process chain to the packed coils ready for shipment. While optimizing all transport and warehousing operations and supporting quality assurance, the system will also save energy and improve safety at work. For several years, German steelmaker Salzgitter Flachstahl (SZFG) has been operating eight warehouse and transport management systems (TWMS/metals from 3tn) for coils in its hot strip and the Thorsten Tönjes, 3tn Industriesoftware GmbH, Holzwickede, Germany Contact: www.3tn.de E-mail: info@3tn.de

MPT International 2 / 2017

cold rolling mill. The now ordered system will optimize all slab logistics for the upstream processes – between the steelworks and the wide hot strip mill, specifically from the four continuous casting plants through to the reheating furnaces. The system will comprise material tracking on the roller tables of the respective production facilities as following: ▪ at the exit of the continuous casting plants,

▪ slab management at the outside slab yards, ▪ slab transport to the hot rolling mill, ▪ storage of the slabs in front of the reheating furnaces in the hot strip mill area and ▪ all slab movements until the furnace entry. The scope of supply also includes a system for calculating the slab temperature, which will optimize hot charging.

MATERIAL FLOW LOGISTICS Tracking the internal material ƃQY CETQUU XCTKQWU YQTMU CTGCU The system will provide efficient transport management of the slabs and make best use of the available storage space. It will optimize multi-layer stacking, taking into account product characteristics and all applicable specifications and restrictions. This will avoid unnecessary shifting operations and speed up the transport processes. For the slab transport to the hot strip mill, the system will plan and coordinate the cross-plant logistics between the steelworks and the hot strip mill as well as the controlled loading of the slabs on different types of wagons. This will make communication by fax and telephone calls superfluous. Moreover, it will no longer be necessary to check the incoming material at the hot strip mill manually, i.e. on the basis of lists and forms. Detlef Gedaschke, project manager “Slab Transport Processes” at Salzgitter Flachstahl GmbH, considers this project an important milestone on the route to Industry 4.0: “Once the new transport and warehouse management system is up and running, we will have closed the last gap to achieve seamless material tracking across various areas of the Salzgitter works. This applies to the horizontal coupling of data with upstream and downstream plants as well as to vertical data coupling with the higher-level material tracking system.” It is a very important aspect that the system can be swiftly adjusted at any time to changing conditions. Detlef Gedaschke: “We have decided in favour of a system from 3tn because the company will be implementing many innovative features, for example the rules editors which we can adapt ourselves. They guarantee that we can act extremely flexibly without having to call in support by a third party.” The warehouse management system will also be very important for product diversification. Salzgitter Flachstahl has been producing an increasing share of special steel grades. This makes it necessary to know exactly which slabs need special treatment, for example, which ones must not cool down below a certain temperature. As it is not possible to reliably measure the current temperatures in all zones of each individual slab, 3tn is going to integrate a temperature model calculator from MEA Engineering GmbH into

the system. This calculator will compute for each slab the current temperature on the basis of parameters such as initial temperature, and storage and weather conditions. Thus it will be possible to optimize the storage of the slabs under temperature aspects and transfer them to the reheating furnaces just in time. This not only ensures that the special grades receive optimal treatment. It also optimizes hot charging of the slabs and will save a lot of energy. Automating the operations and processes in the slab yard also enhances safety at work. In future, no employee will have to enter the slab yard, for example to search any slabs, read the marking on the slabs or attach markings to them. The warehouse management system can be coupled with existing production, transport and planning systems to provide a continuous exchange of data. For example, for loading the slabs on trains, which are also managed by a 3tn system, a link will be implemented to the computers of the local haulage contractor. This avoids any wrong loading, mixing up or unnecessary restacking and shunting movements. To guarantee reliable data acquisition, 3tn will also supply the measuring systems for the seven gripper-type and magnetic cranes in the slab yard. Laser scanners mounted to the load carrying devices of the cranes will measure the length and width of the slabs. 3tn will also integrate radar-sensing equipment for position detection and detection of load changes on the cranes. Commissioning of the system is scheduled to take place in three stages during 2017.

Sophisticated warehouse management technology RTQXKFGU DCUKU HQT implementation of Industry 4.0 The TWMS/metals transport and warehouse management system of 3tn optimizes warehousing processes. All storage activities are target-oriented and in line with the requirements of the product. Most efficient use is made of the storage space available in various warehouses or even plant-wide. The system also optimizes crane movements, avoids unnecessary shifting operations and accelerates the transports. All processes become transparent because the system makes all information readily available and all activities intu-

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Detlef Gedaschke is project manager slab logistics at Salzgitter Flachstahl (picture by courtesy of SZFG)

itively comprehensible while reducing the tracing effort to virtually zero. 3tn developed TWMS/metals specifically for the metals industry. The system is preconfigured for all products, means of transport and warehouse arrangements common in that industry. In one direction, it communicates with ERP and MES systems and, in the other direction, with the basic automation systems and the sensor equipment. A central element of TWMS/metals is the visualization of warehouses in real time as near-reality 3D views. In the crane cabins, the current warehouse situation is displayed exactly as seen by the crane operators. Arrows guide the crane operators from one position to the next, while all information they need for processing an order is being displayed. A three-dimensional view is implemented on the client terminals in the offices. The users may freely move about this display and view the warehouse from any perspective. If they wish to know the position of a certain coil, they can zoom in on it from the total view, as known from “Google Earth”. A characteristic feature of these systems are their extensive scaling and parameter-setting capacities. Custom rule books facilitate the installation and service of the systems. Integrated control editors enable the parameters to be modified during the software run time. By means of the service-oriented architecture, 3tn achieves high scalability and serviceability. If required, processes can be handled by several servers, allowing the system to grow in line with customer requirements. This software architecture also allows updates and service activities for individual warehouses to be performed without affecting the overall system. MPT International 2 / 2017

››› AUTOMATION

Central material tracking system for reliable and accurate management of product data A new technology has been developed for the global tracking of products from WKH DUULYDO RI PDWHULDO ELOOHWV WR WKH VKLSPHQW RI ƂQLVKHG SURGXFWV ZLUH URGV $OO management procedures are centralized in a single digital system ensuring reliable and DFFXUDWH GDWD PDQDJHPHQW Traditionally, material management in the steel mill used to be carried out on paper documents and spreadsheets for every production area. Nowadays, all management procedures should be centralized in a single digital system ensuring reliable and accurate data management. To achieve this, it is necessary to provide the steel company with new management software systems and a hardware infrastructure suitable for a global process management. This article showcases an example installed at a wire rod mill with a production capacity of 750,000 t/year. The wire rod dimensions produced in that mill range from dia. 5.5 to 21 mm. The mill operates with a maximum rolling speed of 110 m/s. The billet feedstock sizes are 140, 160 and 180 mm square, with lengths from 9 to 12 m. The wire rod coil dimensions to be handled are as follows: ▪ coil external diameter: approx. 1,250 mm ▪ coil internal diameter: approx. 900 mm ▪ coil length: approx. 1,000 – 2,500 mm ▪ number of tying bands: 4. The whole production site covers an area of approx. 800 m². The mill yard comprises 250 m x 100 m. Billets are supplied by steelworks of the same corporation. The billet suppliers use a manually tag or a robotic tagging system supplied by Polytec to tag the products in the continuous casting

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plant. An input warehouse handles billets delivered by trucks, while cranes unload billets from trucks and deliver them to the production line. At the end of the production plant, forklift trucks store products in various output warehouses, which are positioned in the various areas of the production site, and load finished products onto trucks for shipment. A gas-fired walking beam furnace performs billet reheating and handling. Billets are conveyed to and from the furnace with pullers, chains and roller tables. A two-strand rolling mill is equipped with exit conveyors for the discharge of rolled products. Finished products are discharged by means of vertical/ horizontal hooks and sent to strapping machines.

Plant layout and infrastructure BM Automation – a company of BM Group, division of BM S.p.A., Borgo Chiese (TN), Italy Contact: www.bmautomation.it E-mail: info@bmgroup.com MPT International 2 / 2017

The new tracking system performs global process tracking, from the arrival of trucks loaded with billets to the loading of finished products onto trucks directed to the mill site. In the

various production stages, the system communicates with the level 3 system (SAP) and with the production system via a dedicated PLC. Every operational area is equipped with terminals and computers, which control the various production processes. They communicate via a facility network or a new third generation Wi-Fi system installed to guarantee full coverage over the customer’s entire site. Every enabled user can access the tracking application with its personal user name and password. Users access the system according to their individual competencies. All levels are managed at an administrative level and are assigned according to specific competences.

