MPT International 3/2017 (Jun)

Metallurgical Plant and Technology G 25074

3

ISSN 0935-7254

Continuous casting of 355-mmthick austenitic steel slabs

June 2016 2017

Towards the Internet of materials: SSAB SmartSteel R&D project

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EDITORIAL

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Innovations in metallurgical technologies and materials Recently, many steel companies in the developed economies have been modernizing their plants aiming not only to increase productivity but also to meet the rising demands of steel consumers in terms of quality and flexibility. For example, ArcelorMittal Industeel – producer of special steels in Belgium – decided in favour of a major revamping of its singlestrand slab caster in order to meet the demand for thick slabs of austenitic grades. The new continuous slab caster has been designed with a larger mould and a greater metallurgical length, with modified straightening segments and for proper application of dynamic soft reduction. The company is now able to produce the thickest austenitic stainless steel slabs ever cast in the world.

In this issue, we are again introducing a new plant built by Chinese steel producer Rizhao Steel Group. As part of its new cold rolling complex in the city of Rizhao, Shandong province, the company now operates one of the most productive continuous pickling lines.

Designed to process around 2 million t/year of hot strip at a process speed of up to 400 m/ min, this new line is one of the fastest plants of its type in the world.

In research and development, the Internet of Things (IoT) has become a central topic in recent years. In terms of materials, engineers are thrilled about the new opportunities provided by 3D printing. This new era also provides great potential for traditional steel products. What if the steel in a car or a house was loaded with intelligent information?

Swedish steel company SSAB has recently completed the R&D project “SmartSteel” to explore the concept of a digital platform that enables steel products to be loaded with knowledge. The idea behind this innovation is to make information available relative to a steel item wherever it may be processed.

MPT International regularly covers innovations in metallurgical technologies and materials. But this time we have made them a special focus of this issue.

MPT International 3 / 2017

680

PROCESS CONTROL SYSTEMS

Danieli Automation automates plants through integrated systems for equipment, process and power control, handling jobs from order placement through product delivery.

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SCRAP SHEARS AND SHREDDERS

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BLAST FURNACE AND CONVERTER PROJECTS

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ENVIRONMENTAL PLANTS

ELECTRIC ARC FURNACES

SECONDARY METALLURGY STATIONS

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CASTING STRANDS FOR SLABS, BLOOMS, AND BILLETS

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Our original technology, process know-how, in-house design and manufacturing along with proprietary automation systems, environmental solutions and customer service for a competitive and sustainable steel and nonferrous metals industry.

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HOT STRIP, PLATE AND COLD MILLS

STRIP PROCESSING AND FINISHING LINES

HEAVY SECTION, RAIL, BAR AND WIREROD MILLS

DRAWING AND PEELING MACHINES

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SEAMLESS TUBE AND WELDED PIPE PLANTS

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EXTRUSION AND FORGING PRESSES

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ALUMINIUM HOT AND COLD MILLS

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››› CONTENTS

International industry news 24

World Steel Association short range outlook 2017 – 2018 Worldsteel forecasts that global steel demand will increase by 1.3% to 1,535 million t in 2017 following a growth of 1.0% in 2015

Research & Development 26

New European research initiatives for CO2neutral steel production Coverphoto: Overview of the Arvedi ESP line No. 1 – endless production from casting to coils – at Rizhao Steel Holding Group Co., Ltd. (Rizhao Steel) in China Primetals Technologies, Ltd., London, UK Contact: www.primetals.com E-Mail: rainer.schulze@primetals.com

European steel companies have started three new research initiatives to develop solutions to prevent CO2 from steelmaking processes being discharged to the atmosphere. Project partners from the energy sector and others joined these initiatives

Continuous casting 32

Continuous casting machine for the production of 355-mm-thick austenitic stainless steel slabs

36

In order to meet the demand for thick plates, ArcelorMittal Industeel, Belgium, decided in favour of a major revamping of its single-strand slab caster. The company is now able to produce the thickest austenitic stainless steel slab ever cast in the world

Cost, quality and environmental performance improvements due to modular roll line units China Baowu Steel Group Corporation, formerly known as Baosteel, is driving up the performance and reliability of its continuous casting machines using SKF ConRo roll line units

Hot rolling

Special equipment

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New electric steel plant and merchant bar mill at BMM Ispat Ltd. in India The new production facilities are designed for a production of 850,000 metric tons of merchant bar per year and expand BMM Ispat’s capacities for structural steels

Compact infrared thermometer with the new IO-Link communication interface IO-Link is a systems-independent and non-proprietary interface and can therefore be used in all classic field bus systems for process automation purposes

Material flow logistics

Automation

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Modernization of coil transport systems in hot strip mills ensures high plant availability and improved product quality From 2012 to 2014, thyssenkrupp Steel Europe implemented an extensive growth-orientated modernization of its hot strip mills. A major part of this project was the upgrade of the coil transport systems

Strip processing 44

Rizhao Steel operates one of the most productive continuous pickling lines The Chinese steel producer operates a new plant 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

MPT International 3 / 2017

Towards the Internet of materials: SSAB SmartSteel forms a basis for the circular economy SSAB has recently completed an R&D project to explore the concept of a digital platform that enables steel products to be loaded with knowledge. A unique identity code in the steel plate provides customers and their machinery with appropriate data and instructions

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36 Columns 8

International industry news

58

Literature service

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Technical innovations

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In the next issue

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Cartoon

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Imprint

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MPT International 3 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

Africa Egypt Egyptian Steel places mill services contract. Harsco Corporation has signed a new, ten-year mill services contract with Egyptian Steel, manufacturer of rebar, wire rods and billets.

The contract calls for the provision of mill services at Egyptian Steel’s Ain Sokhna plant, a new steelmaking facility now under construction. Under the terms of the agreement, Harsco will provide slag and scrap management and material handling services, with future plans to design and operate onsite metal recovery and briquetting plants. Harsco’s services are scheduled to begin in January 2018.

The Americas Brazil ArcelorMittal to build new drag chain conveyor. ArcelorMittal has ordered a drag chain conveyor from Aumund for its João Monlevade plant.

The existing shock-pressure-proof drag chain had been built about 20 years ago

by Louise Fördertechnik, which later on was acquired by Aumund Fördertechnik. Aumund will now also supply a type Louise TKF drag chain conveyor.

However, the new model will no longer require the shock-pressure-proof design of its predecessor because of the change in classification of the plant segment.

The new double-strand drag chain conveyor with a capacity of 3 kW, a centre distance of 10.4 m and a performance of 25 t/h, will be used for bunker extraction. Shipment of the machine is planned for June 2017.

Brazil Silat starts up new rebar and wire rod mill. Silat has commissioned the new rebar and wire rod mill supplied by Russula. Wire rod produced on the first day of operations was flawless and commercially saleable.

MPT International 3 / 2017

The single-strand wire rod mill produces 5.5 to 16 mm wire rod and rebar in coils. Fed from the bar mill finishing stands, the rod outlet includes among others a ten-pass, high-speed twist free finishing block, controlled cooling line, coil forming station, pallet conveyor, hook conveyor and a coil compacting and tying machine.

In the wire rod outlet, the laying head allows for more consistent coil formation and rolling stability. With this innovative technology Silat will be able to roll at 110 m/s sustained speeds. Russula’s compacting and handling system is completely automatic.

USA Outokumpu enhances stainless bar production. Outokumpu is going to enhance the stainless bar production in its facilities in Richburg, South Carolina. New capabilities will include a new coil-to-bar line to cover bar sizes from 15.2 to 31.75 mm and full reinforcement bar capabilities. Capacity will be expanded in the area of coil-to-bar peeling where capacity has been constrained. The line will use hot-rolled coil bar feedstock which is straightened, peeled, chamfered and polished to finished bars. The investment will increase Outokumpu’s stainless bar production capacity by more than 15,000 t/year.

USA Charter Steel to build new SBQ mill. Charter Steel is going to build a new special bar quality (SBQ) bar mill adjacent to its existing coil mill and steelmaking operations in Cuyahoga Heights, Ohio. The highly automated rolling mill will utilize precision sizing to produce diameters from 19 to 83 mm in bar lengths from 3.7 to 15.3 m. The highly automated rolling mill will feature Kocks precision sizing technology that includes the Kocks 4D Eagle profile gauges that provide feedback to the Kocks SCS® (size control system) to allow for real-time optimization of rolling conditions and best product tolerances. The project will not interrupt existing steel coil operations. Charter

Steel expects to commission the new mill in the second half of 2018.

USA Nucor Steel orders production lines for new cold rolling complex. Andritz Metals has received an order from Nucor to supply turn-key production lines for the new specialty cold rolling mill complex at the company’s sheet steel mill in Hickman, Arkansas. Start-up of the plant is scheduled for the second half of 2018. The 590,000 t/year expansion project will increase Nucor Steel Hickman’s production of specialty grades, including third-generation, advanced high-strength steels, high-strength low-alloy steels, and high-efficiency electrical steels. The Andritz Metals’ scope of supply includes a high-performance push pickling line with line speeds of up to 200 m/min for pickling hot-rolled carbon steel. Besides complete in-house electrics and automation, an advanced multi-roll leveller and a powerful 4-high skin pass mill are included. The order also comprises a reduction cold rolling mill equipped with the Andritz S6-high technology as well as a temper rolling mill in 4-high design.

USA Gerdau Cartersville to modify continuous caster. Primetals Technologies has received an order from Gerdau to modify the continuous caster at its location in Cartersville, Georgia. The project will give the capability to produce an additional beam blank format. This will allow Gerdau to roll larger finished products for applications in the building and construction industries. Commissioning of the modified plant is scheduled for the end of 2017.

The four-strand continuous caster was installed by Primetals Technologies in 1998/99 and is designed for annual production of 692,000 t. Up to now it has been possible to produce two billet formats, two bloom formats and one beam blank format. The upcoming modification of the caster by Primetals Technologies will enable casting of an additional beam blank format with larger dimensions.

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››› INTERNATIONAL INDUSTRY NEWS

Asia China Baosteel Zhanjiang to expand hot strip mill. Chinese Baosteel Zhanjiang Iron & Steel Co., Ltd. has contracted SMS group to supply a new coiler for its Zhanjiang hot strip mill. The machine will be specifically designed to coil high-strength grades and thick strips. The SMS-supplied 2,250-mmwide hot strip mill has been in operation since the end of 2015. It has a designed capacity to produce 5.5 million t/year of hot strip with final thicknesses between 1.2 and 25.4 mm and widths from 800 to 2,100 mm. The new coiler will be positioned downstream two existing coilers installed as part of the first construction phase. The new coiler will be used for strips of greater final thicknesses and higher strengths, such as tube and pipe steels of strength classes X100 and X120 or ultra-high-strength

strips of 1,200 N/mm². To be able to coil such product, it will be equipped with reinforced mechanical components such as a pinch roll unit and hold-down rolls with aprons for safe and reliable wrapping of the strip head around the coiler mandrel. The first coil is scheduled to be produced at the end of 2017.

China Shandong Rizhao orders Steckel/ plate mill. Shandong Iron & Steel Group Rizhao has placed an order with SMS group for the supply of a Steckel/plate mill. The mill will be designed for an annual output of 1.3 million t of heavy plate. It will be able to produce plate between 4 and 50 mm thick and from 1,650 to 3,250 mm wide. The slabs used as feedstock for the rolling mill will be produced by a new continuous caster also to be supplied by SMS group. Thanks to the high slab weight of 57 tons, the envisaged

output of 1.3 million t/year can be achieved with only one mill stand. The slab width of 3,250 mm corresponds to the maximum plate width. Therefore, no broadsiding passes are needed.

The rolling line will comprise a Steckel mill stand with a connected edger at the entry side. The mill will allow Shandong Rizhao to roll strips up to a length of 600 m, which will be divided to mother plate lengths of maximum 50 m by a “flying” cross-cut shear. SMS group will also supply X-Pact® electrical and automation systems for the entire plant. The new plant is scheduled to go on stream in 2019.

China Hebei Jingye to install high-capacity EWR/K welding unit. Danieli is going to supply a new EWR system for the No. 5 rolling mill of Hebei Jingye in Pingshan. The new line will be designed to weld 12-m-long, 165-

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INTERNATIONAL INDUSTRY NEWS mm square billets at 220 t/h for a continuous production of 10 to 40 mm rebars. The new welder will include the new Danieli spark killer system. Being self-cleaning and easy to maintain, the new unit will be able to collect more than 70% of spatter material generated during the flashing/welding cycle. The level-2 automation system provided by Danieli Automation will ensure optimal control of all welding parameters.

Once combined with Danieli’s K-Spool system, the EWR-K welder will allow the production hot rolled coils of up to 5 t. Regular production is scheduled to start in late summer 2017.

China Zhejiang Wanliyang orders automatic closed-die forging press.