In-bound area In this area, operators handle the unloading of billets from trucks and their loading into the production line for the production process. Previously, when goods were unloaded from trucks, operators used to manually handle the delivery documents handed over by drivers and to inform the crane operators via radio.

AUTOMATION Accordingly, the stock status used to be manually recorded on paper sheets and spreadsheets. In the new tracking system, this procedure has been centralized and digitalized. After a delivery document has been stored in the tracking system, operators can view the input stock status in real time. Then, after defining where billets are to be sent, the crane operators automatically receive general information on the billets to be unloaded and the respective pile of des-

‹‹‹

on printed documents. Billets were manually searched by type and operators used to be informed via radio and by means of paper sheets about the stocks from which billets had to be collected and sent to the production line. In the new tracking system, all these data have been concentrated in a dedicated software interface specifically for warehouse managers who automatically receive production schedules from the facility level 3. By selecting the relevant production batch, the tracking

tion. Any job order update executed by a warehouse manager is also automatically sent to the crane operators, who receive an immediate notification by means of a general notification. Managing the input stock from the new tracking system has reduced the rate of mistakes made by operators in this area. Now, every single storage unit in the billet warehouse can be viewed in real time including the percentage of storage space utilization and all the details on every single billet

system automatically suggests stocks and billets according to the quality of the billets to be produced and the availability. By confirming the billets, warehouse managers automatically send a notification to the crane operators in the production area. They have constantly available a list of the loading operations to be performed via Wi-Fi terminal. The crane operators then select the production batch to be managed starting from the oldest one and confirm the performed operation by pushing a button for every handled load (max. 1 to 5 billets per load). In doing so, the production line receives a new load of billets and the input stock is updated according to the new situa-

and cast. The new system helps warehouse managers select the billets to be processed by means of filters appropriately configured in cooperation with the production managers. Crane operators thus receive information and any corrections quickly and safely. All information can be recorded for production data diagnostics. Moreover, stock status and production data can be exported.

General layout of the automation structure

tination by means of Wi-Fi terminals installed in their cabins. All they need to do is confirm the unloading operation by pushing a button and the system will automatically update the stock status. This notification also occurs when a warehouse manager decides to take goods from one stock to another. Thanks to this solution, operators can directly communicate via an application and the system can track every handling operation for real-time updates of the stock status. Besides this procedure, an interface is used in this area to enable operators to handle the billets to be sent to the production line. Formerly, operators used to receive production schedules

Suppliers’ side, robotic cell for billet tagging The suppliers of the billets apply the metal tag on each billet; some suppliers perform the tagging manually, others MPT International 2 / 2017

››› AUTOMATION

use a robotic cell to automatically identify the billet position and tag it. The information data on the tag are: number of heat, number of strand, progression of each strand. Production line operators – divided by management areas – operate the plant from terminals and control pulpits. In addition to this, operators used to manually record production data for every single billet without assigning a univocal technical datasheet to it. In contrast, the new tracking system ensures the univocal association of billet and, subsequently, wire rod data, guaranteeing real-time tracking in every stage along the production line. To achieve this, several software and

ing system, which compares them with the current production information. If they do not match the ongoing production process, operators are notified by means of visual warning so that they can analyze the problem and decide whether or not a billet should be discarded. Thanks to this integration into the production process, the tracking system – in combination with the datamatrix readers – allows to check every billet sent to the production line and prevents that wire rod production is not in line with the specified quality standards. At the same time mistakes deriving from incorrect charges made by crane operators in the production area are minimized.

Billet tagging

mechanical adjustments were made, as described below. Starting from the entry side of the production line, two datamatrix readers were installed. They consist of two mobile reading heads which read the billet tag automatically. This is necessary in this specific case because the orientation of the billet may not be correct. By interfacing with the production line, the datamatrix system dynamically positions these two heads by means of redundant lasers according to the length of the identified billet, while vision cameras read its faces and identify the general data necessary for the tracking operation (cast strand and casting numbers). After having been read, these data are sent to the trackMPT International 2 / 2017

After the entry area, the tracking system monitors billets as they pass the various stations until they reach the rolling mill. After entering the first stand, the products are identified by the system as wire rods. The system also allows to handle half wire rods, which are manufactured from two half billets cut in the roughing mill. The tracking system automatically handles these production modes by aligning the data of the downstream stations. A special feature of this system is its capability to also automatically manage manual operations (separations, scrapping). Operators can always manually intervene in the system in case of deviations due to manual operations that the tracking system cannot foresee.

Handling of wire rod at the mill exit Downstream of the rolling area, the production plant is equipped with vertical and horizontal hooks to take wire rods transported by conveyors to the exit. To guarantee univocal data, a new RFID system was installed in this area. A passive RFID device was installed on every post and active RFID antennas were mounted along the production line. Essentially, every wire rod leaving the mill is associated to the vertical hook that collects it by assigning its univocal sequential production number to the passive RFID device. From this point on, i.e. for all the following stations, it is possible to read the tracking information and perform assignments automatically from the active stations. Thanks to this solution, it is possible to know exactly and at any time which wire rod is in any of the 51 mobile stations (hooks). The RFID system also enables data to be safely transferred from one station to another since tracking data are saved both in the software and hardware of passive RFID devices. This reliable procedure also allows to accurately manage automatic printing of data on labels downstream of the production line. Every wire rod is manually labelled by operators (in the future, a robot-based solution is planned to attach the labels automatically; this solution is already in the BM – Polytec product catalogues). Previously, operators used to manually print labels in order to know which order corresponded to the specific wire rods and which labels had to be stuck onto them in a manual control procedure. With the new solution, printers automatically receive data from the tracking system, a printing trigger is sent and operators only need to take the labels and stick them onto the corresponding wire rods leaving the mill. In doing so, the occurrence of errors caused by operators in the label printing process is minimized ensuring proper assignment of data managed by the tracking system. As soon as wire rods are manufactured and labelled, they are collected by forklift truck drivers and carried to the output warehouse. Previously, operators used to manage the stocks of finished products by communicating with warehouse managers via ra-

››› AUTOMATION

dio and manually assigning the stock data contained in spreadsheets. Now, the new tracking system allows to manage this operation independently, that is, it can be directly carried out by forklift truck drivers. Operators select the wire rods they have collected and the relevant stock of destination from Wi-Fi terminals installed in the forklift trucks. After concluding the operation and confirming it in the tracking system, the stock status is updated. In doing so, it is possible to know at any time where finished products have been stored, update the output stock in real time, control the operations performed by each operator during the production process and subsequently analyze the historical reports of handling operations.

Centralized data management As mentioned above, in the past operators used to store process data manually. With the new tracking system, these data are saved automatically. The tracking system is provided with a PLC, which communicates with the various automation systems of the production line, reads process data cyclically and sends them to the tracking system via trigger. The tracking system updates the central database by associating the received data to univocal numbers that identify every finished product. In doing so, every wire rod has its technical datasheet containing all the relevant process data, so that operators can export them in tabular form for reports and analyses. In addition to production data, also production time is automatically saved in the new tracking system. By using a special algorithm, it is possible to calculate the time required to roll every single billet. This makes it possible to determine plant productivity for every job order. With this functionality, foremen can analyze plant efficiency by filtering data according to given parameters such as timeframe and production batch. The new tracking system introduces a new concept that ensures of unequivocal tracking. Every billet, from which one or two wire rods can be produced depending on how they are machined, is connected with several unequivocal data collected along the MPT International 2 / 2017

whole production process. Complete tracking is achieved for every plant station and operators can quickly view the current production status. In doing so, it is possible to prevent any problem deriving from mixing casts for different job orders. This solution allows to automatically collect process data in a single central database with the possibility of subsequent reporting. It also increased reliability in terms of data management and tracking in order to enable operators to speed up control procedures with minor adjustments for manual interventions, which cannot be foreseen by the tracking system.

Out-bound and shipment areas As mentioned in the previous paragraph, in the new tracking system, forklift truck drivers at the exit site of the production line select the stock of destination, i.e. where the finished products will be stored. These stocks are divided and spread throughout the customer’s site. In order to guarantee complete management by the tracking system, that is of all storing areas, full coverage was provided by means of third generation Wi-Fi antennas. These antennas are connected with two centralized redundant controllers and enable operators to carry out every loading and unloading operation from any enabled station by means of special terminals installed in their forklift trucks. Previously, stock status was updated manually but now, thanks to the new tracking system, it is possible to view its updated status in real time, with all the details of every stored wire rod. It is also possible to smoothly manage handling operations between warehouses. Warehouse managers are provided with a tool, which – by applying proper filters – enables them to search for specific wire rods within the entire output stock and to get the details of every stock. Thanks to this solution, it has been possible to eliminate problems concerning warehouse correspondence, the time required for data collection and productivity with reference to the operations performed by forklift truck drivers and foremen. Material shipment operations used to be carried out with paper documents, manual data entries and man-

ual updates of stock statuses. Thanks to the new tracking system, the documentation for truck drivers is already in the system, thus simplifying the work for the operators. Load data can be viewed by selecting it in the relevant management interface. After reaching the warehouse, operators load the wire rod, confirming it by means of a barcode scanner. Barcode scanners are used to read data matrix codes printed on labels and check the correspondence between loads and the requirements stated in the relevant document. After completing loading operations, warehouse data alignment is carried out automatically. Thanks to the new tracking system, it is possible to quickly manage loading operations of finished products. This solution helps operators in search and verification operations and guarantees safe loading also due to the fact that the system operates in combination with barcode scanners and terminals on forklift trucks. The stock status data are always aligned, thus allowing foremen to perform accurate analyses to optimize the management process.

Laboratory During and after the rolling process, samples of the produced wire rods are analyzed to check their correspondence with the data specified by the customer in the relevant order. These analyses also used to be carried out with spreadsheets and production data were updated manually. In the new tracking system, these data are centrally managed in a single system constantly connected with the production plant. After the samples have been taken, operators associate them with the univocal data shown by the tracking system. Laboratory operators update test results in a dedicated interface. They may access specific information according to their user privilege. After storing the data, quality assessment operators can search for the performed analyses and export them for additional statistics. These data are also sent to the level 3 system for issuing the quality certificate related to the respective job order. Thanks to this solution, management operations, which used to be executed with spreadsheets by different users in the various production areas, have been

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Global Presence, Local Service.

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş AUTOMATION is required for the alignment of those handling operations, which are not managed by the tracking system, or for operations, which are incorrectly carried out by operators in the warehouses.

Ring and roll management

Wi-Fi coverage

integrated in a centralized system. This speeds up data retrieval. Since the system is constantly connected with the production line, data correctness and quick data alignment are ensured, while significantly speeding up all operations.

Stock inventory Originally, operators used to manually align stock status data by updating management spreadsheets for both billet and wire rod warehouses. The new tracking system offers the possibility to instantly and safely carry out these operations by aligning stock data with the use of Wi-Fi barcode scanners. With these barcode scanners, operators enter the data of every billet stored in each storage unit of the input warehouse or add them, in case they are missing. After concluding this veriMPT International 2 / 2017

fication process, warehouse managers check the updates and send a final confirmation to the tracking system. Barcode scanners are also used to confirm the wire rods stored in every storage unit of the output warehouse by using the data matrix codes on labels, if necessary. Here, too, warehouse managers check the performed updates and send them to the tracking system for final confirmation. Of course, minimum requirements for inventory activities, e.g. the suspension of handling operations in this area, are previously agreed with production activities. With this solution, operators can quickly update the stock status thanks to the possibility of also verifying the data entered by the tracking system at a central level. Tracking itself ensures a high degree of alignment of the stock status data; this procedure

The management of rings and rolls of rolling stands has been integrated in the new global tracking system and connected with the production line. Originally, both were manually managed with spreadsheets, which included master data and the machining received in the various grinding processes. The new system offers the possibility to constantly monitor and record all the operations related thereto. By means of a dedicated interface, operators can enter the master data of new items, together with their dimensional details and the current utilization status. Every machining operation connected with these items is managed and recorded by the system. These items may be installed in the rolling mill at a later stage according to the production. For their management, operators use a dedicated interface, where these items are associated to the respective rolling stand. After confirming this operation, the central tracking system associates the processing time to a specific item according to the production batch. With this solution, foremen automatically view the updated item wear rate in real time. It is possible to arrange scheduled maintenance for these items by setting binding parameters, which enable the system to send a notification to the operators and manage the relevant action.

Conclusions The new tracking system offers a centralized system concept for product tracking. Finished products are considered as univocal items (identified by sequential numbers), with which all process management operations and data are connected. In some cases, management operations and data are automatically associated, whereas, in other cases, they are manually associated by operators. In addition, the new hardware infrastructure has strengthened and completed the tracking system ensuring fast and safe global product tracking in every production area.

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

Truck handling goes digital: thyssenkrupp steel division KU KPVTQFWEKPI C FKIKVCN VTCHĆ&#x201A;E management system thyssenkrupp Steel Europe handles roughly 20,000 trucks per month. With around 30 minutes available to load and unload each truck, any delays in arrival can quickly throw WKH HQWLUH VFKHGXOH LQWR GLVDUUD\ 7R DFKLHYH JUHDWHU Ć&#x192;H[LELOLW\ *HUPDQ\Ĺ&#x2019;V ELJJHVW VWHHO producer has introduced a solution that enables trucks en route to the company to FRQWLQXRXVO\ UHSRUW WKHLU SRVLWLRQ LQ OLQH ZLWK GHĆ&#x201A;QHG UXOHV IRU H[DPSOH XVLQJ DQ DSS that drivers can download to their smartphone.

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In the last 30 years the amount of car and truck traffic at the gates of thyssenkruppâ&#x20AC;&#x2122;s steel mill in northern Duisburg, Germany has multiplied to almost 120,000 arrivals and departures a week. The companyâ&#x20AC;&#x2122;s steel division expects a further 20 percent increase by 2025. For example, more than one million metric tons of granulated blast furnace slag is transport-

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

MPT International 2 / 2017

ed away by truck for further processing every year. There are 600 loading points on the plant site which are used regularly, and some 60 partner companies use the road network. In addition, the roads around the plant can be extremely congested, caused by a decaying infrastructure, e.g. many of the bridges in North Rhine-Westphalia. â&#x20AC;&#x153;To meet these challenges we are turning to advanced digital solutions that are now being implemented on a step-by-step basis,â&#x20AC;? says Ulrike HĂśffken, head of logistics at thyssenkrupp Steel Europe AG. â&#x20AC;&#x153;This will significantly improve the situation for carriers and truck drivers and ease the

traffic situation in the vicinity of our site. We are taking the way we organize goods flows to the next level, you could call it Logistics 4.0.â&#x20AC;?

New control system navigates trucks to thyssenkruppâ&#x20AC;&#x2122;s site in Duisburg and calculates time of arrival at loading points What is the quickest route to the plant? How can truck drivers find their way around the extensive site in the north of Duisburg? How does a loading point know when the delivery will really arrive? Answers to these questions

MATERIAL FLOW LOGISTICS have now been found â&#x20AC;&#x201C; using digital technology. Central elements include navigation around the thyssenkrupp site and a trucker app, which will be available sometime this year. The almost ten square kilometre site has 70 kilometres of roads, which can be confusing for many users. Non-locals frequently lose their way and cannot find their loading point or the exits. To remedy this, thyssenkruppâ&#x20AC;&#x2122;s steel division is working with HERE, a developer and provider of cloud-based map services backed by a consortium of leading car manufacturers. Maps and services from HERE are used in a large number of satellite navigation (satnav) systems. The site of the Duisburg steel

tem communicates with drivers and enables them to respond flexibly to changes. It also allows transport flows to the plant to be controlled. Overall this is expected to make things much easier for truck drivers while reducing congestion in the surrounding area. The traffic control system will also assist with the loading and unloading of trucks. The steel division of thyssenkrupp already provides time slots for carriers or at many loading stations time corridors of 1.5 to 3.5 hours. Several trucks are scheduled during this period and loaded on a first come, first served basis. Despite this service, there were still problems, caused e.g. by traffic holdups, that disrupted procedures

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mill has now been digitally scanned, and the geographical data will be available for use shortly. Partner companies, external service providers and employees will then be able to key the facility or loading point they are looking for into their satnav system and reach their destination more easily. The reference points on the navigation map are also part of the new traffic control system from Siemens. In the future, when truck drivers announce a delivery, e.g. via the trucker app, they will receive a suggested route online. This will take account of traffic holdups, roadworks etc. and keep them away from residential areas. The sys-

and caused deadlines to be missed. The thyssenkrupp employees at the loading points often did not know whether and when a delivery would be arriving. In the future a track & trace tool will provide greater flexibility in managing the time slots. Based on the calculated arrival times, the logistics system can change loading sequences or switch to a different time slot. Information on changes to the loading point, for example, is sent to truck drivers with the navigation route. GPS data provide a constant flow of information on the current location of trucks and update the estimated time of arrival continuously, making the system highly flexible.