Zhejiang Wanliyang Transmission from Hangzhou, Zhejiang province, has ordered a fully automatic closeddie forging press from SMS group. The

W E

forging press, type MP 2500, will have a press force of 25 MN and the capacity to forge up to five million parts per year.

The new press, which will be mainly used to produce gear wheels in up to four forming steps, is scheduled to start operation in June 2018. The press will feature programmable ejectors, an electrically actuated automatic walking beam system, a mechanically coupled and retractable die spraying system.

Philippines SteelAsia to build new reheating furnace. Rebar producers SteelAsia has ordered a second reheating furnace from Fives. The Stein reheating walking beam furnace with a capacity of 100 t/h will be installed at SteelAsia’s Batangas site. The contract covers the design, manufacture, supply and on-site supervision of the furnace installation. The furnace will use proportional combustion technology

C O N V E Y

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to reheat steel products. It is scheduled to be put into operation in March 2018.

United Arab Emirates Union Iron & Steel to install billet welding system. Union Iron & Steel has placed an order with Primetals Technologies to supply ERT-EBROS endless rolling technology for the company’s existing bar rolling mill in Mussafah industrial area, Abu Dhabi.

Primetals Technologies will be supplying the billet welding system, including a deburring station, extraction system and complementary equipment such as pinch roll and roller table. The ERT-EBROS system will be designed for an annual production capacity of 420,000 t and will accommodate billets with a square cross-section of both 130 mm x 130 mm and 150 mm x 150 mm.

The scope of supply also includes the fluid systems, the electrical equipment and automation system and technolo-

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››› INTERNATIONAL INDUSTRY NEWS

News in brief Companhia Siderúrgica de Pecèm (CSP), Brazil, has successfully completed all final acceptance tests with regard to batteries Nos. 1 and 2 at its Cearà works. Paul Wurth, contracted by Posco Engineering & Construction, provided the engineering, supplied key components and supervised the erection and commissioning of two identical batteries with 50 coke ovens each.

Hyundai Steel, South Korea, has issued the FAC for a continuous bloom casting machine supplied

by Primetals Technologies to the Dangjin production facility. The caster is designed to produce 1.1 million t/year of blooms. It is part of a new plant set up for the production of special steels for the automotive industry, for which Primetals Technologies also supplied a bar mill and a wire rod mill.

AK Steel, USA, has opened its new Research and Innovation Center in Middletown, Ohio. The new facilities further expand AK Steel’s steel development capabilities with regard to advanced high-strength carbon and specialty steels, electrical steels and new stainless steels.

Posco, South Korea, has brought LD (BOF) converter No. 1 back into operation after modernization in steel works No. 1 at its Gwangyang site. In the course of the project, Primetals Technologies had equipped the converter with a new tilting drive. The modernization took place while the other two converters in steel works No. 1 remained in operation and was completed five days before the scheduled deadline.

Nucor, USA, is going to upgrade the rolling mill at its steel bar mill in Marion, Ohio. As part of the project, SMS group will supply a new walking beam reheating furnace.

MPT International 3 / 2017

gy packages for control of welding. The new ERT-EBROS plant is scheduled to commence operation in the late 2017.

Vietnam MY VIET Industries orders reversing cold mill. MY VIET Industries has ordered a twin-stand reversing cold mill CCM® (compact cold mill) and a push-pull pickling line from SMS group’s Indian subsidiary Esmech Equipment. The new plants, installed at the Pho Noi A Industrial Park location in the Hung Yen province in the south of Hanoi, are scheduled to be put into operation by autumn 2017. The CCM® in six-high design will be designed for an annual production capacity of 400,000 t. It will roll low-carbon steel strip in widths of up to 1,250 mm and minimum final gauges down to 0.15 mm.

Maximum rolling speed will be of 1,400 m/min. The mill will come with hightech components, such as the bending block cassettes and the CVC®plus shifting mechanism. Thanks to the directly driven work rolls of a minimum diameter of 300 mm, it will be possible to roll high reductions per pass. The scope of supply of SMS group also includes the fluid and media plants, such as high and low-pressure hydraulics, and the emulsion plant.

Europe Belarus MMPZ orders production complex for tinplate. SMS group is going to supply a plant complex for the production of tinplate to Miorskij Metalloprokatnyi Zavod (MMPZ group) located in Miory. The new works will initially have an annual capacity of 150,000 t.

Provisions will be made to increase the capacity to up to 240,000 t at a later stage. SMS group will supply a reversing cold mill, an electrolytic cleaning line, a batch-annealing plant, a combined double-reducing and skinpass mill, an electrolytic tinning line and two packaging lines – one for sheet packs and one for coiled product. The rolling and strip treatment plants will

be equipped with X-Pact® automation systems. MMPZ group plans to use the new facilities mainly for the production of tinplate for the packaging industry and of cold-rolled sheet. In order to be able to flexibly respond to future market demands, the plants will also be designed to produce non-coated sheet in commercial (CQ) and drawing quality (DQ) grades. The first plant units are scheduled to start producing in the second half of 2018.

Bosnia and Herzegovina ArcelorMittal Zenica inaugurates major investment projects.

ArcelorMittal Zenica has officially inaugurated three new investment projects. The first one is the industrial-scale hybrid filtration system installed in its sinter plant, cutting dust emissions to well below the EU limit of 20 mg/Nm3.

The company plans to install a second filter, so that the dust emissions from both stacks of the sinter plant can be filtered. The filter technology is the culmination of a collaboration between the Danish engineering company FLSmidth and ArcelorMittal’s R&D team.

New technology has also been introduced to achieve major reductions in smoke and gas emissions from ArcelorMittal Zenica’s coke battery. The smokeless charging car cuts charging times, delivering an almost smoke-free charging process and prevents CO2 emissions being released into the atmosphere. The technology was provided by the UK engineering firm John M. Henderson Machines.

The third investment has been made to make ArcelorMittal Zenica the first plant in ArcelorMittal Europe to produce rebar in coil. The corresponding equipment was provided by SMS Meer. The project will raise annual production from 300,000 to 320,000 t, while achieving improvements in the product quality.

Bosnia and Herzegovina ArcelorMittal Zenica to reline blast furnace. Danieli Corus and ArcelorMittal have signed a contract for the reline of the blast furnace No. 4 operated by ArcelorMittal in Zenica.

After the reline, the furnace will have

INTERNATIONAL INDUSTRY NEWS a working volume of 2,003 m³, a major increase compared to the current volume of 1,765 m³. The hearth refractory and part of the hearth shell will be replaced based on a new design by Danieli Corus. Outside the furnace, portions of the refractories in the hot blast main, bustle pipe and trough, and runner system will be replaced. Danieli will also install a thermocouple system for thermal monitoring of the furnace lining.

The furnace reline is scheduled for the first quarter of 2018. Danieli Corus will provide operational assistance services during blow-down, salamander tapping and blow-in.

France ArcelorMittal to revamp plate mill. Industeel France, part of ArcelorMittal, is going to revamp its plate mill in Le Creusot, which specializes in flat rolled and forged products for the aerospace, defense and nuclear industries. The order for the revamp has been placed with Danieli. Quality improvements in the rolled product will be achieved by revamping both the primary and secondary descalers and by applying the DanHYD technological package. Danieli will install a new pumping room, new hydraulic valves, redesigned ramps and nozzles, and a new electro-mechanical lifting system for the top header as well as a dedicated automation system. The new equip-

ment will achieve increased descaling pressure by a higher impact force, a greater spray width, more flexible valve control and highly efficient power management of the pumps.

France Schmolz + Bickenbach to increase potential for aerospace products.

Ugitech, a Schmolz + Bickenbach group company located in Ugine Cedex, will invest around 17 million euros in a new annealing furnace and associated heat treatment and logistics facilities to become a NADCAP certified steel producer by 2019. After Deutsche Edelstahlwerke Siegen and Witten steel works, Ugitech will be the third Schmolz + Bickenbach production site with NADCAP approved heat treatment facilities. The Schmolz + Bickenbach group continues to invest in technologies and processes to meet the rising demand for materials for aerospace applications and to expand their leading position in this market.

Germany ArcelorMittal Duisburg to install new steel plant control system. PSI has been commissioned by ArcelorMittal Duisburg to implement PSImetals as the production management system at their basic oxygen steel-

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making plant. PSImetals will replace a 35-year-old system, thus further enhancing production process reliability.

The goal is to achieve a seamless integration of the new system into the existing, highly heterogeneous IT environment with its numerous interfaces. The modern, user-friendly HMI for visualizing and controlling the production process, will enable the steelmaker to make modifications to the models, alloy calculations, and algorithms by themselves in the future. The metallurgical models in use today will be implemented in the new system.

Germany VDM Metals to build new bright annealing line. VDM Metals is planning to expand strip production at the Werdohl site by building a new bright annealing line. This project will require extensive construction measures such as a new hall building and a furnace tower. The currently used annealing unit was built in 1977. Construction of the new bright annealing line will enable the company to boost its production capacity by 30%, while extending its range of products. It will become possible to produce strips with widths between 350 and 830 mm and thicknesses between 0.40 and 4 mm.

Also the coil weight will be increased.

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››› INTERNATIONAL INDUSTRY NEWS

of 2017. Completion and commissioning of the entire plant are earmarked for the beginning of 2019.

quent size changes. A new 80 t/h reheating furnace will bring the round blooms of 200, 220 or 240 mm to rolling temperature.

tural products for bridge construction, off-shore projects and shipbuilding.

Russia Italy Italy

www.vip-kommunikation.de

Acciaierie Venete to install new SBQ mill. Acciaierie Venete has again chosen Danieli technology for its new mill located in Padua. With the new Danieli drawing/rolling block, the mill will produce SBQ round bars from 18 to 82.5 mm square, and in the future flats and hexagons from 30 to 60 mm to high dimensional tolerances of 1/8 DIN. Featuring four-roll technology, the drawing/rolling block, also called “The Drawer”, will provide great production flexibility thanks to free-size rolling up to 4 mm and quick production changeover in less than 4 minutes. The Danieli Automation 4.0 system will provide Acciaierie Venete the complete production control systems from the liquid steel up to the finished product, facilitating the production of small steel lots and fre-

Cimolai to install automatic measuring system. At the Cimolai works in Padua, Danieli W+K will install an automatic measuring system for large-diameter pipes. The system is going to replace current manual procedures and improve the precision and reliability for longitudinally submerged-arc welded products with outside diameters of up to 2 m and lengths reaching 15 m. The new system will control the straightness and outside diameter of extra-large pipes in a fully automatic mode using a precise, efficient and user-friendly interface. The internal automatic calibration system substantially eliminates the requirement to feed sample pipes. Cimolai is a steel fabricator, highly specialized in struc-

JSC Ural Steel to revamp vacuum degasser. JSC Ural Steel, part of the Metalloinvest group, has awarded Danieli Centro Met the order to revamp the existing vacuum degasser operating in Novotroitsk. The revamp will enable JSC Ural Steel to increase the productivity of its existing twin-tank, twin-cover vacuum degasser from 1.1 to 1.8 million t/ year of special steels, including rail and wheel grades. The scope of supply includes a new, full steam ejector vacuum pump which will be installed parallel to the existing one, allowing both VD tanks to operate independently and simultaneously. A new hydraulic suction line switch will make it possible to operate both vacuum degassing tanks using either the existing or the new vacuum pump. The start-up for the revamped unit is scheduled for the end of 2017.

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MPT International 3 / 2017

INTERNATIONAL INDUSTRY NEWS

Russia

Russia

MMK to modernize continuous caster and heavy-plate mill.

Magnitogorsk Iron and Steel Works (MMK) has awarded SMS group the order to modernize its No. 6 continuous slab caster and the heavy-plate mill, and upgrade both plants’ X-Pact® electrical and automation systems.

The caster, which currently produces slabs of thicknesses 190, 250 and 300 mm, will in future be able to also produce slabs with a thickness of 350 mm.

The maximum cast width will remain unchanged at 2,700 mm. The future higher weight per metre of the slabs will optimize the plate yield from each slab. The SMS group’s scope of supply for the continuous caster includes the basic and detail engineering, the optimization of the secondary cooling system, the adaption of the X-Pact® electrical and automation systems, the upgrade of the technological process models (level 2) and supervision of installation and commissioning. The project is scheduled to be completed by the end of 2017.

MMK completes reconstruction of sulphure capture systems. Magnitogorsk Iron and Steel Works (MMK) has completed reconstruction of sulphur capture systems designed for removing sulphur compounds and fine dust from sinter gases at the second sinter plant.

The reconstruction included construction of a complex of dust and gas capturing units, which processes the full volume of sinter gases removing sulphur compounds and fine dust. The complex includes three cleaning systems. The sulphur capture system at the second sinter plant has a degree of purification of up to 95% for sulphur dioxide.