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Paperless processing KORTQXGU GHĆ&#x201A;EKGPE[ CPF avoids waiting times at the plant gates Every day more than 2,000 trucks pass through one of the two main gates to the thyssenkrupp site in Duisburg-Beeckerwerth, as well as over 13,000 passenger cars and vans. Processing delivery documents and weighing the inbound and outbound trucks was increasingly leading to congestion and long waiting times. To improve the situation thyssenkruppâ&#x20AC;&#x2122;s steel division has started to modernize the handling processes at the relevant gates. This involves a changeover to digital traffic control and automated self-handling by truck drivers as well as extensive structural improvements. â&#x20AC;&#x153;This redesign offers our employees and partner companies a state-of-the-art gate system,â&#x20AC;? says Ulrike HĂśffken. â&#x20AC;&#x153;Processes are significantly faster, safer and more efficient.â&#x20AC;? The changeover to digital handling is already being introduced on a stepby-step basis. The gate check sheet with QR code is the â&#x20AC;&#x153;keyâ&#x20AC;? to access the site. It forms the link between the physical transport and the digital world and in the future can be produced at special self-service terminals or in advance via a web portal. There will also be a smartphone app. In addition to safety checks and faster handling at the gates, weigh stations and loading points on site, the system will help with the planning and execution of deliveries. To increase flexibility for carriers, thyssenkruppâ&#x20AC;&#x2122;s steel division is already using time corridors at many points as described above. Infrastructure measures will include additional lanes, which can be opened as required via traffic signals, and a traffic circle. In addition, a modern traffic control centre will be installed and additional automated truck weigh stations built at the two main gates. Digital components will also be deployed here, such as automated vehicle profile recognition, detectors and weigh cells, as well as route guidance via the digital plant map. A key part of the plan is a close-by truck stop that in the future will serve as a buffer parking area in the event of unforeseen delays at the entrances. The structural changes are scheduled for completion in fall 2017. MPT International 2 / 2017

››› MATERIAL FLOW LOGISTICS

“Our new logistics set-up at the gates will set an example for other industrial sites,” says Ulrike Höffken. “In addition to improving safety and service it will provide carriers with access to our site without waiting times wherever possible. In the future, we want trucks to be in within five minutes and out again after an hour.”

First application for Industrial Data Space The new information system for truck logistics at thyssenkrupp Steel Europe will be the first application for the Industrial Data Space, a new virtual data space in which companies can exchange information securely. As part of the “Industrial Data Space” initiative, the project to modernize the plant gates will include a connection to the initiative’s planned data room. It proves that the idea behind the Industrial Data Space works. Industrial Data Space aims to solve a basic problem that many PC users know: the use of cloud services to share data with others involves risks. No-one knows how securely their information is saved, how long it will remain stored or what the service provider does with it. The Industrial Data Space aims to eliminate these uncertainties. There, users retain full control over their data.

The Industrial Data Space e.V. initiative currently comprises around 40 industrial companies, the German Electrical and Electronic Manufacturers’ Association (ZVEI) and the Fraunhofer Society. Their joint objective is to create a data room in which companies can network securely, retain absolute control of their data and exchange information easily and quickly via standardized interfaces. “One key element of Industry 4.0 is data exchange between industrial companies,” says Dr. Reinhold Achatz, chief technology officer of thyssenkrupp AG and chairman of the Industrial Data Space initiative. Industrial Data Space is being developed by Fraunhofer Society in a project funded by the German Ministry of Education and Research. Users can define exactly which information may be made available to which partner and for how long. They know exactly what is happening with their data at all times and can set limits for the use of their information. thyssenkrupp is playing a pioneering role in this forward-looking project, and not just as the first user. Reinhold Achatz: “Our application is a first example of the possibilities offered by the Industrial Data Space. Many more applications from other companies will follow very quickly.”

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'EQPQOKECN ENGCPKPI CPF Ć&#x201A;PKUJKPI YKVJ C PGY IGPGTCVKQP QH TQNNGT EQPXG[QT DNCUVKPI U[UVGOU Roller conveyor blast machines are used to remove scale and rust from billets, bars, tubes, sections and sheet metal components. The German manufacturer of blasting systems AGTOS has enhanced its machine concept with special emphasis on high blasting speed thanks to use of powerful turbines. The treatment of bars, tubes and sections, but also of metal sheets and small welded structures is particularly demanding for the blast machine. AGTOS, the blasting systems manufacturer with headquarters in Emsdetten, Germany, has enhanced its machine concept, offering different types of solutions in conformity with varying market trends. Special emphasis was placed on high blasting speed thanks to the use of powerful turbines. Even with increasing throughput speeds, the resulting surfaces must always be of top quality. This requires suitable high-performance turbines. They blast the abrasive reliably and with a high level of energy onto the surface of the workpieces. Their output determines the workpiece throughput speed. Depending on the required blasting quality, turbines with blast wheels of different diameters are used. The power of the motors (kW) varies too. Nevertheless, the principle always remains the same. AGTOS uses single-disc wheels which have proved to be highly efficient even under rough conditions. The throwing blades are fastened in supporting discs on one side. The advantages compared to the popular double-disc wheels are the short installation times and reduced number of wear parts. These measures play an important role for the economic efficiency of the machines. With this configuration, only six (compared to eight or more) throwing blades are used. Compared to other turbines,

Design scheme of an AGTOS roller conveyor shotblasting machine for long steel products

AGTOS high-performance turbines are characterized by a high shot flow and, thereby, a higher blasting performance with the same shaft power. The maintenance-friendly design ensures quick completion of service tasks. The material of the wear parts is adapted to the type of abrasive used. If the wear parts are made of hard alloys, a long service life is possible even in the case of highly aggressive, sharp-edged abrasives.

Design-related advantages Ulf Kapitza, AGTOS Gesellschaft fĂźr VGEJPKUEJG 1DGTĆ&#x192;Ă&#x20AC;EJGPU[UVGOG )OD* 'OUFGVVGP )GTOCP[ Contact: www.agtos.de ' OCKN KPHQ"CIVQU FG

MPT International 2 / 2017

As a manufacturer of special-purpose machines, the AGTOS designers attach great importance to the userfriendly design of the machines. The relatively low height of the machines ensures that they can be set up even in spaces with a low ceiling. Anoth-

er advantage is the fact that it is often possible to use the machines without a special foundation. This saves building costs and increases the flexibility of the machines in terms of their setup and location of use. The operator elements of the machines are customized in line with the specific requirements of the customers. This is made possible thanks to mirror-image assemblies and a modular system. Since the robust machines are intended for multi-shift operation, the blast chamber, whose housing is made of manganese steel, is additionally lined with wear-resistant plates. Several rubber curtains prevent vagabonding abrasive material from escaping the machine. The maintenance time of the curtains has been drastically reduced by ensuring that they can be pulled out

SURFACE TREATMENT to the sides. As a result, they do not have to be removed and reinstalled via the machine. Sealing of profile blasting processes against the environment is often a major challenge for conventional machines. Here, AGTOS has developed an economic solution by using special, highly resistant pendulum seals. AGTOS attaches great importance to the preparation of the abrasive material. The abrasive cleaning process can be controlled by adjustable air conduction that, in turn, can be controlled via several different controllers. This has a positive effect on the blasting result, the reuse of the abrasive material and, in particular, on the level of wear inside the machine. After a machine has been handed over to its new owner, the operating personnel are specifically trained for this task.