MMK plans to complete approximately 87 environmental initiatives under its Environmental Programme in 2017. The investments include construction of a new sinter plant and continuous hot-dip galvanizing lines at its metal-coating shop No.3 at rolling mill No.11, as well as

‹‹‹

15

construction of new stationary wagon damper at the sinter burden shop.

Russia NLMK orders walking beam furnace. Tenova has recently been contracted by NLMK for the supply of a 320 t/h walking beam furnace for the hot flat shop at their plant in Lipetsk. The furnace supplied by Tenova will feature ultra-low NOx Flexytech® technology. Start-up of the furnace is scheduled for September 2019.

Sweden SSAB to install new compressor technology for cold blast supply. SSAB has placed an order with MAN Diesel & Turbo for its latest MAX1 axial compressor technology. The new axial compressor will

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16

››› INTERNATIONAL INDUSTRY NEWS be installed at the Luleå site to improve the cold blast supply, while significantly reducing power consumption and operating costs. The compressor will operate at ambient temperatures ranging from -40° to +30°C, with blast furnace compression asking for quick reaction times to serve alternating demands of the steel production process. Commissioning is scheduled to take place in the second quarter of the year 2018.

With this project for SSAB, the MAX1 technology developed by MAN Diesel & Turbo is for the first time coming into operation beyond the air separation industry.

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Sidenor to modernize bar mill. Sidenor Aceros Especiales has placed an order with SMS group for the modernization of its bar mill in Basauri. The SMS group scope of supply includes all the mechanical, thermal and electrical components, the automation system and complete erection and commissioning, which is scheduled for September 2017. The existing reversing three-high stand in today’s semi-continuous mill will be replaced by a six-stand continuous roughing mill with compact stands (CS) in V-H arrangement. The project also includes the supply of a new walking-beam furnace of modular design, allowing for a future increase in capacity. The furnace will also be equipped with the SMS Prometheus level-2 automation system. Through the use of SMS ZeroFlame flameless burners, pollutant emissions into the atmosphere will be minimized.

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Swiss Steel to upgrade facilities. Schmolz + Bickenbach has announced a major investment in its subsidiary, Swiss Steel. A new walking beam furnace and two new Garrett coilers will be installed at the Emmenbrücke site.

The production potential for special steels will increase by around 8%. The new walking beam furnace will provide optimal and more efficient heating, preparing the billet for being further processed in the downstream rolling mill. The new Garrett coilers used to wind the rolled products after they have been processed in the rolling mill will allow an increase in ring weight from currently 1.8 t to over 2.2 t. The Garrett coilers are expected to be commissioned in 2018, followed one year later by the commissioning of the walking beam furnace. Full operation is expected to be reached by the end of 2020.

Turkey Diler orders new bell-type annealing plant.

Diler Iron and Steel Industry and Trade has ordered a bell-type annealing plant from Danieli Olivotto Ferrè.

The new plant, to be installed at Dilovası, Kocaeli, will

be designed mainly for spheroidize annealing of rod in coils of outside diameters ranging from 1,250 to 1,400 mm, with wire diameters between 4.5 and 27 mm.

The furnace will be designed to accommodate stacked charges of up to 1,900 mm high and weighing between 1,650 and 2,350 kg. The plant will process coils under a protective nitrogen atmosphere and will consist of three bases designed for a maximum loading capacity of 40 t, plus two bell furnaces and a cooling hood. Each base will be provided with a centrifugal fan capable of recirculating up to 190,000 m3/h of annealing atmosphere.

Companies GFG Alliance places bid to acquire Mesabi Metallics. British-based GFG Alliance, which includes global industrial and metals group Liberty House plus the resources and energy group SIMEC, has stepped up its North American expansion programme with a consortium bid to acquire all the assets of Mesabi Metallics Company – formerly known as Essar Steel Minnesota – and ESML Holding. This includes a 7 million t/year iron ore pellet plant at Nashwauk Minnesota with an expansion potential to 14 million t/year, plus magnetite resources and hematite mineral resources.

The move follows closely upon the agreement Liberty has reached with ArcelorMittal to buy the Georgetown steelworks in South Carolina with its electric arc furnace and rod mill. Under the Mesabi Metallics plan, SIMEC would concentrate on the mining side of the business, while Liberty would focus on developing the direct reduced iron (DRI) and hot briquetted iron (HBI) plants, whose products would be used in its electric arc furnaces in America and globally.

ABB to acquire B&R. By acquiring B&R (Bernecker + Rainer Industrie-Elektronik GmbH), ABB is closing its historic gap in machine and factory automation. B&R is an independent provider focused on product- and software-based, open-architecture solutions for machine and factory automation. The company, founded in 1979, is headquartered in Eggelsberg, Austria. With the acquisition, ABB will expand its industrial automation offering by integrating B&R’s innovative products in PLC, industrial PCs and servo motion as well as its software and solution suite. On closing of the transaction, B&R will become part of ABB’s Industrial Automation division as a new global business unit – Machine & Factory Automation – headed by the current managing director, Hans Wimmer. The co-founders of B&R, Erwin Bernecker and Josef Rainer, will act as advisors during the integration phase to ensure continuity.

Quaker Chemical and Houghton International to combine. Quaker Chemical and Houghton International have executed a definitive agreement to

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››› INTERNATIONAL INDUSTRY NEWS

News in brief Acciaierie Valbruna, Italy, has started up the three-strand continuous billet caster modernized by Primetals Technologies. The plant is now able to produce stainless steel and special alloy billets with larger cross-sections up to 180 mm.

BMM Ispat, India, has granted Primetals Technologies the FACs for an electric steel plant and a merchant bar mill installed at the Hospet production site. For the electrical steel plant, Primetals Technologies engineered and supplied the mechanical and electrical equipment for an electric arc furnace, a ladle furnace, a vacuum degassing plant and the alloying and additive systems.

Steel Dynamics, USA, has unveiled the new double-coat continuous coil coating line supplied

by Danieli Fata Hunter. The line is designed to process cold rolled, galvanized, pickled hot strip and Galvalume® steel coils with a maximum width of 1,829 mm and a maximum base metal thickness of 1.93 mm. It has a yearly capacity of 250,000 t.

PAO Severstal, Russia, has granted SMS group the FAC for the comprehensively modernized tandem cold mill “2100” at the Cherepovets facility. The mill upgrade by SMS group comprised the complete replacement of the entry section and the four mill stands, and the installation of rolling technologies of the latest generation. Through this revamp, PAO Severstal has increased its overall capacity by 200,000 t to 1.3 million t.

The International Stainless Steel Forum (ISSF) has released figures for the full year 2016 showing that stainless steel melt shop production increased by 10.2% year-on-year to 45.8 million t.

combine the companies. Both Quaker Chemical and Houghton International are headquartered in the Philadelphia area. The new company’s metalworking capacity will be comprised of specialty products that include removal fluids, forming fluids, protecting fluids, heat treating fluids, industrial lubricants and greases. The expanded portfolio is expected to generate significant cross-selling opportunities and allow further expansion into markets such as India, Korea, Japan and Mexico.

The completion of the transaction, which is expected by the end of 2017 or early 2018, is subject to customary closing conditions, including regulatory approvals and approval by Quaker Chemical shareholders. The companies will continue to operate independently until the transaction is completed.

Divestment of Aperam Stainless Services & Solutions Tubes Europe completed. Aperam has completed the divestment of Aperam Stainless Services & Solutions Tubes Europe, its stainless steel welded tubes entities located in Ancerville (manufacturing plant) and Annecy (distribution centre) in France, to Mutares AG based in Munich, Germany. Mutares acquires companies that are being sold in the course of a repositioning process of their owners and show a clear potential for operational improvement.

NDC Technologies to invest in Technology Centre. NDC Technologies, provider of precision measurement and process control solutions, will be consolidating its Irwindale, California, USA production and administration functions into its Dayton, Ohio facility, which will subsequently become the new company headquarters. Significant investment will then be made in the Irwindale facility which will undergo major infrastructure improvements to become the new Web Process Solutions Technical Centre of Excellence.

Oryx Stainless and PGI conclude transaction. Oryx Stainless Holding MPT International 3 / 2017

and minority shareholder PGI have entered into an agreement concerning a purchase of 30% of the shares in their joint venture Oryx Stainless PGI, Bangkok, Thailand. Oryx Stainless PGI is a leading stainless steel recycling company in South East Asia. The two companies agreed that Oryx Stainless will acquire all the shares held by PGI, becoming the sole owner of Oryx Stainless PGI. The closing of the transaction is expected to take place by the end of May. The acquisition is part of the implementation of Oryx Stainless’ international growth strategy aiming at an increase in its market share in one of the fastest growing markets for the recycling of stainless steel and its alloys.

Z Capital acquires Premier Thermal Solutions from Gerdau. Z Capital Partners, the private equity management arm of Z Capital Group, have reached an agreement to acquire Atmosphere Annealing and NitroSteel, collectively known as Premier Thermal Solutions (PTS), from Gerdau. With Z Capital’s financial backing, PTS plans to expand its metal heat-treating service offering by adding capabilities organically, through strategic acquisitions and by diversifying into additional end-markets.

Nucor acquires Omega Joist. Nucor has acquired the assets of Omega Joist, producers of open web steel joists based in Nisku, Alberta, Canada. This acquisition complements the Vulcraft facility, which Nucor is currently constructing in Ancaster, Ontario. Omega Joist will operate as Vulcraft-Omega and will become part of Nucor’s eleven other joist and deck production facilities. Nucor plans to add additional products to Vulcraft-Omega’s product portfolio, including steel deck.

NLMK’s engineering centre renamed NLMK Engineering. Lipetsk Gipromez, a major engineering and project design company in the Russian metals and mining industry and part of NLMK group, has been rebranded and renamed to NLMK Engi-

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INTERNATIONAL INDUSTRY NEWS neering. The changes to the company’s name, logo and strategic positioning are a reflection of the extensive development it has undertaken over the last two years.

Joint agreement between Harsco and Hydro. Harsco Corporation and Hydro Industries, a UK-based leader in water treatment technologies, have entered into a joint agreement to expand the use of Hydro’s unique technology across Harsco’s footprint at more than 140 steel-producing sites across the globe. The new agreement will enable both companies to bring environmental and recycling solutions to the steel and metals industries, particularly in the treatment and processing of oily mill scale.

SHS Ventures acquires shares in Zensor. SHS Ventures, a venture capital company of SHS – Stahl-Holding-Saar and VSE, has acquired shares in Zensor, a Belgian service provider based in Brussels. Zensor has developed an integrated solution to monitor infrastructure with sensor data, providing predictive maintenance for large, stationary parts of technical plants and infrastructure. In addition to the investment by SHS Ventures, Paul Kumpen, a Belgian entrepreneur and business angel, has invested in Zensor, making funds available to finance the growth of the company.

Eurofer 2017/2018 outlook. According to Eurofer, EU steel market conditions are improving, both on the demand and the supply sides. EU apparent steel consumption ended 2016 on a stronger note than anticipated. Q4 steel demand grew by 7.1% year-on-year due to the combined effect of a higher than expected gain in real steel consumption and significantly lower inventory reduction than was anticipated on the basis of the normal seasonal inventory pattern over the year. The improved balance between import and domestic supply appears to have been sustained over the first quarter of 2017.

In 2017 and 2018, EU steel demand is

forecast to continue to grow at a moderate rate, the key uncertainty for EU steel producers remains to what extent third country imports will exert a negative impact on the demand-supply balance in the EU. According to director general Axel Eggert, the EU needs to tackle vigorously unfair trade and to stand to its promise to address global overcapacities in the framework of the Global Steel Forum.

By sector, the strength of the automotive industry is again confirmed by Q1 2017 activity growth, but production in the metal goods and steel tube sector also expanded at a healthy pace.

Meanwhile, activity in the construction and mechanical engineering sectors improved compared with the same period of last year, albeit at a more moderate rate. Prospects for 2017 and 2018 are mildly positive.

‚‚‚

21

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Liberty agrees in principle with ArcelorMittal to buy Georgetown steelworks. Liberty House has reached agreement in principle with ArcelorMittal to purchase Georgetown steelworks in South Carolina, including its 540,000 t/year electric arc furnace and 680,000 t/year rod mill. If completed as planned, the acquisition will give Liberty the opportunity to reopen and revitalize the facilities which were closed in August 2015.

Loesche pools combustion, drying and hot gas businesses. Loesche group is going to merge their activities in the combustion systems and drying systems sector into a central location at their head office in DĂźsseldorf under the name Loesche Thermal Applications. Alongside the established hot gas generators (LOMAÂŽ, HGG), the business incorporates combustion systems for solid, liquid and gaseous fuels as well as complete drying systems for a wide variety of industrial applications.

With the engineering resources available at the head office in DĂźsseldorf, efficient and optimized complete system solutions can be implemented centrally. Competencies in the area of combustion technology have been pooled by merging Loesche with A TEC GRECO Combustion Systems Europe.

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MPT International 3 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

News in brief

Personalities

Baotou Iron and Steel, China, and Fives are commissioning two continuous galvanizing lines to produce a wide range of high value-added automotive steels. In addition, Fives has designed and supplied furnaces for two continuous annealing lines.

Usiminas appoints new CEO. The board of directors of Usinas Siderúrgicas de Minas Gerais has approved the removal of Rômel Erwin de Souza from the positions of chief executive officer and director vice-president of technology and quality. Because of this deliberation, the board approved the appointment of Sergio Leite de Andrade for the positions previously held by Rômel Erwin de Souza.

INTECO, Austria, has ordered an 60-t AOD from UHT. The AOD is part of an order for a new specialty steel plant placed with INTECO by a customer in East Asia.

ArcelorMittal Asturias (Avilés), Spain, has successfully started up slab caster No. 1 revamped by SMS group. The two-strand bow-type caster slab caster has been rebuilt into a caster of vertical bending design.

Appointment of board members designate of Liberty Speciality Steels. In anticipation of completion of its agreed acquisition of Tata Steel UK Speciality Steels, Liberty House group has launched its new Speciality Steels business and appointed three executives to lead the operation. The management board designate of Liberty Speciality Steels will include Jon Bolton as chief executive, Peter Hogg as chief operations officer and Chris Kirby as chief financial officer. Jon Bolton is currently chief executive of Liberty’s plates and UK steel development, and chair of the employers’ body UK Steel. Peter Hogg is moving from his role as director of long products maker, British Steel, while Chris Kirby joins the team following a number of years as a senior consultant to major international metals, mining and energy firms.

Fujan Fuxin Stainless, China, has brought on stream the new slab grinding plant supplied by Danieli. Installed in Zhangzhou, the new grinding plant processes 350,000 t/year of stainless steel slabs.

ArcelorMittal Indiana Harbor, USA, has upgraded the 2.0m hot strip mill including the rebuild of two of its three walking beam furnaces, with particular emphasis on effective insulation.

Executive changes at ABB. Bernhard Jucker, president ABB Europe region and long term member of the ABB group executive committee, has decided to retire from his executive roles effective 30 June 2017, after a career at ABB spanning more than 35 years.

Bernhard Jucker will continue to serve ABB as chairman of the board of directors of ABB Germany and as an advisor to the senior leadership team. He will be succeeded by Frank Duggan, who joined ABB in Sweden in 1984 and currently holds the position of president of the AMEA region. In addition to his responsibilities as president of the Europe region, Frank Duggan will assume the role of managing director of ABB in Ireland.

MTS Systems appoints new chief financial officer. MTS Systems, a global supplier of high-performance test systems and sensors, has appointed Brian Ross, currently MTS Systems corporate controller, as senior vice president and chief financial officer. Brian Ross will replace Jeff Oldenkamp who is resigning from the company to pursue other opportunities.

BASF’s Coatings division with new president. Markus Kamieth, president of the BASF’s Coatings division since 2012, has been appointed to the board of executive directors of BASF SE. He will be succeeded by Dirk Bremm,

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INTERNATIONAL INDUSTRY NEWS who served among others as vice president of BASF Coatings Solutions in Tultitlán, Mexico, and senior vice president for Construction Chemicals Americas in Beachwood, Ohio, USA.

Vale nominates new chief executive officer. Murilo Ferreira, CEO of Vale, has not renewed his contract after the expiration of his term in May 2017.

Fabio Schvartsman has been elected to succeed Ferreira as chief executive officer.

Vacuumschmelze increases management team. Vacuumschmelze has made three additions to its management team: Ralf Koch, as vice president of research and development, Scott Pelhank, as vice president of global sales, and Jeremy Martin, as general manager Americas.

AIST Steelmaker of the Year 2017. Roger K. Newport, chief executive officer and board member of AK Steel, has been named Steelmaker of the Year at AISTech 2017. Roger K. Newport is being recognized for his strategic and dynamic leadership at AK Steel. He has steered efforts to strengthen the company’s balance sheet and has helped to bring new steels to the market. In addition, he has continued to support AK Steel’s ongoing investment in research and innovation, which can be seen in the expansion of its research team and the opening of the company’s brand new research centre in Middletown, Ohio.

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Events ›

10 – 14 September 2017 Düsseldorf, Germany Organizers: Steel Institute VDEh, TEMA Technologie Marketing www.eccc2017.com

ECCC Creep & Fracture Conference 2017. According to the European Creep Collaborative Committee (ECCC), approximately two hundred engineers and scientists from all over the world are expected to attend the fourth edition of this international conference and exchange latest research and development results involving the creep behaviour of high-temperature materials and components for the power plant industry.

› GFG Alliance appoints development director for Australia.

Michael Morley, specialist in mergers, acquisitions and restructures, has been appointed to spearhead a drive by the GFG Alliance into the Australian market and will be GFG’s development director for Australia. He joins the GFG Alliance as its member companies, Liberty House and SIMEC, step up their efforts to secure and develop steel, energy and mining assets in Australia.

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11 – 14 September 2017 Graz, Austria Organizers: The Austrian Society for Metallurgy and Materials ASMET www.ifm2017.org

IFM 2017. The 20th International Forgemasters Meeting addresses the following main topics: recent developments in the forging industry, advanced and new forging materials and production technologies, testing and quality management, plant engineering and equipment, numerical analysis and simulation, and environmental management.

›

19 – 21 September 2017 Bangkok, Thailand Organizers: Messe Düsseldorf www.wire-southeastasia.com; www.tube-southeastasia.com

wire and Tube Southeast Asia 2017. Held biennially, these co-staged trade fairs connect key local and global manufacturers, suppliers and service providers for the wire, cable, spring-making and fastener industries with stakeholders in tube, pipe, pumps and valves industries.

MPT International 3 / 2017

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››› INTERNATIONAL INDUSTRY NEWS

World Steel Association short range outlook 2017 – 2018 World Steel Association forecasts that global steel demand will increase by 1.3% to 1,535 million t in 2017 following growth of 1.0% in 2016. In 2018, it is forecast that world steel demand will continue to grow by 0.9% and will reach 1,548 million t.

Commenting on the outlook, Mr T. V. Narendran, chairman of the worldsteel Economics Committee said, “In 2016, steel demand recovery was stronger than expected with the upside mostly coming from China. We believe in 2017 and 2018 we will see a cyclical upturn in steel demand with a continuing recovery in the developed economies and an accelerating growth momentum in the emerging and developing economies. We expect that Russia and Brazil will finally move out of their recessions. However, China, which accounts for 45% of global steel demand, is expected to return to a more subdued growth rate after its recent short uplift. For this reason, overall growth momentum will remain modest.”

Steel recovery strengthens, but geopolitical uncertainty clouds outlook With the risk of global recession receding and economic performance improving across most regions, a number of geopolitical changes still create some concern. US policy uncertainties, Brexit, the rising populist wave in current European elections and the potential retreat from globalization and free trade under the pressure of rising nationalism add a new dimension of uncertainty in investment environments. To balance this, risks from ongoing conflicts in the Middle East and in Eastern Ukraine appear to be reducing.

In the capital markets, the probable US FED interest rate increase and any appreciation of the US dollar are like-

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

MPT International 3 / 2017

ly to have global impact. In particular, it may provoke capital outflows from the emerging economies and place a risk on corporate debt in the developing countries, which has climbed significantly over the last few years.

The pickup in oil prices in 2016 helped the fiscal position of oil producing countries. In 2017/18 oil prices are expected to show a moderate gain but any spike in oil prices to the levels seen in 2010 – 2012 seems unlikely despite the recent OPEC agreement on oil production cuts. Other commodity prices also rebounded due to stronger activities in China, but no further hikes are envisaged. The mildly rising oil prices may stimulate investment in economies worldwide.

Automotive sector will decelerate, but construction sector could pick up The automotive sector has been the top performer among key steel using sectors thanks to the consumption driven recovery in the developed economies, low oil prices and the government stimuli programmes supporting automobile purchases in several countries. However, this may now be approaching a peak. The construction, building and infrastructure sector, which accounts for 50% of global steel use, has been showing a divided picture between the developing and developed economies. This sector has been a major driver for steel demand in the developing countries driven by urbanization, but activity in the developed economies since the 2008 financial crisis has been more subdued.

This appears to be about to change with a recovery in construction activities apparent in the EU through the improving economic conditions and the potential renewal initiatives for infrastructure in the US. The machinery sector could also benefit from rising in-

vestment activities if the uncertainties surrounding the global economy can be contained. On the other hand, depression in shipbuilding activities is expected to continue for some time given the global glut in shipping capacity.

China slowdown The economic rebalancing and reform agenda of the Chinese economy continued for the first half of 2016, only to be interrupted by the government’s mini stimulus measures designed to reduce the speed of the decline. This produced a short term boom in infrastructure investment and the housing market, which stimulated demand for steel and other commodities. As a result, China’s steel demand showed growth of 1.3% in 2016. While the Chinese economic outlook appears stable and steel demand continues to remain strong in the early part of 2017, this is expected to gradually decelerate as the government tries to retighten its real estate policies. China’s steel demand is expected to remain flat in 2017 and then decline by -2% in 2018.

Developed world Benefiting from strong fundamentals, newly announced measures related to fiscal stimuli and rising infrastructure spending, the United States is expected to continue to lead growth in the developed world in 2017/18.

However, despite a recovery in oil prices, a rebound of investments in the oil and gas sector may be limited given the increased efficiency of shale producers.

The EU recovery is solidifying with many positive developments. Eurozone monetary policy is expected to remain on its current path, at least in 2017, while fiscal tightening is not expected to strengthen further and risk

INTERNATIONAL INDUSTRY NEWS of disinflation has significantly receded. If political stability can be maintained, investment is expected to pick up to provide a further boost to the recovery. Benefiting from the improving global economy and weak yen, Japan’s steel demand is expected to show a stable recovery. Steel demand in the developed economies will increase by 0.7% in 2017 and 1.2% in 2018.

Developing world Having dealt with the structural problems and fall in commodity prices, the Russian and Brazilian economies are stabilizing and expected to show modest growth in 2017. Russian growth will continue to pick up in 2018 as structural reforms take more effect. After the demonetization shock, the Indian economy is expected to resume growth, although

‹‹‹

25

on a slightly weakened basis. The ASEAN countries are expected to demonstrate solid growth in 2017/18. However, the region remains vulnerable to currency volatilities associated with US interest rate hikes and dollar appreciation. Steel demand in the emerging and developing economies excluding China, which accounts for 30% of world total, is expected to grow by 4.0% in 2017 and then 4.9% in 2018.

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26

››› RESEARCH & DEVELOPMENT

New European research initiatives for CO2-neutral steel production European steel companies have started three new research initiatives to develop solutions to prevent CO2 from steelmaking processes being discharged to the atmosphere. Project partners from the energy sector and others joined these initiatives to work and research cooperatively on the development of new technologies to reduce the impact of our industry on global warming.

L SYNTHE ANO SIS TH ME Synthesis gas Start-up heater

in various process stages of steel production.

The technology supplier for the proton exchange membrane electrolyser is Siemens. VERBUND, the project coordinator, will provide electricity from renewable energy sources and is responsible for development of grid-relevant services. Further partners in the project are the research institution ECN from the Netherlands, which is responsible for the scientific analysis of the demonstration operation and the transferability to oth-

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About EUR 12 million in funding from the EU Horizon 2020 programme have been allocated for implementing the H2Future project with the goal of producing green hydrogen. The green hydrogen for industrial use and for balancing the power reserve market will be produced in an electrolyser with proton exchange membrane (PEM) technology. The total project volume amounts to about EUR 18 million over the course of 4.5 years.

The partners in the project are the companies voestalpine, Siemens, VER-

BUND, and Austrian Power Grid (APG) as well as the research-partners K1-MET and ECN. The consortium is building a pilot facility – one of the world’s largest electrolysis plants for producing green hydrogen. The plant will be built and operated on the premises of voestalpine in Linz, Austria. The green hydrogen generated there will be fed directly into the internal gas network, allowing the testing of the use of hydrogen

Reactor

Austria: “H2Future” project for the production of green hydrogen

CTROLYSIS ELE

O2 Anode

Oxygen

H2 Cathode

Hydrogen

H2O

COMPOSITION OF STEEL MILL GAS The steel mill gas contains important raw materials for the chemical industry 2% methane (CH4)

8% hydrogen (H2) 43% nitrogen (N2)

25% carbon monoxide (CO)

22% carbon dioxide (CO2)

SHARE OF RENEWABLE ELECTRICITY Solar and wind power can be used to produce hydrogen in an environmentally friendly way. Figures in percent.