Maintenance- and GPXKTQPOGPVCNN[ HTKGPFN[ ECTVTKFIG ƂNVGT U[UVGO The filter system sets new standards and contributes essentially to the relia-

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bility of the process. The dust-laden air is withdrawn from the blasting chamber and flows through the impact separator where heavy dust particles are separated from the airflow. From there, it passes into the lower filter chamber. When it flows through the filter cartridges, the dust is completely removed and the clean air flows upwards into the clean gas chamber.

The filter cartridges are cleaned by compressed-air bursts based on the differential pressure. The dust particles are guided into a hopper and collected in a dust collector. From the upper filter housing, the cleaned air is fed to the outside or back into the factory hall. If a filter cartridge is damaged, additional filter inserts catch the dust.

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››› SURFACE TREATMENT

Inauguration ceremony at the ArcelorMittal works in Kessales, Belgium

ArcelorMittal inaugurates YQTNF U ƂTUV ,GV 8CRQT &GRQUKVKQP line for the steel industry ArcelorMittal has opened a new production line – the Jet Vapor Deposition (JVD) line – at its facilities in Kessales, Belgium. The JVD technology coats moving strips of steel in a vacuum chamber, by vaporizing zinc onto the steel at high speed. The JVD technology, which will be used to produce coated steels for automotive and other industrial applications, offers multiple advantages. ArcelorMittal has opened a new, 63 million euros production line – the Jet Vapor Deposition (JVD) line – at its facilities in Kessales, Belgium. His Majesty King Philippe of Belgium officially inaugurated the line at an event, held on 3 February 2017. The opening was the culmination of years of scientific investigation by ArcelorMittal’s research and development teams in collaboration with the Metallurgical Research Centre, CRM group, to create

ArcelorMittal Gent-Liège, Belgium Contact: http://automotive.arcelormittal.com/ coatingscoldstamping E-mail: jan.cornelis@arcelormittal.com

MPT International 2 / 2017

a new, breakthrough technology for the metallic coating of steel. The invention continues the Walloon tradition of stretching the boundaries of coating technology for steel – the first hot dip galvanizing line was commissioned in 1881 in Flémalle and the world’s first electrolytic galvanized steel rolled off the production line in March in in 1954. The new JVD line is part of a major 138 million euros investment programme within the scope of the 2014 Industrial Plan, an agreement between ArcelorMittal, the Walloon government, Sogepa investment fund (Société de Gestion et de Participations) and the social partners. The JVD project was financed by Sogepa through ARCEO, a joint venture between Sogepa and ArcelorMittal.

Coating steel strip under vacuum and at low temperatures The JVD technology coats moving strips of steel in a vacuum chamber, by vaporizing zinc onto the steel at high speed. Zinc is used to coat steel to prevent corrosion, in order to improve durability. The JVD technology, which will be used to produce coated steels for automotive and other industrial applications, offers multiple advantages including: ▪ A lower environmental footprint. A life-cycle assessment evaluating the environmental impact of this process as a whole – the coating, the use phase of the products, the waste products and their management – showed a higher yield and lower energy consumption than other coating techniques. JVD technology has

SURFACE TREATMENT

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al solution that’s now operational and means we can bring unique solutions to our clients in many different markets.” JVD is a breakthrough process, not only in terms of production process but also in terms of product development. It creates two brand new product families to ArcelorMittal’s unique range of metallic coatings: Jetgal® and Jetskin™.

Consistent surface, dependable protection the lowest ‘global warming potential’ – a measure used in life-cycle assessment – of any industrial steel coating process. ▪ It ensures an exceptionally uniform coating, which enhances the surface quality and makes welding easier for the customer. ▪ It guarantees excellent adhesion of the coating, regardless of the steel grade, even for the new ultra-high strength steels currently under development. ▪ Coating the steel under vacuum and at lower temperatures removes the risk of the steel or zinc oxidizing. ▪ It is a highly flexible process thanks to its ability to produce different coating thicknesses (one side versus another) and to coat a variety of substrates regardless of their chemical composition. Speaking at the event, Matthieu Jehl, CEO of the ArcelorMittal Gent-Liège cluster, said: “ArcelorMittal’s strength lies in its ability to innovate and push the

The QR code above links to an animated ƂNO QP ;QW6WDG GZRNCKPKPI VJG JVD technology

boundaries of steelmaking. The 63 million euros investment made in the JVD line together with our partners, and the wider investment plans for ArcelorMittal Gent and Liège clearly underline that ArcelorMittal believes in the steelmaking future of Belgium. I am extremely proud of all the ArcelorMittal employees who have contributed to this project.” Jean-Claude Marcourt, vice-president of the government and Walloon Minister of Economy, Industry, Innovation and Digitalization, who was present at the inauguration, said: “Today reconfirms the worldwide leadership of Wallonia in the field of coating technology. The future of Walloon steel depends on innovation. In this way, we will be able to further develop production thanks to the know-how and the excellence of our highly-qualified people.” Renaud Witmeur, president of the Sogepa management committee, said: “The JVD technology demonstrates the Liège basin’s steel sector expertise and innovation capacity. This investment by Sogepa, alongside ArcelorMittal, demonstrates our commitment to contribute, alongside our private partners, to the future of the sector in Wallonia through truly innovative products.” Greg Ludkovsky, vice president and head of research and development at ArcelorMittal, added: “The JVD process is unique – a world-first – and is the result of a breakthrough scientific development. Today’s inauguration is the culmination of eight years’ hard work by ArcelorMittal and the CRM group, starting with a small laboratory trial and ultimately becoming a full industri-

Jetgal® is the brand name for the JVD zinc coating applied to steel grades for the automotive industry. It has been developed for steels including ultra highstrength steel Fortiform®, which is produced at ArcelorMittal Gent and Liège. Jetskin™ is the brand name for the JVD zinc coating applied to steel grades for industrial applications such as household appliances, doors, drums and interior building applications. Jetskin™ products feature impressive advantages as following: ▪ outstanding surface quality for unpainted or post-painted products, ▪ homogeneous coating with a matt aspect, ▪ double- or single-sided zinc coating, ▪ customizable coating thickness per side, ▪ significantly lower ecological footprint due to the efficiency of the new JVD process. Jetskin™ grades meet all requirements of EN 10152. Double sided coatings are available from 18 to 72 g/m², customized coating thicknesses per side are available upon request. Different grades of Jetskin™ are available for cold forming, structural or high strength low alloy steels to meet different applications. Jetskin™ is delivered in fully REACH compliant flat formats such as sheets, slitted coils or coils. A supply chain team is devoted to implement the just-in-time approach. Jetskin production line configuration allows to reduce lead time of three weeks and to improve normally the service performance for Jetskin™ comparing EG process. Jetskin™ is ready to respect short lead time for reducing the time for trials homologation. MPT International 2 / 2017

››› MATERIALS

Peculiarities in crystal structure of titanium alloys pave the way for new applications Metals which can be bent as gum pave the way for new industrial applications for example in the aerospace industry. These so-called gum metals exist but the mechanism EHKLQG WKLV EHKDYLRXU ZDV VWLOO XQVHWWOHG DQG WKXV GLIƂFXOW WR EH XVHG IRU DSSOLFDWLRQV Scientists from Germany have observed a new phase transformation within the crystal structure in a titanium alloy. The advancement in knowledge actually helps to understand the behaviour of the gum metals. Scientists from the Max-PlanckInstitut für Eisenforschung (MPIE) in Düsseldorf, Germany, discovered peculiarities in the crystal structure of titanium alloy. The researchers used X-rays to reveal the inner structure of a special alloy consisting of titanium, niobium, tantalum and zirconium. This titanium alloy displays some unusual mechanical properties under mechanical stress: “On being deformed, it does not become harder or brittle, the way metals usually do, but instead it bends, almost like honey. In scientific terms, it has a very low elastic stiffness and very high ductility,” explains Dierk Raabe, director at the MPIE. This makes the alloy extremely attractive for various industrial applications. In the aerospace industry, for example, it can be used as a kind of crash absorber. “When an aircraft’s turbine is damaged by hail or a bird strike, there is a risk that individual parts may shatter and damage the fuselage too. If parts of the protective casing around a turbine were made of this type of gum metal, they could capture the flying debris because the impact would not destroy but only deform them,” says Raabe. The researchers have revealed peculiarities in its nanostructure using various techniques like X-rays, transmission electron microscopy and atom