3

5

6

10

17

20

24

25

27

33

1990 1995 2000 2005 2010 2011 2012 2013 2014 2015

thyssenkrupp techforum 02.2016

“Carbon2Chem” is investigating ways of using steel mill gases to produce chemicals (picture: thyssenkrupp) MPT International 3 / 2017

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››› RESEARCH & DEVELOPMENT

er industrial sectors, and the Austrian transmission system operator APG, which will provide support in integrating the plant into the power reserve markets. The Austrian COMET Competence Center K1-MET provides its expertise in the operation of the plant and demonstrates the potential applications in the European and global steel sector.

With H2Future, key questions about sector coupling will be handled, such as evaluating potentials and possibilities for using green hydrogen in various process stages of steel production.

In addition, the transferability of this technology to other industrial sectors which use hydrogen in their production processes will be investigated. A further focus is integrating the responsive PEM electrolysis plant into the power reserve markets by developing demand-side management solutions, thus compensating for short-term fluctuations in the increasingly volatile power supply by means of load management for bulk consumers.

In the last ten years, voestalpine group has spent more than EUR 2.2 billion on the ongoing operation of its environmental facilities in Austria. “We are working consistently on the further development of our processes towards the gradual de-carbonization of steel production in order to be optimally positioned for the future challenges in terms of climate and environmental protection,” said Wolfgang Eder, chairman of voestalpine AG. The group is striving for the replacement of coal through the use of alternative energy sources in steel production over the next two decades by bridging technologies, primarily based on natural gas, like in the new direct reduction plant in Texas, USA. “With the construction of the new pilot plant for the production of CO2-neutral hydrogen at our

voestalpine AG, Linz, Austria Contact: www.voestalpine.com thyssenkrupp Steel Europe AG, Duisburg, Germany Contact: www.thyssenkrupp.com SSAB, Luleå, Sweden Contact: www.ssab.com

MPT International 3 / 2017

Linz location, we are taking a further step towards the long-term realization of the technology transformation in the steel industry,” Eder adds. However, the prerequisites needed are the provision of sufficient energy from renewable sources as well as political framework conditions, which allow for a secure long-term planning.

The EU Fuel Cells and Hydrogen Joint Undertaking (FCH JU) is a unique public private partnership supporting research, technological development and demonstration activities in fuel cell and hydrogen energy technologies in Europe. Its aim is to accelerate the market introduction of these technologies, realising their potential as an instrument in achieving a carbon-lean energy system. Fuel cells, as an efficient conversion technology, and hydrogen, as a clean energy carrier, have a great potential to help fight carbon dioxide emissions, to reduce dependence on hydrocarbons and to contribute to economic growth. The objective of the FCH JU is to bring these benefits to Europeans through a concentrated effort from all sectors. The three members of the FCH JU are the European Commission, fuel cell and hydrogen industries represented by Hydrogen Europe and the research community represented by the Research Grouping N.ERGHY.

Germany: research project “Carbon2Chem” Carbon2Chem is a ten-year collaborative research project initiated by thyssenkrupp. It is developing ways of converting steel mill gases into raw materials for chemical products. Much of the greenhouse gas CO2 contained in these gases would then no longer be discharged into the atmosphere.

Carbon2Chem is characterized by broad-based, cross-industrial cooperation. 16 further partners from the areas of basic and applied research and various sectors of industry are involved in the project. It will create a new network of steel production, electricity generation and chemical production.

Carbon2Chem is being funded by Germany’s Federal Ministry of Education and Research (BMBF) providing over EUR 60 million. The project is part of the climate change initiative KlimaExpo.NRW.

At present, gases from steel production are mainly used in power plants to produce electrical energy and heat for the production processes. But the process gases – including CO2 – could also be used as raw materials. Carbon2Chem is investigating ways of using steel mill gases to produce chemicals. This would also mean that the greenhouse gas CO2 would no longer be discharged into the atmosphere. The energy required for the chemical processes is to come from excess electricity from renewable sources. It will be roughly ten years before the technology is ready for industrial-scale use.

The basic chemical processes and technologies required for the industrial use of steel mill gases are largely known. It is already technically possible to convert process gases from steel production into ammonia as a starting product for fertilizers, though not yet cost-efficiently. This process would also recycle part of the CO2 contained in the steel mill gases. Another possibility would be to produce methanol from mill gases, a process which would recycle almost all the CO2 they contain.

But fluctuations in the generation of energy from renewables still present a challenge: Catalysts are needed for the chemical conversion process that can cope with these sharp fluctuations. More research and development work is required in this area. Cost-efficient methods of producing hydrogen – even with sharp fluctuations in the energy supply – will also have to be developed. Scrubbing and preparation of the steel mill gases is another area requiring further research.

Work started last November on the construction of a technical centre on the premises of thyssenkrupp Steel Europe in Duisburg. On this occasion, Heinrich Hiesinger, CEO of thyssenkrupp AG, emphasized that Carbon2Chem is a step toward the steel production of the future: “If the project is successful, it will significantly reduce CO2 emissions from steel production.

At the same time Carbon2Chem can make an important contribution to stabilizing the power networks.” Andreas Goss, CEO of thyssenkrupp Steel Europe AG, stated that Carbon2Chem will place steel production on a new, sustainable footing.

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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.

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RESEARCH & DEVELOPMENT The Carbon2Chem processes will be tested in a pilot plant at the roughly 2,600 square metre building complex to translate the results of basic research to industrial scale. The centre is scheduled for completion in spring 2018.

Sweden: initiative for a carbon-dioxide-free steel industry In Sweden, steelmaker SSAB, together with mining company LKAB and energy company Vattenfall launched an initiative to solve the CO2 issue in the Swedish steel industry back in the spring of last year. The project’s goal is to come up with a process that emits water instead of carbon dioxide by using hydrogen instead of the current procedure that’s based on blast furnaces burning coal and coke. The research project will take a look at processes such as ▪ fossil fuel-free pellet manufacturing, ▪ hydrogen-based direct reduction, and ▪ the use of sponge iron in electric arc furnaces, along with providing an electrical power supply source for hydrogen manufacturing and storage.

The initiative is divided into three phases: a pre-feasibility study that will run through the end of 2017, followed by research and testing in a pilot plant through 2024, and the final step, which involves carrying out testing in a full-scale demo plant through 2035.

Sweden is ideally suited for this type of initiative with its specialized, innovative steel industry, access to fossil fuel-free electrical power, and Europe’s highest-quality iron ore. However, in order to complete the project, a substantial nationwide cooperative effort will be needed from the Swedish government, research institutions, and universities over a period of 20 – 25 years.

SSAB’s, LKAB’s and Vattenfall’s initiative for a carbon-dioxide-free steel industry has gained additional support from The Swedish Energy Agency. In February 2017, the agency passed a resolution to finance a 4-year long research project for SEK 102 million (approx. EUR 10.5 million), with The Swedish Energy Agency providing SEK

56 million (approx. EUR 5.79 million) of this amount and the three companies contributing the remaining SEK 46 million (approx. EUR 4.75 million).

At the same time, the three companies behind the initiative, SSAB, LKAB, and Vattenfall, have decided to form a corporate joint venture to spur on this initiative.

“The Swedish Energy Agency’s decision to provide more financing for the initiative for a carbon-dioxide-free steel industry is very exciting news for us. It shows how important this work is not only for the steel industry, but also for Fossil Free Sweden 2045,” says Martin Lindqvist, CEO and group manager of SSAB. “It’s a real inspiration that The Swedish Energy Agency is helping to support Swedish companies in their efforts to introduce new innovative, environmentally-friendly manufacturing processes,” says Jan Moström, CEO and group manager of LKAB. “The announcement is extremely positive news. It’s a big help in our challenge to find a long-term solution to the carbon dioxide problem, where Vattenfall will be contributing in the areas of electrification and sustainable hydrogen production. We have a unique opportunity in front of us to break new ground and make a valuable contribution toward a fossil fuel-free Sweden,” adds Magnus Hall, CEO and group manager of Vattenfall.

The Swedish Energy Agency previously supported the initiative with SEK 7.7 million in funding for the feasibility study. The Swedish Energy Agency’s decision to provide additional funding for the initiative opens the door for the launch of a number of new research projects by organizations such as KTH, Luleå University of Technology, SWEREA MEFOS, Lund University, Stockholm Environmental Institute, and RISE, who will work toward the goal of a carbon-dioxide-free steel industry.

“One of the biggest challenges we face with global warming is reducing industrial use of fossil fuels. Investigating how to replace coal and coke with hydrogen in the Swedish iron and steel industries is both an obligation and a unique global opportunity to improve our competitiveness in the future,” states The Swedish Energy Agency’s director general, Erik Brandsma.

‹‹‹

31

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32

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

Continuous casting machine for the production of 355-mm-thick austenitic stainless steel slabs In order to meet the demand for thick plates ArcelorMittal Industeel, Belgium, decided in favour of a major revamping of its single-strand slab caster. The entire dismounting, erection and commissioning activities were executed during a short shutdown of only four weeks. ArcelorMittal Industeel is now able to produce the thickest austenitic stainless steel slab ever cast in the world.

ArcelorMittal Industeel in Belgium is renowned as a first-class producer of special steels. Their product mix includes all grades of stainless steels, high-strength steels, protection steel, pressure vessels steels, wear resistant and steels for moulds and tools. In order to meet the demand for thick plates ArcelorMittal Industeel

/QFKĆ&#x201A;ECVKQPU VQ VJG ECUVGT FGUKIP The first aspect to be taken into consideration when implementing an increase in slab thickness is to increase the casterâ&#x20AC;&#x2122;s containment length (metallurgical length). To guarantee a sufficiently high casting speed in order to not have a too

First slab

decided in favour of a major revamping of the slab caster aimed at increasing the plate thickness. In April 2014 Danieli was awarded the contract for this revamping, the main targets of which were an increase of the slab thickness to up to 355 mm and a small increase in slab width.

5VGHCPQ $CH &CPKGN 8CVCHW 9KNNKCO 6COK &CPKGNK % 5 R # $WVVTKQ +VCN[ %QPVCEV YYY FCPKGNK EQO ' /CKN KPHQ"FCPKGNK EQO

MPT International 3 / 2017

low temperature in the unbending zone, the revamped caster had to be provided with additional horizontal segments, taking into consideration the constraints of the existing layout.

The solution was to replace the old extracting unit with three horizontal segments, each of them equipped with two pinch rolls to guarantee the required slab withdrawal force. The replacement of the existing extraction unit with Danieliâ&#x20AC;&#x2122;s Optimum segments resulted in a modification of the existing foundation and the construc-

tion of additional extraction guides.

Their design had to be carefully studied in order to maintain the possibility to extract new segments through the existing casting platform. To minimize strains within the slab, the geometry of the existing straightening segment was modified, too, as well as the arrangement of unbending zone.

A new mould was supplied with a larger lateral strand support to minimize the effect of narrow side bulging.

In addition to this all the hydraulic cylinders in the existing segments of the caster were replaced. As the revamping targets also included an increase in the casterâ&#x20AC;&#x2122;s width, additional cooling of the external bearings was provided.

Also additional technological studies were necessary. The increase in casting thickness meant an increase in steel throughput in the mould, so it was necessary to verify if the existing SEN was suitable for the new condition. Both, CFD studies and water modelling were carried out, which identified some potentially critical conditions, like single roll pattern [1], leading to the necessity of supplying a new design of SEN. For proper application of dynamic soft reduction, dedicated technological packages such as the Q-Cool solidification model for secondary cooling and Q-Core control for soft reduction were installed. Last but not least new Level 1 automation for the control of the new segments had to be integrated into the existing automation system.

'TGEVKQP CPF EQOOKUUKQPKPI QH VJG TGXCORGF ECUVGT As ArcelorMittal Industeel operates only this single-strand slab cast-

CONTINUOUS CASTING

Single roll (SR)

Intermediate (INT)

Double roll (DR)

SEN studies, CFD and water modelling

er, the plant outage for the revamp was particularly critical. Only four weeks were available for the erection and cold test activities. After that period the caster had to be started up and smoothly ramped up to full production. Danieli, in close cooperation with the ArcelorMittal Industeel project team, completed all the activities including dismantling of old equipment, installation and commissioning of the revamped machine in only four weeks.

After the incident-free shutdown the caster restarted operation on 27 August 2015 casting the first heat after the revamp. After a few hours of stoppage for the necessary fine-tuning, the machine was put into regular operation.

Thanks to the skills of the ArcelorMittal operators, supported by the Danieli site team, an impressive learning curve was recorded, based on a production schedule of 50 sequences through to 8 September when the successful casting of the first 355 mm slab marked the completion of a major milestone of the revamping project.

6GEJPQNQIKECN VWPKPI For effective application of dynamic soft reduction it is important to set the right point [2] along the casting strand [2]. For this it is necessary to determine the end position of the liquid pool (mushy zone) inside the strand by a programme calculating in real time the solidification profile of the slab, taking into account key casting parameters.

This is done by the Q-Cool technological package. To be effective, this model needs a proper tuning as its reliability depends on the data input. Although heat transfer coefficient data are based on statistical data coming

from experience, for a new caster tuning may become necessary.

The tuning activities covered the following two aspects: ▪ tuning of the secondary cooling model in order to have an accurate prediction of the surface’s temperature, ▪ verification of liquid pool end point by the use of Q-Pulse.

The verification of the liquid pool end point is particularly important in the case of Industeel, as all grades cast can be considered “special”, i.e. material properties differ largely even within similar grades.

Technical data of the CCM Design capacity

350,000 t/year

Heat size

200 t

Main radius

12 m

Metallurgical length

26.5 m

Slab thickness

220 – 355 mm

Slab width

1,700 – 2,200 mm

Main caster data

‹‹‹

33

6WPKPI QH VJG EQQNKPI RCTCOGVGTU The reliability of secondary cooling models largely depends on the input data [4]. In many cases measurement campaigns are necessary to validate the applied parameters.

The first tuning of the secondary cooling model was performed with fixed pyrometers installed in the caster, a laser scanner installed at caster exit and by manual measurements where necessary. After the first measuring campaign, a first tuning of heat exchange coefficients was done. The fixed pyrometers can only provide some average data, and where scale and steam are present their reliability is low. To further improve the tuning of the model a second campaign with contact measurements was carried out.

One of the features of Q-Cool is to provide a “detailed” simulation of the caster’s temperature profile taking into account in real time the contribution by the heat exchange due to radiation from roll contact and the effect of secondary cooling. This provides a very detailed temperature profile which can be compared with contact measurements. For this purpose a second more accurate campaign was carried out installing a thermocouple that was in contact with the slab surface. Results allowed more accurate final tuning.

6WPKPI QH UQHV TGFWEVKQP The correct application of soft reduction is vital for its success. Correct estimation of the liquid pool and evaluation of macro etches are the basis for the tuning activity [3]. To be able to physically determine the

Sectional view of the mould narrow side foot rolls MPT International 3 / 2017

››› CONTINUOUS CASTING

liquid pool end, the Industeel caster was equipped with a tool, integrated as a part of the soft reduction control. Called Q-Pulse, the system works using the normal equipment for dynamic soft reduction, applying the principle of observing the mould level response to movements of the segment position.

A periodic small pulsation is issued to a segment position (entry or exit), and the response of the mould level to that frequency is recorded through FFT analysis embedded in the Danieli mould level control system, known as Q-Level+. If correspondence between the two frequencies is found, it means that final solidification is not yet complete. Thanks to this device it has been possible to perform a fine-tuning of the soft reduction position for all steel grades cast.

The Q-Pulse tool has been applied on different steel grades, and casting parameters have been tuned in terms of reduction profile and casting speed in order to get the best results. It has to be kept in mind that with the great thickness of the slabs cast at Industeel even a slight change in casting speed may result in not negligible differences in the liquid pool end. As a result, slabs free from segregation and porosity have been obtained for the different steel grades cast.

3D view of Industeel caster

TC 0 - center - 09 Sept 2016 - 12:29:18

1400 1300 1200

Slab surf temperature, °C

34

1100 1000 900 800 700 600 500

&KOGPUKQPCN VQNGTCPEGU One of the typical problems of slabs of great thickness is the bulging of the narrow face. Special attention has been paid to this aspect by designing narrow face support. This has resulted in slabs free from guttering on the broad faces and only very limited bulging of the narrow faces.

%QPENWUKQPU Thanks to the close cooperation between the two companies, the challenging task was completed within the set timeframe. This project has confirmed once more that good teamwork and accurate tuning of all the technological packages are the keys to obtaining top results.

MPT International 3 / 2017

400

0

5

10

TC measurement TC measurement jJRCPCB LPC online forecast 15 20

*.! MDkGLC QGK Pyrometer signal Landscan v cast, mm/min 25

Position from TOC, m Contact thermocouple measurements: red line actual measurements, black line model calculation

References [1] Pierre H. Dauby, “Continuous casting:

Bernhard, “ Methods for assesment of

make more steel and better of it!” Revue

slab centre segregation as a tool to con-

de Metallurgie 109, 113 - 116 (2012)

trol slab continuous casting with soft

[2] Chang Hee Yim, Joong Kil Park, Byong

reduction” ISIJ International, Vol 46

Don You, Seung Man Yang, “The Effect

(2006) pp. 1845 - 1852

of Soft Reduction on Center Segregation

[4] Bryan Petrus, Kai Zhen, X Zhou, Brian

in C.C. Slab” ISIJ International, Vol 36

G. Thomas, Josef Bentsman “Real-Time,

(1996), pp S231 - S234

Model-Based Spray-Cooling Control

[3] Hubert Preßlinger, Sergiu Ilie, Peter Rei-

System for Steel Continuous Casting”

singer, Andreas Schiefermüller, Andreas

Metallurgical and Materials Transac-

Pissenberger, Erik Parteder, Christian

tions B Volume 42B, February 2011

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36

››› CONTINUOUS CASTING

CCM4 at Baowu Steel Group Corporation, Shanghai works, equipped with ConRo bearing units from SKF (all pictures by courtesy of SKF)

Cost, quality and environmental performance improvements due to modular roll line units China Baowu Steel Group Corporation, the country’s largest steelmaker, formerly known as Baosteel, is driving up the performance and reliability of its continuous casting machines using SKF ConRo roll line units. High reliability, extended service life and a comprehensive remanufacturing programme keep the continuous casting machines working longer for less.

Continuous slab caster No. 4 is a twostrand continuous casting machine first installed at the Baowu’s Shanghai steel works in 2006. The machine produces 2.8 million tonnes of carbon steel slab every year, but was suffering quality and productivity issues due to the early failure of the bearings in the

SKF group, Gothenburg, Sweden Contact: www.skf.com E-mail: sabine.hergenroder@skf.com

MPT International 3 / 2017

horizontal segment of its 1,750 mm wide roll line. A combination of overload and the ingress of cooling water into the bearings meant the average service life of a roller on the line was only 3.4 months. Blocked rollers were a source of quality issues in slab production and the need to regularly replace the units was a significant cause of production downtime.

To address the issue, Baowu Steel Group replaced two roller units on the line with SKF ConRo technology.

SKF ConRo is a robust, self-contained,

modular roll line that includes bearings, seals, housings, grease, roll bodies and water connections. The design uses a patented sealing system that protects bearings from ingress of water and contaminants.

The installation of the new ConRo units on the CCM4 machine has more than tripled the service life of the rollers, to an average of 14 months. Thanks to their greater longevity and reliability, the company recouped its investment in ConRo technology in less than six months.

CONTINUOUS CASTING

‹‹‹

37

CCM4 pulpit at Baowu Steel Shanghai

SKF ConRo is a relubrication free solution for continuous casting

The QR code links to video on YouTube explaining the SKF ConRo solution for continuous casting

Second period in service Now the original ConRo units are enjoying a second life, thanks to SKF’s tightly controlled remanufacturing programme. At the end of their first period in service, the units are returned to SKF in Shanghai, where they are remanufactured to stringent specifications. The process includes replacement of bearings and seals and requalification of the body, roll mantle, hosing and sleeves.

The remanufacturing programme also provides an opportunity to upgrade some components, based on analysis of their performance in production.

The first remanufactured units were returned to Baowu Steel Group in October 2015 and have now completed more than a year in service – delivering

the same level of performance as new units, at only 30 percent of the cost.

Remanufacturing offers important environmental benefits too, with a significant reduction in energy and raw material consumption, compared to the production of new equipment.

“The SKF ConRo units have helped us to cut unplanned down-time and reduce production costs,” says Jianqing Yao, director of equipment at Baowu Steel Group Corporation’s Shanghai steelmaking plant. “The availability of the remanufacturing programme

has extended those benefits, allowing us further reduce the overall operating cost of our machine.”

Baowu Steel Group has worked closely with SKF since the early 1990s, and the two companies have extended their collaboration with a series of strategic partnership agreements since 2005. Thanks to SKF’s continuing investment in its production and service capabilities in the country, Baowu Steel Group’s most recent order for an additional eight units were the first ConRo units to be manufactured in China.

MPT International 3 / 2017

38

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş HOT ROLLING

New electric steel plant and merchant bar mill at BMM Ispat Ltd. in India %00 ,VSDW /WG ,QGLD LVVXHG WKH Ć&#x201A;QDO DFFHSWDQFH FHUWLĆ&#x201A;FDWHV IRU D QHZ HOHFWULF VWHHO SODQW DQG D QHZ PHUFKDQW EDU PLOO VXSSOLHG E\ 3ULPHWDOV 7HFKQRORJLHV 7KH SURGXFWLRQ IDFLOLWLHV DUH GHVLJQHG IRU D SURGXFWLRQ RI PHWULF WRQV RI PHUFKDQW EDU SHU \HDU DQG H[SDQG %00 ,VSDWvV FDSDFLWLHV IRU VWUXFWXUDO VWHHOV In February this year, Primetals Technologies received the final acceptance certificates (FACs) for an electric steel plant and a merchant bar mill supplied to BMM Ispat Ltd. The com-

Exit area of the cooling bed, where the cooled bars are bundled before cold cutting

High-speed delivery system of a bar mill from Primetals Technologies

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 3 / 2017

panyâ&#x20AC;&#x2122;s integrated iron and steel plant is located at Danapur about 12 km away from Hospet in the state of Karnataka, India. With the electric steel plant and the bar rolling mill the company is expanding its production capacities for structural steels. It is designed for the production of a wide range of end products. These include reinforcing steels, round bars, flat and square bars, angles and channel sections. Low and medium-carbon or low-alloy steel grades as well as spring and free cutting steel can be processed. Primetals Technologies had received the orders in 2012. Hot commissioning took place in August 2016.

For the electrical steel plant, Primetals Technologies engineered and supplied the mechanical and electrical equipment for the metallurgical plants as following: â&#x2013;Ş an electric arc furnace with a tapping weight of 110 t, â&#x2013;Ş a 110-t ladle furnace, â&#x2013;Ş a vacuum degassing plant and â&#x2013;Ş the alloying and additive systems.

The electric arc furnace is specially designed for the combined charging of direct-reduced iron (DRI) and hot metal. The electric arc furnace, the ladle furnace, the material charging systems and other auxiliaries are equipped with a dedusting system. The scope of supply also included the entire Level 1 automation and process automation (Level 2) systems, furnace transformers and a dynamic compensation system Static Var Compensator (SVC).

For the merchant bar mill, Primetals Technologies supplied the complete mechanical and electrical equipment of the rolling line and the cooling zone as well as systems for bundling and tying up the bars produced. The rolling line includes:

â&#x2013;Ş the upstream equipment for loading and unloading the billet heating furnace, â&#x2013;Ş a six-stand roughing mill in an H-V arrangement, â&#x2013;Ş a six-stand intermediate mill in an H-V-V arrangement, â&#x2013;Ş an eight-stand finishing mill, also in an H-V-C arrangement, â&#x2013;Ş cooling bed.

The stands of the intermediate and finishing mills are equipped with quickchange fixtures, while after the finishing mill there is also a quenching system. The finishing mill and the 102-metre-long cooling bed are linked by two delivery systems. One of them is designed as a twin-channel highspeed system and achieves speeds of up to 25 metres per second.

The rolling mill is supplemented by a finishing shop complete with machines for straightening, bundling, stacking and strapping the rolling stock. Diverse shear systems along the rolling line and in the cooling zone rounded off the mechanical equipment.

The scope of supply also included the process automation (Level 2), mechatronic components, the motor control center and speed-controlled drive systems for the main and secondary drives including all motors. Primetals Technologies was also responsible for supervising installation and commissioning and for training the customerâ&#x20AC;&#x2122;s personnel.

A few years ago, BMM Ispat Ltd., the second largest steel company in the state of Karnataka, India embarked upon a capacity expansion at the existing facilities in Hospet. The electric steel plant and the bar mill are parts of this programme. The iron ore used stems from the group companyâ&#x20AC;&#x2122;s own mines in the region.

www.harald-wehrle.de

Tools & Equipment

Consulting & Qualification

Engineering & Projects

Services & Spare Parts

Since 1983, the Badische Stahl-Engineering GmbH (BSE) has been acting as a service provider for increasing the efficiency and productivity in the electric steel industry worldwide.

BSE is a sister company of the Badische Stahlwerke GmbH (BSW), one of the world’s most efficient Electric Arc Furnace steel plants.

We are Steelmakers!

BSW and BSE – a unique partnership that will help you to reach even ambitious goals.

This unique partnership between BSW and BSE ensures that all products and services provided by BSE are not just based on mere theory, but on more than 4 decades of own proven operational experience.