Max-Planck-Institut für Eisenforschung, Düsseldorf, Germany Contact: www.mpie.de E-mail: y.ahmedsalem@mpie.de

MPT International 2 / 2017

probe tomography. Titanium alloys nor- down rapidly from a high temperature, mally occur in two different phases. At some of the atoms change position to room temperature, the atoms are usual- adopt the energetically more favouraly found in the so-called alpha phase, ble arrangement of the alpha phase. The at high temperatures they switch to the movements of these atoms lead to mebeta phase. The metals display differ- chanical stress along the phase boundaent properties, depending on which phase they occur in. Gum metals primarily consist of the beta phase, which is stable at room temperature in the case of these alloys. With the help of X-rays at the accelerator centre DESY the Max Planck scientists were able to analyse the crystal structure of the alloy during the tran- Scanning electron microscopy image showing the sition. “When a sam- different phases in the peculiar gum-type titanium alloy ple is treated with (picture by courtesy of Jian Zhang, Max-Planck-Institut für X-rays, the radia- Eisenforschung GmbH) tion is reflected by the crystal lattice of the metal. This pro- ry, almost as if the different phases were duces a distinct pattern of reflections, a tugging on each other. When this stress so-called diffractogram, from which we exceeds a critical value, a new arrangeare able to deduce the relative positions ment is adopted, the so-called omega of the atoms, in other words the crys- phase. “This newly discovered structal structure that they adopt,” explains ture only arises when sheer stress is Ann-Christin Dippel, who was in charge generated at the phase boundary, and of the X-rays experiments at the DESY it facilitates the transformation of the measuring station. alpha into the beta phase. It can only This way the researchers at the MPIE exist between two other phases because have discovered a new mechanism dur- it is stabilized by them,” reports Raabe. ing the phase transformation. The team When the stress drops below the critof Jian Zhang has observed a new struc- ical value because of the new layer, a ture, which forms when the beta phase new alpha phase layer is formed boris transformed into the alpha phase: the dering on an omega phase. This results omega phase. If the beta phase is cooled in a microstructure consisting of lots

MATERIALS of layers, some of them on an atomic scale, each having a different structure. This transition also occurs when static forces are applied and is completely reversible. The scientists are now hoping that the newly discovered structure will help them to better understand the properties of this material and later to develop new, improved varieties of titanium alloys. Jian Zhang and his colleagues present their findings in the journal Nature Communications [1]. The Xi’an Jiaotong University in China and the Massachusetts Institute of Technology in the USA were also involved in the research. The Max-Planck-Institut für Eisenforschung GmbH (MPIE) conducts basic research on metallic alloys and related materials to enable progress in the fields of mobility, energy, infrastructure, medicine and safety. It is financed by the Max-Planck Society and the Steel Institute VDEh. In this way, basic research is amalgamated with innovative developments relevant to applications and process technology.

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Schematic model of the titanium alloy showing the crystal structure of the different phases involved during heat treatment (picture by courtesy of Jian Zhang, MaxPlanck-Institut für Eisenforschung GmbH)

Reference [1] J. Zhang, C.C. Tasan, M.J. Lai, A.-C. Dippel, D. Raabe: Complexion-mediated martensitic phase transformation in Titanium. Nature Communications, 8, 2017; DOI: 10.1038/ncomms14210

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MPT International 2 / 2017

››› TECHNICAL INNOVATIONS

Tin plating process based on methane sulfonic acid SURFACE COATING Tin plating, a critical process for applying tin to steel substrates, faces challenges with the demands for lower consumption, reduced costs, improved product qual-

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In the metallurgical industry we briquette e. g. steel mill residues, sponge iron (hot and cold), chrome ore, nickel powder, copper concentrate, and other ﬁnes. Briquettes are used for feeding shaft furnaces, BOFs, RHFs, EAFs, and other reduction or melting units. Köppern – Quality made in Germany. • State of the art technology • Process technology know-how • High plant availability • Quick roller replacement

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MPT International 2 / 2017

ity, and reduced environmental impact. Quaker Chemical now offers an optimized solution with the Quaker Stantek® MSA (methane sulfonic acid) tinplate process. This technology provides benefits including enhanced product quality, highest possible tin utilization and increased tin efficiency leading to reduced costs versus competitive electrolytes. The process, which features a patented flux system, is REACH and ROHS compliant. Contact: www.quakerchem.com

Distance meter for high-temperature targets MEASURING EQUIPMENT Delta has launched a new digital, high-resolution, compact laser distance meter: Dilas FT1500. With highlights such as a measuring range of up to 500 m, fast sampling time from 10 ms and high accuracy of +/-1 mm, it is suitable for high-temperature targets of up to 1,300°C. Thanks to its optional cooling plate, the new system can resist even the harshest of conditions in steelmaking facilities. It is designed for non-contact dimension measurement and position control of hot or cold products. Like most other sensors developed by Delta, Dilas FT1500 is mounted in a compact aluminium housing (IP66) with air purging to protect the optics. It can be equipped with a strong connector for easy connection. The unit is very user-friendly and easy to handle. A rotary switch is provided to choose between preconfigured modes or

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selected parameters (time, distance far or near). A high-intensity 5-digit display at the rear of the sensor indicates the distance and status of the sensor by dedicated LEDs for product presence and control/alarm. If to be used under extremely difficult conditions involving direct radiation, the sensor can be equipped with an optional heat shield.

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AC electrolytic pickling process SURFACE TREATMENT Marcegaglia recently hosted the annual meeting of the Technical Group Steel No. 5 (Finishing and Coating) of the European Commission held to assess the steel industry projects being financed, mainly by the Research Fund for Coal and Steel. At the meeting, the intermediate results of the ACE-PICK demonstration project, launched to industrialize and validate the world’s first alternating current (AC) electrolytic pickling process/ technology, were presented. The process was initially developed on a laboratory scale by Centro Sviluppo Materiali, which still owns the relevant patent, before being put into industrial operation at the Marcegaglia plant at Gazoldo degli Ippoliti with positive outcomes over a period of more than 15 months. As well as Centro Sviluppo Materiali and Marcegaglia, the active participants in the ACE-PICK project include ArcelorMittal Bremen, Tenova and Scanacon. The AC electrolytic pickling process is a major breakthrough in the treatment lines for flat products, since it can significantly reduce the treatment times normally required with conventional processes, on both hot and cold rolled products, and makes the use of sandblasters and/or scale-breakers no longer necessary. This has obvious benefits for surface quality, especially for products intended for bright annealing. What’s more, for stainless steels, the process has delivered a significant reduction in environmental impact thanks to the lower specific consumption of reagents such as hydrofluoric and nitric acids.