Badische Stahl-Engineering GmbH Robert-Koch-Straße 13 D -77694 Kehl/Germany Phone (+49) 78 51/8 77- 0 Fax (+49) 78 51/8 77-133 eMail info@bse-kehl.de www.bse-kehl.de BSE America 1811 Sardis Road North, Suite 210 Charlotte, NC 28270 Phone (704) 553-1582 www.bse-america.com

40

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

Modernization of coil transport systems in hot strip mills ensures high plant availability and improved product quality From 2012 to 2014, thyssenkrupp Steel Europe implemented an extensive growthorientated modernization of its hot strip mills No. 1 and No. 2 in Duisburg-Bruckhausen and in Duisburg-Beeckerwerth, respectively. A major part of this project was the upgrade of the coil transport systems, with the goals of improving both the systemsâ&#x20AC;&#x2122; availability and overall coil quality.

Coil transport with the coil eye horizontal

In 2012, tkSE ordered new coil transport systems from German engineering company BWG Berg werk- und Walzwerk-Maschinenbau GmbH, headquartered in Duisburg. BWG had supplied the equipment for the original coil transport system of the tkSE hot strip mills in Duisburg, started up in the 1960s, as well as for a major up-

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MPT International 3 / 2017

grade in 1979. In addition, BWG had supplied equipment for tkSEâ&#x20AC;&#x2122;s strip processing lines, including installation and commissioning. Also for the most recent upgrade, tkSE reiterated their trust in BWGâ&#x20AC;&#x2122;s technical expertise and the quality and reliability of equipment engineered and supplied

by BWG. The concept for the coil transport was developed in close co-operation with tkSE and involved the replacement of the coil handling systems in both hot strip mills up to the designated coil storage areas. With respect to the extensive and sophisticated product range produced by tkSE, the coil

transport systems for both hot strip mills were designed for maximum flexibility, productivity and product quality. The new concept for the transport and storage of the hot rolled coils required extensive modifications of the existing facilities. Two major design aspects had to be considered for the new coil transport system: â&#x2013;Ş creation of multiple transfer points along the transport path and â&#x2013;Ş conversion of the transport system from coil eye vertical to coil eye horizontal orientation.

The underlying idea was to create increased transport flexibility through the use of multiple coil transfer points

41

Downcoiler 3

‹‹‹

Downcoiler 2

Downcoiler 1

MATERIAL FLOW LOGISTICS

Hot strip mill No. 1 Chain conveyors

Coil lifts Strapping machines Marking machines

Chain conveyor

Walking beam conveyor

Chain conveyor Strip inspection

Chain conveyors

Coil storage area Layout scheme of the coil transport system of the hot strip mill No. 1 at the tkSE Duisburg-Bruckhausen works

and improve coil quality by eliminating coil edge damage due to coil eye vertical transport handling. By transporting the coils with the eye horizontal, it was possible to address the issues of both edge damage and coil unwinding or springing open when down-ending the eye vertical coils for further processing.

BWG’s overall scope of supply for tkSE included engineering, detailed design and supply of the mechanical, hydraulic and electrical equipment, material flow management engineering and visualization, removal/ dismantling of existing equipment, installation of the new equipment, check-out, start-up and commissioning including training of the tkSE operating and maintenance personnel.

The new coil transport system includes visual surface inspection for quality control/quality assurance and a material flow management system interfaced with the coil storage management and tracking system.

The material flow paths at both lines differ in some details as they had to be adapted to the available space in the existing mill buildings. However, in both cases it is basically a combination of longitudinal and cross transport systems using both chain-type and walking beam conveyors. Custom-designed transfer devices ensure smooth and safe transfer of the coils from one transport system to the next. Where

required, transfer points are equipped with lifting or lowering devices to cover differences in floor level.

The overall coil transport system and the individual sub-sections are designed such that incidents or malfunctions in one section will not require a shutdown of the hot strip mill.

Instead, coil transport will be maintained via an emergency strategy. The walking beam conveyors are powered by a fully hydraulic drive unit using a BWG patented control system for conveyor movement. Under normal conditions, the system operates with long strokes in order to cover the transport distance as fast as possible. However, in case of an incident occurring in the coil removal from the mill, the system

switches to short stroke operation. This creates additional coil positions allowing the number of accommodated coils to be doubled and creating an operational buffer to continue mill operation.

There are three downcoilers and three strapping machines at each hot strip mill. In that area the coils are moved on saddle chain-type conveyors. The coils can be removed from the chain conveyors by the overhead crane. Heavy-duty machines for strapping the coils of thick-gauge highstrength grade strips and automatic coil marking machines are installed adjacent to the next conveyor section, a walking beam conveyor, featuring a calibrated coil weighing system.

Horizontal transport via chain conveyor MPT International 3 / 2017

42

››› MATERIAL FLOW LOGISTICS

In tkSE’s hot rolling mill No. 1, a maximum of 48 coils are rolled per hour, at an average sequence time of 75 seconds. Mill capacity in continuous operation amounts to up to 280,000 t/month. In hot rolling mill No. 2, it is possible to convey 72 coils/h at a sequence time of 50 seconds, amounting to 490,000 t/month. In order to achieve these performance rates, operation of the coil transport and storage system has to be absolutely reliable.

From the start, BWG Duisburg had planned to use only very robust high-quality components. For example, both walking beam conveyors and chain conveyors are equipped with side guides in order to minimize wear of the track rollers and rails. Coil troughs and coil deposits are designed to accommodate coils weighing up to 40 t and reliably cope with the coil handling by crane, as well as to reduce surface damage of the transported coils.

3WCNKV[ OQPKVQTKPI CPF OCPCIGOGPV The new coil transport systems are equipped with monitoring devices to assure quality. The coils are conveyed to their destinations via target-oriented chain and walking beam conveyor systems in order to minimize the use of overhead cranes for coil handling.

Coil condition is monitored not only

Hot rolling mill No. 1

Hot rolling mill No. 2

Strip width

600 – 1,500 mm

750 – 2,030 mm

Strip thickness

1.0 – 12.7 mm

1.5 – 25.4 mm

Coil weight

6 – 35 t

max. 40 t

Initial coil temperature

800°C

900°C

Sequence

75 seconds

50 seconds

Key data of the tkSE hot strip mills in Duisburg

by visual inspection but also by the use of a laser measuring system.

In line with the requirements of tkSE’s quality management protocols, individual coils are removed from the central coil transport system and transferred to the newly installed off-line strip inspection station. Here a sample is taken for inspection: some strip is uncoiled, the sample cut off and positioned vertically to allow complete and unobstructed visual inspection of both sides of the sample. After the visual inspection of the strip sample has been completed, the cutoff strip sections can be cropped into up to 1-metre-long pieces and collected in a scrap box. In addition, it is possible to cut individual sample pieces to lengths between 100 mm and 500 mm using the crosscutting shear. These shorter samples are collected in a drawer installed under the shear for safe retrieval for further testing and evaluation.

#WVQOCVGF OCVGTKCN ƃQY KPETGCUGU NKPG CXCKNCDKNKV[ After commissioning, a proven 99.5% of availability of the coil transport system was achieved. This exceptional performance results mainly from the robust mechanical equipment design coupled with the high degree of systems automation, including the integration of the local controls for the strapping and marking machines together with the controls for the hydraulic power supplies and the strip inspection systems.

As an important part of the overall coil tracking and automation strategy, the new material tracking system supplied by BWG has been connected to tkSE’s warehouse management system.

The positions of each coil are continuously displayed and tracked. This information is evaluated and checked for plausibility by the warehouse manage-

Walking beam with BWG patented conveyor movement control

MPT International 3 / 2017

MATERIAL FLOW LOGISTICS

‹‹‹

43

ing converters, transformers, low voltage distribution, automation devices and visualization systems, were tested for functionality. In addition, also all available automation devices, visualization systems, fieldbus components, and communication links to higher-level systems as well as the interfaces to auxiliary units such as the coil marking and strapping machines were integrated into these tests.

The disassembly of existing equipment, installation of new equipment and commissioning by BWG took place in several carefully planned phases and, wherever possible, during running production. Thanks to the detailed planning of the above mentioned disassembly and installation work including piping, cabling and testing, cold and hot commissioning periods were significantly reduced and a short start-up curve was achieved.

Strip inspection station

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Coil transfer point

ment system. Large displays installed above the exit area of the rolling mill show the ID numbers of the hot strip being coiled in the downcoilers.

/QFGTPK\CVKQP FWTKPI TWPPKPI RTQFWEVKQP The coil transport systems for both hot rolling mills No. 1 and No. 2 were modernized and upgraded while mill production was ongoing. In order to keep production interruptions and restrictions to a minimum, assembly units of the new systems were as far as possible installed on existing foundations. Where required, the modernization concept allowed for new foun-

dations to be built during production, prior to the mill outage for final installation and system cutover.

Before delivering the electrical equipment to the site, it was workshop-tested by simulation techniques.

Also the hardware and software components were workshop-tested to the maximum extent possible. In both rolling mills, the integration tests of the new equipment were started prior to cold commissioning together with the operating personnel of tkSE. After delivery of the equipment, the electrical equipment was assembled and connected as far as possible prior to the mill outage. All electrical equipment and systems installed by then, includ-

The modernization resulted in the following substantial improvements: ▪ improved coil quality due to coil transport with the coil eye horizontal, ▪ early detection of strip surface damage thanks to a new inspection station that provides complete visual inspection of both sides of the uncoiled strip sample combined with the collection of samples for metallurgical testing and evaluation, ▪ improved working conditions for the operating personnel and implementation of the latest safety standards, ▪ increased coil transport system performance resulting from the highly automated transport process and the robust mechanical equipment design, ▪ increased flexibility in operating sequences through the creation of transfer points that allow safe intervention by the mill crane in case of incidents.

According to tkSE, this latest transport concept upgrade in the hot strip mills provides improvements in performance and quality. Additionally, it has made it possible to expand the range of high-quality, high-margin products.

MPT International 3 / 2017

44

››› STRIP PROCESSING

Side trimming section of the continuous pickling line from Primetals Technologies at Rizhao Steel Group Co., Ltd in Rizhao, Shandong province, China (picture by courtesy of Primetals Technologies)

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 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.

Rizhao Steel Group Co., Ltd (Rizhao) has built a new cold rolling complex in the city of Rizhao in Shandong province, China. The company issued recently the final acceptance certificate (FAC) for its continuous pickling line (CPL) supplied by Primetals Technologies. The CPL plant processes ductile and forming steels of the Japanese grades SPHC, SPHD and SPHE, HSLA (high-strength low-alloy) 330 – 440 and dual-phase steel DP 590 and HSLA 590.

The strip processing line can pickle hot strip with thicknesses ranging from 0.8

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 3 / 2017

to four millimeters, and widths from 900 to 1,600 millimeters, and handle coils weighing up to 35 metric tons. The strip speed upon entry is 800 meters per minute, the pickling runs at 400 meters per minute, and speeds of up to 520 meters per minute are reached in the exit section.

After having received the order in November 2013, Primetals Technologies supplied a double coil charging section and double pay-off reels in the entry section. A six-strand strip accumulator accommodates the strip. A scale breaker is installed upstream of the pickling station, which has five flat pickling tanks equipped with an acid recirculating system.

Downstream there is a rinsing tank with five compartments with an associated water treatment system and drier. The strip then passes through a

skin-pass mill and a tension leveler, followed by a four-strand exit accumulator.

The strip is then side-trimmed, before passing through an inspection station to ensure it has the required surface quality.

Two recoilers with a rotary shear are installed in the exit section. The scope of supply also included two coil discharging cars, a coil transfer car and a walking-beam coil transfer system. Primetals Technologies also supplied the complete electrical and automation equipment.

The project was handled by an open consortium comprising Rizhao, Shanghai Winham Machinery and Equipment Co., Ltd. and Primetals Technologies.

Primetals Technologies was responsible for the engineering, supply of key components, monitoring the components produced in China, and supervising construction and commissioning.

Excellence in Strip Processing Technologies

Since 1955.

Quality meets Innovation.

We combine solid engineering experience, know-how and innovative ZVS\[PVUZ MVY [OL ILULÄ[ of our valued customers.