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››› TECHNICAL INNOVATIONS

(QNM NQD ÖMDR QDBNUDQX QDBXBKHMF @MC processing in direct reduction plants RECYCLING Tenova HYL and Diproinduca Canada Ltd. have entered into a commercial alliance agreement for the development and commercialization of the DRB (direct reduced briquettes) technology for recovery and recycling of iron ore fines in direct reduction plants. Iron ore low value by-products in direct reduction plants include the fines from scrubbing systems of material handling, iron ore screening and the sludge mainly produced in the scrubbing systems of the reduction and cooling gas circuits. These fines are currently disposed of at cost or sold as low priced by-products. The DRB technology is based on the production of briquettes made from the recovered iron ore fines from various sources and suitable for production of DRI with the same quality of the

DRI actually being produced in the direct reduction plant. This technology has been developed and tested in the past two years with successful results at industrial scale, for example at Ternium Monterrey, Mexico. Test results have shown an average metallization of 94 – 95% with a carbon content of about 3% and low fines generation. The values are all at the same level as the DRI actually produced from iron ore pellets, reflecting the excellent behavior of the briquettes in terms of porosity and mechanical strength during the reduction process inside the industrial reactor. In Monterrey a demonstration plant has been installed with the purpose of recycling fines from screening and sludge. Contact: www.tenova.com

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MPT International 2 / 2017

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TECHNICAL INNOVATIONS

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Slide discs as strip side guides for coiler HOT ROLLING MILLS Eco Slide Discs strip mill. They will replace the convenfrom Primetals Technologies have tional wear plates. The reference plant at been in successful use at the hot-strip voestapline Stahl has shown that the romill of voestalpine Stahl in Linz, Aus- tatable discs can be used for up to severtria, since August 2014. The Eco Slide al months, whereas the previous equipDiscs are mounted vertically between ment lasted for only a few days. The Eco the table rollers and are automatical- Slide Discs are scheduled to be installed ly and synchronously rotated by a se- at ArcelorMittal Eisenhüttenstadt in July lectable angle after a variable number 2017. of strip sequences have passed. With Entry side of down coiler unit with slide conventional wear plates, the strip al- Contact: www.primetals.com disc beams ways cuts into the plate at the same point, whereas with Eco Slide Discs, the wear is distributed evenly around the entire surface of the circular disc. This lengthens not only the service life of the wear parts but also the period of continuous operation of the entry side guides from the previous several days to several months. The periodic rotation of the discs means that only small amounts of material chafed from the strip edges can adhere to the discs, which are then removed during subsequent strip passage. The self-cleaning effect of the Eco Slide Discs eliminates the need for manual cleaning of the wear plates, which was previously required for certain strip qualities to prevent Stressometer® Systems. Turning steel into gold. strip edge deposits from falling off and damaging the surface of the strip. Results from the voestalpine reference plant have so far shown that it is sufficient to turn over the Eco Slide Discs or replace The golden jubilee offering of Stressometer Flatness Control System brings mill speed them with new wear discs and productivity to a completely new level. Reduction of strip breaks, rejects and pass time, leads to rewards up to hundreds of thousands dollars/euros on the bottom line. during a planned downNo wonder our customers believe we are turning steel into gold. Stressometer Flatness time for repairs after four Systems – unstoppable for five decades. www.abb.com/stressometer to sixteen weeks of maintenance-free operation. Recently, Primetals Technologies has received an order from ArcelorMittal EiABB AB senhüttenstadt, Germany, Measurement & Analytics Force Measurement to install Eco Slide Disc side Phone: +46 21 32 50 00 guides on the entry side beams of a coiler in a hotMPT International 2 / 2017

››› TECHNICAL INNOVATIONS

Metals gauging solutions MEASURING EQUIPMENT Metals gauging systems from NDC Technologies enable manufacturers to significantly improve product quality, increase productivity and realize manufacturing savings. NDC’s new W200 optical width system uses the most advanced technology to measure the width of strip and plate products with the highest accuracy. Its modular, scalable architecture provides the flexibility to install this system in roughing and finishing mills, the coiler on hot strip and Steckel mills, as well as the exit of cold or hot plate mills and levellers.

The AccuRay® TDi-700 X-ray system provides highly accurate and reliable thickness gauging of sheet and other flat rolled products in all typical rolling mill and processing applications. NDC’s Rometer™ optical flatness systems provide configuration flexibility for the most demanding applications such as hot strip mills, Steckel mills and plate mills regardless of mill size, configuration or age. The Beta LaserMike LaserSpeed® gauge directly measures the length and speed of hot or cold products with better than +/-0.03% accuracy and +/-0.02% repeatability. It is an ideal solution for replacing mechanical contact tachometers or encoders.

Optical width measuring system

Contact: www.ndc.com

Laser-optical thickness measurement MEASURING EQUIPMENT For thickness measurement of strip and plate material, Micro-Epsilon has developed a new sensing system – thicknessSENSOR. The pre-assembled system is designed for easy integration without requiring any complex sensor alignment. Due to its compact design, the system is also suitable for implementation in a confined installation space. The material thickness is detected according to the difference principle. Two laser triangulation sensors are fixed opposite to each other on a stable frame.

They measure the material surface in a non-contact method. The evaluation unit integrated into the frame calculates the thickness values and outputs these via different interfaces. The intuitive web interface provides the new thicknessSENSOR with unique ease of use and enables the user to load individual presets for the respective measurement task. Up to eight user-specific sensor settings can be stored and exported in the setup management feature. The measurement task can be optimized using the video signal display,

Non-contact thickness gauge

signal peak selection and freely adjustable signal averaging. Contact: www.micro-epsilon.com

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.

MPT International 2 / 2017

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

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TECHNICAL INNOVATIONS

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"NMUDQSDQ ENQ LDCHTL @MC KNV B@QANM %D,M FERROALLOYS Swedish UHT – Uvån Hagfors Teknologi builds CLU® converter plants for the production of medium and low-carbon FeMn. Super-heated steam which is used as one of the process gases acts as coolant by controlling the temperature in the metal bath through the endothermic reaction that occurs when the steam is split into oxygen and hydrogen after injection. By balancing the temperature, the need for cooling material decreases and the Mn yield is enhanced. In December 2016, UHT commissioned a CLU® converter with the ca-

pacity of 12 t at Hira Power & Steel in Raipur, Chhattisgarh, India. The converter is used for refining high-carbon FeMn to medium and low-carbon FeMn to meet the increasing market demand for a superior product. UHT supplied a complete converter package comprising vessels, trunnion ring, hydraulic converter drive, gas mixing station, level-1 PLC and level-2 real-time UTCAS® process control system as well as process design and engineering of auxiliaries. Contact: www.uht.se

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Mixing technology for preliminary stage in coal dust pelletization RECYCLING Haver Engineering has recently presented new research on coal dust agglomeration carried out jointly with the Institute of Mineral Processing Machines at TU Bergakademie Freiberg, Germany. Pelletization produces granules which are easy to dose, opening up completely new markets for their use. For the production of the pellet feed, Eirich mixing technology was used. The investigations by Haver Engineering have demonstrated that it is technically feasible for fine materials such as dusty hard coal fractions to be transferred in particle sizes which do not generate dust. Improvements in the characteristics of the material resulting from agglomeration in the Haver Scarabaeus disk pelletizer, such as a uniform particle size distribution for the granules, improved flow and spreading properties, prevention of demixing, permeability adapted to requirements and very good dosing accuracy, open up new areas of application. In practically every case such agglomeration processes are preceded by a mixing process. The low inherent moisture in the dust generally means inadequate compactability; for

recycling processes, other materials often have to be mixed in as well, e.g. carbon carriers. This is where the use of Eirich mixing technology has proved highly beneficial. The mixers come in sizes from 1 l to 3,000 l and have just a single rotor tool. The rotor can – depending on the task – run at speeds of more than 30 m/s. This makes it possible to generate high shear forces and distribute liquids, binders and additives quickly. For build-up agglomeration on disk pelletizers or in drum pelletizers, the Eirich mixer not only delivers savings in terms of binder quantities but also achieves uniform strength values for the resultant pellets. A typical example is the mixing/coating of finely dis-persed iron ore concentrate with bentonite. In this case mixers are run with fill quantities of 12 m³ in a continuous process with a throughput rate of up to 1,200 t/h for months without interruption. In sizes of up to 15 mm the pellets have uniform strength, which is what is required for use in blast furnaces or direct reduction processes. Contact: www.eirich.com

Polytec manufactures customized robotic cells integrated with advanced machine vision systems for meltshop, rolling mills, mini mills and tube mills. @

PolySAMPLE

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Multi tool robotic solution for continuous casting (temperature, shroud insertion, oxygen opening)

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2 7 3 7

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MPT International 2 / 2017

››› TECHNICAL INNOVATIONS

Interface for acquiring data from IR line scanners TEMPERATURE MEASUREMENT Infrared non-contact temperature measurement specialist Ametek Land confirms the development of an interface between ibaPDA systems and Landscan LSP-HD infrared line scanners to acquire temperature measurement data from steel strips in rolling mills. Developed by software company iba, ibaPDA is a powerful, PC-based acquisition and recording system for maintenance, process analysis and quality control. The ibaPDA-Interface-Landscan is a highly effective method of acquiring data from Ametek Land LSP-HD infrared line scanners. The interface benefits customers using the ibaPDA system, allowing them to measure temperature profiles and distribution for the steel application specific LSP-HD 10/11 and LSP-HD 20/21 line scanners. Highly visual data is displayed live in the ibaPDA system, and users can view trended temperature measurements, product ID, scanning speed, environmental temper-

ature and position of the strip. This recorded measurement data also can be visualized in detail and analyzed with ibaAnalyzer, which is supplied free of charge with the interface. The ibaAnalyzer offers a 2D colour display that shows at a glance the temperature distribution of the whole strip, graded in colours. The temperature profiles provide accurate information about the temporal and local temperature distribution on the steel strips, allowing users to closely monitor product and process quality. Trended data and other analog and digital measurement values and all signals recorded during the process can be displayed and related to the temperature distributions. When used for hot-rolled strips in rolling mills, the infrared scanner measures the temperature over the whole width of the strip in high resolution and provides 1,000 temperature samples per line with a sampling rate of up to 150 Hz. When used in the binary

Infrared line scanner

mode it is possible to reduce the number of samples, depending on application, from 1,000 per line to 500, 250 or 100, to minimize the amount of data. Scanning data from Land scanners can now be acquired continuously in real time synchronously with other process and machine data. ibaPDA stores all data in measurement files, which are the basis for offline rootcause analysis using the powerful ibaAnalyzer. Contact: www.landinst.com

VTLG

Measuring the strip thickness in cold by VOLLMER rolling mills

LASER-OPTICAL: non-contact and irrespective of the alloy PRECISE: +/- 1 μm accuracy per mm of strip thickness COMPACT: installation near the roll gap www.vollmergmbh.de

MPT International 2 / 2017

TECHNICAL INNOVATIONS

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“I am experiencing bearing failures in my mill. How can advanced lubricants help to reduce the frequency of this problem?” We had a customer, one of the world’s largest integrated steel mills, with a similar problem. The customer previously used an oil in the circulation system of the hot rolling mill that had resulted in frequent damage to plain bearings. The wear in bearings, emulsion problem and deposit formation increased bearing temperature, leading to a reduction of the rolling speed. ExxonMobil recommended Mobil VacuolineTM 525 circulation oil, with excellent water separation performance and anti-wear properties. The Mobil VacuolineTM 500 series of lubricants are high performance heavy duty circulating oils designed for steel mills.

50% and lubricant related bearing failures were eliminated. The customer no longer experienced any emulsion problems or deposit formation in oil and corrosion equipment. This reduced maintenance had the added benefit of reducing employee interaction with equipment, therefore lessening the risks associated with heavy machinery. It also reduced annual oil consumption, lowering maintenance and oil disposal costs.

Response from Jarmo Vihersalo, ExxonMobil Industrial

During three years’ successful service, Mobil VacuolineTM 525 helped the customer decrease oil consumption by

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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Cartoon

The climate is changing indeed. All kinds of thunderstorms are moving around the world. And they don´t leave the steel industry out. MPT International 2 / 2017

››› LITERATURE SERVICE Free and fair trade 16 pages, English

Free and fair trade Positions of the steel industry in Germany on foreign trade

In this publication the German Steel Federation formulates the positions of the steel industry in Germany on foreign trade. Topics covered include: structural changes in the global steel industry, shifts in global trade flows, unfair imports endangering the European steel industry, trade defences, and the steel industry in Germany as backbone of the economy. Contact: E-mail:

www.stahl-online.de info@wvstahl.de

Handling technology for heat treatment 8 pages, English A brochure outlining the range of machines, equipment and services offered by Dango & Dienenthal for handling and transport operations in heat treatment and forging plants. Examples and references are provided of applications in new production lines and for integration into existing plants. Contact: E-mail:

www.dango-dienenthal.de jhb@ddh-hamm.de

Laser distance measurement 4 pages, English A product brochure featuring the Dilas FT1500 non-contact laser measurement sensor supplied by Delta. The laser is designed for hot or cold, stationary or moving non-shiny surfaces. The brochure includes detailed descriptions of the equipment’s technical characteristics. Contact: E-mail:

www.deltasensor.eu info@deltasensor.eu

Heat protection and insulation 16 pages, English A catalogue of insulation products offered by Jutec. Products featured include certified woven fabrics, jacketing, moulded parts, pipe sheaths, exhaust systems, non-wovens and insulating boards, belts, cords, fastening technology as well as full device protection. Contact: E-mail:

www.jutec.com info@jutec.com

Material selection guide 24 pages, English, German This guide, published by Steeltec, identifies five steps that manufacturers of advanced steel components can take to identify the right steel for their purposes. Among others, the guide provides checklists that enable users to translate their processing and product requirements into material properties. Contact: E-mail:

MPT International 2 / 2017

www.steeltec-group.com presse@steeltec-group.com

IN THE NEXT ISSUE…

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Continuous casting ArcelorMittal Industeel, Belgium, produces thickest austenitic stainless steel slabs ever cast in the world ArcelorMittal Industeel is a first-class producer of special steels. In order to meet the demand for thick plates the company decided in favour of a major revamping of its single-strand slab caster. A critical point was the short shutdown period of four weeks, during which the entire dismounting, erection and commissioning activities were to take place. Thanks to the successful cooperation between the plant supplier and the ArcelorMittal project team, this challenging task was completed within the specified timeframe.

Strip processing Rizhao Steel operates one of the most productive continuous pickling lines Chinese steel producer Rizhao Steel Group Co., Ltd (Rizhao) operates a new continuous pickling line supplied by Primetals Technologies. The pickling line is designed to process around 2 million t/year of hot strip. With a process speed of 400 m/ min, it is one of the fastest plants of its type. The pickling line is part of a new cold rolling complex in the city of Rizhao in Shandong province. It processes not only ductile and forming steels, but also two-phase steels and high-strength lowalloyed (HSLA) steel grades.

Special equipment Water treatment plant at Big River Steel, Arkansas/USA A water treatment plant has been designed, supplied and installed for the world’s first Flex Mill, which integrates a meltshop, hot strip mill and cold strip complex. The water system treats and supplies the water for all those systems. It includes a make-up water system, which treats the water originating from several deep wells, a purging system and the waste treatment system for the rolling emulsions. The overall system has been designed to reduce fresh water requirements to contain operational costs and maintenance requirements. This preview may be subject to change.

Metallurgical Plant and Technology

Advertising Manager: Sigrid Klinge

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

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

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

+49 211 6707-568 Assistant Editor: Edith Mielke

+49 211 6707-572 e-mail mpt@stahleisen.de Publishing Staff: Managing Director: Frank Toscha

Production/Layout: Mike Reschke e-mail mike.reschke@stahleisen.de Advertising rate card No. 40 of 01.01.2017 Publication: Every 2 months Annual subscription rate (incl. postage): Germany: € 209.00 incl. 7% VAT Member states of the EU: subscribers with VAT ID number € 195.33; subscribers without VAT ID number € 209.00 Other countries: € 209.00 Single copy: € 42.00 Minimum subscription period 12 months. Termination of subscriptions can only be made from 31st December and notice of termination must be received by the Publishers by 15th November. Otherwise, the subscription is automatically renewed and payable for a further 12 months.

© 2017 Verlag Stahleisen GmbH, Düsseldorf This journal and all articles and illustrations contained in it are protected by copyright. With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems. Upon acceptance for publication, the author agrees to grant, transfer and assign to the publisher all exclusive rights to publish the work during the lifetime of the copyright. In particular, the publisher will have full authority and power to reproduce the work for commercial purposes in copies of any form (microfilm, photocopy, CD-ROM, or other means) and/or to store the work in electronic or other databases. Certification of circulation by the German Audit Bureau of Circulation (IVW) Permit number: 011-224, ISSN 0935-7254 Printed by: Kraft Premium GmbH Industriestr. 5–9, 76275 Ettlingen, Germany Printed on paper bleached totally chlorine-free (TCF) using heavy metal-free printing ink.

MPT International 2 / 2017

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

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