BWG – Your Specialist for Customised Solutions, Processing Lines and Modernisations Since 1955, our name has been synonymous with premium equipment and technical solutions which set bench-marks for the metallurgical industry. In addition to the steel and stainless steel metal industries, we have been a reliable partner to the leading aluminium and non-ferrous metal producers for many years, with a focus on:

࠮ :[YPW WYVJLZZPUN SPULZ ࠮ :WLJPHS[` WYVJLZZPUN LX\PWTLU[ ࠮ *VPS OHUKSPUN LX\PWTLU[ ࠮ 4VKLYUPZH[PVU VM L_PZ[PUN WYVJLZZPUN WSHU[Z We have an excellent track record of realising new ideas based on thorough research HUK KL]LSVWTLU[ ^OPJO OH]L SLK [V ZPNUPÄJHU[ PUJYLHZLZ PU WYVK\J[P]P[` WYVK\J[ X\HSP[` LULYN` LѝJPLUJ` HUK LU]PYVUTLU[HS WLYMVYTHUJL

BWG Bergwerk- und Walzwerk-Maschinenbau GmbH Mercatorstr. 74 –78 47051 Duisburg, Germany

>L SVVR MVY^HYK [V ^VYRPUN ^P[O `V\ VU [OL PTWSLTLU[H[PVU VM [LJOUVSVNPJHS ZVS\[PVUZ [OH[ TLL[ [OL OPNOLZ[ Z[HUKHYKZ VM X\HSP[` HUK PUUV]H[PVU

Phone: +49 203 99 29-0 Fax: +49 203 99 29-400 E-Mail: info@bwg-online.de

Technology made in Germany. Since 1955.

www.bwg-online.de

46

››› SPECIAL EQUIPMENT

Compact infrared thermometer with the new IO-Link communication interface Keller ITS, a specialist manufacturer for non-contact thermometers, has now equipped its models of the CellaTemp PK series with the new IO-Link communication interface. IOLink is a systems-independent and non-proprietary interface and can therefore be used LQ DOO FODVVLF ƂHOG EXV V\VWHPV IRU SURFHVV DXWRPDWLRQ SXUSRVHV Intelligent sensors and actuators are the basis for the implementation of “Industry 4.0”. The sensor technology with standardized digital interface is therefore the foundation for integration in field-bus independent automation processes with consistent communication down to the lowest field bus level. Keller ITS, specialist and manufacturer of infrared thermometers for non-contact temperature measurements now offers its CellaTemp® PK series with the new IOLink interface technology.

A major benefit of IO-Link are easy, fast and safe and thus cost-saving wiring requirements. Commissioning is made easy with standardized cables with screw connectors. Incorrect connections or grounding problems are no issue at all. The interference-free signal level of 24 V DC improves the device’s operating reliability.

As the parameters are set on the highest level, the operating reliability of the interface is also ex-

CellaTemp® PK series smart pyrometer with IO-Link interface

Albert Book, Business Unit Director Infrared Thermometer Solutions, Keller HCW GmbH, Ibbenbühren, Germany Contact: www.keller-msr.com/pyrometer E-mail: albert.book@keller-msr.de

MPT International 3 / 2017

tremely high. Upon exchange of a sensor, the identification of the new sensor is automatically checked and the configuration parameters stored in the IO-Link master are automatically transferred to the new sensor. An operating error is therefore impossible. The worldwide, non-proprietary standardization of the IO-Link interface in accordance with IEC 61131-9 allows using the infrared thermometer in all classic field bus systems. In standard mode (SIO), the temperature sensor can be used in conventional process control systems via its analogue output as it was used before. In IO-Link mode, a switching signal and diagnostic data are transmitted in parallel with the measurement readings. Its diagnostic function makes troubleshoot-

ing easy, i.e. in case of cable breakage or short-circuit, either from a central spot or even by remote maintenance.

All 43 types of the CellaTemp® PK series with various wavelengths and measuring ranges from -30 to 2,500°C ffor a llarge variety i t off measuring i tasks t k are, as a standard, equipped with the new IO-Link interface. The infrared thermometers are available as single channel devices or with the reliable two-colour technology. Optionally,

the sensors are available with a patented LED spot light. The green LED spot, usually clearly visible to the human eye, marks the exact size and position of the measurement area and the correct distance to the target. The devices are equipped with a powerful LED display and keys to configure the parameters and functions on site as required.

As before, the devices can be used in conventional control systems via their classic analogue 0(4) – 20 mA output.

The diagnostic function allows a needbased maintenance in case of malfunction.

Models with a separate optical sensor are used for environments with temperatures up to 250°C or in highly electromagnetic fields or when there is limited space to install the pyrometer. The optical fibre transmits the infrared radiation to the electronic unit.

The length of the fibre optics cable can be up to 50 m.

Especially with swinging objects as in wire rod production, at a roller stand or in i inductive i d ti heating h ti plants l t where h the “hot spot” is moving, the panorama pyrometer® CellaTemp® PKL 63 with rectangular measurement area allows for a safe detection of the measuring value.

SPECIAL EQUIPMENT Two-colour pyrometer technology Modern two-colour pyrometers detect the infrared heat radiation to determine the temperature not only at one wavelength area as with a conventional spectral pyrometer but at two wavelength areas at the same time and place.

A quotient is then calculated from the two measured radiation intensities.

This value is approximately proportional to the temperature. The specialty and the big advantage of a two-colour pyrometer is that the temperature value remains at a constant level, even when the infrared radiation emitted from the target is reduced, for example, by dust, vapour or dirty protective glasses. The temperature is still measured correctly even with a very low signal strength (90% reduction). Therefore, two-colour pyrometers are preferably used for industrial applications in extreme ambient environments and under adverse measuring conditions, such as rotating kilns in the cement industry, rolling

mills in the steel industry or foundries to measure liquid metals. A variation of the radiation properties of the target object, i.e. of the emissivity coefficient, does not have a negative influence on the temperature measured, as the variation remains neutral regarding the wavelengths.

It is another advantage of this measurement principle that the target object may be of a smaller size than the target marker in the pyrometer’s viewpath. This makes a two-colour pyrometer less sensitive to the correct focus distance as well as to target adjustment and inaccuracies when measuring small targets, such as spots in inductive heating systems. Another application where a two-colour pyrometer delivers more accurate readings is the temperature measurement of glass drops or of glass poured into a mould.

The pyrometer’s measuring principle prevents the measuring signal from being affected by the type of glass and its colour or the diameter of the glass

‹‹‹

47

drop, whereas changing production factors may produce wrong temperature values when measuring with a single-colour pyrometer.

Modern two-colour pyrometers are equipped with a smart contamination monitoring function (SCM). A very strong contamination of the inspection glass or the lens of the pyrometer or a high concentration of dust and vapour in the viewpath towards the object to be measured trigger an alarm signal. This ensures a high operating reliability. In addition, it saves costs as regular maintenance and visual control by the service personnel is no longer needed.

The two-colour pyrometer offers the option to evaluate the spectral temperatures as well. Practically, the device can work as a “double pyrometer”, i.e. as a two-colour pyrometer or a spectral pyrometer. This feature offers interesting opportunities for signal evaluation, such as an analysis of the radiation properties of the target object.

framag Industrieanlagenbau GmbH Neukirchner Straße 9 4873 Frankenburg, Austria Tel.: +43 (0) 7683 5040-0 E-Mail: sales-ht@framag.com www.framag.com

torch cutting technology t NJOJNVN DVUUJOH MPTT t QFSGFDU DVUUJOH RVBMJUZ t IJHI DVUUJOH TQFFE t TIPSU DZDMF UJNF t MPX NFEJB DPOTVNQUJPO t MPOH MJGF UJNF

MPT International 3 / 2017

48

››› AUTOMATION – IT

Towards the Internet of materials: SSAB SmartSteel forms a basis for the circular economy SSAB has recently completed an R&D project to explore the concept of a digital platform that enables steel products to be loaded with knowledge. A unique identity code in the steel plate establishing a link between the plate and information provides customers and their machinery with appropriate data and instructions to help them to select and use SSAB steels in whatever application.

The idea behind SSAB SmartSteel is to make information and instructions available relative to a steel item wherever it may be processed. Each link in the production chain can utilize and accumulate information, forming a basis for both the circular and platform economy.

The result would be less waste than at present and improved productivity and flexibility. The amount of information accumulated throughout the manufacturing chain would enable the development of new services and accelerate and improve the efficiency of product development at each stage. On top of this, the accumulated information would enable end users to ensure the quality, safety and durability of the product.

Material and manual go hand in hand Products in the metals industry are typically processed in production facilities of a large number of different companies before they are dispatched to the end users. Materials and items flow from one site and company to another.

Today, however, the material and associated information generally take different routes. The material is transported by road or rail, whereas the information is sent by e-mail. Also at the customer’s site they usually end up in different places and remain separated. It may even happen in the worst case that someone has to cycle around a component manufacturer’s site looking for a particular item.

Eva Petursson, Seija Junno, SSAB AB, Luleå, Sweden Contact: www.ssab.com E-mail: seija.junno@ssab.com

MPT International 3 / 2017

What if the steel in a car or a house was loaded with intelligent information?

Certainly, items are marked, but information relative to them is usually kept in an office e-mail or archive database.

Let alone the instructions for use, which may be in a thick manual or handbook on the engineer’s shelf. When a machine or piece of equipment needs repairing, it may take a lot of time and effort to find out what material has been used and how it can be repaired.

SSAB SmartSteel is a concept designed to help solve this problem. Steel plate is marked with a unique identity code establishing a link between the material and information related to it, e.g. the exact history, composition, properties and instructions for use for that particular item. This is an idea currently trialed and developed in cooperation with several partners.

Material and machine in dialogue SSAB SmartSteel enables a dialogue between the material and the ma-

chine. In future, a machine tool or manufacturing system that processes smart steel will be able to read the identity code of the steel plate to be processed and automatically adjust as required. This will considerably reduce errors and material waste. Further benefits can be expected from the use of fine-tuned robots.

One of the aims of the SSAB SmartSteel concept is to provide continuous lifecycle traceability from the raw materials in the mine throughout the manufacturing process, the scrap and the re-use. This can be achieved if all manufacturers involved in a product feed information relating to the product and its use into a cloud-based repository. Sharing and combining information must be secure and security solutions are an important area for development within the SSAB SmartSteel concept.

The same idea can also be applied to the control of the production chain. The entire chain could be tuned for optimal op-

50

››› AUTOMATION – IT

eration, which is not the same as the current goal to minimize costs in all stages.

While the costs or use of time in one stage might increase, it may be possible to save costs or produce more at another stage.

Heading towards platform economy and ecosystems In future, companies will not necessarily compete with one another as they do today. Instead, competitiveness will be built on entire processing chains and networks. SmartSteel may create a basis for building ecosystems in the metals industry. Looking ahead, information accumulated by different parties can be combined, thereby taking a great leap towards transparency and sustainability. Excess quality or safety margins will no longer be required. In the same context, the basis for a digital platform economy will be built. The opportunities for new business building on the shared information are virtually unlimited.

The implications for productivity and reliability can be just as great as those of automation when it entered the factories. The information accompanying the material may revolutionize the entire manufacturing industry if we are bold enough to open up the borders and see the common interest as being greater than our own interest.

In the circular economy, production and consumption generate minimum loss and waste. Already today, steel is fully recyclable. The new SmartSteel idea will

enable better classification regarding steel composition, which will make it more efficient and attractive also for users to recycle steel.

When customers know the exact composition and properties of steel plate, they do not need to buy excess quality. This will improve material efficiency throughout the manufacturing chain. Precise adjustment of machinery based on batch-specific information results in reduced waste and re-ordering.

In addition, a common database will allow the development of new services without additional physical outlay.

More partners being sought for the development work The SSAB SmartSteel concept has been developed in collaboration with a number of universities and industry players in projects funded by Tekes – the Finnish Funding Agency for Innovation – and the Academy of Finland.

International researcher networks have been checked to make sure that no similar idea has been carried out earlier. The idea was tested and piloted with various customers and equipment suppliers. Actual development work is about to begin. Areas of development include the marking of metal components, information architecture, cloud systems, data security, ways of sharing information and business models. Also common standards will be required.

Since no company can do this kind of work alone, the project needs to partner

with different manufacturing chains, customers, subcontractors and logistics companies. The idea can be honed and clarified in small, quick trials. It is applicable in principle to any material whatsoever. In this way we can speak about the Internet of materials.

The best ideas are created when top people in different fields work together. Likewise, the SSAB SmartSteel idea was also created in a project with top researchers active in the fields of user experience, industrial engineering, service development and materials science working on challenges arising in a steel mill. It takes time to build a common language and mutual trust, but it is well worth the effort.

Conclusion SSAB has recently completed the first stage in a research and development project aimed to examine the SmartSteel (SSAB SmartSteel) concept, a digital platform that can be used to share information about steel. A unique identity code links steel plate and information related to it in order to provide customers and their machines with information about how to choose and use SSAB’s steel in different applications. The idea is to share SSAB’s steel knowledge with partners.

The vision is a cloud-based platform that contains instructions for different stakeholders in the value chain about the use of SSAB’s steel and which can be linked to similar cloud systems of other players along the manufacturing chain.

CALCIPRO® Visit us at ESTAD booth #39 AlzChem AG

New Calcium Treatment Technology based on Calcium Carbide Cored Wire

Dr.-Albert-Frank-Str. 32 | 83308 Trostberg, Germany | T +49 8621 86-2219 | metallurgy@alzchem.com

MPT International 3 / 2017

WWW.ALZCHEM.COM

TECHNICAL INNOVATIONS

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51

Fatigue-resistant safety couplings for encoders SPECIAL EQUIPMENT Sensor specialist Johannes Hübner Giessen has developed new safety couplings specifically designed to meet the needs of heavy-duty applications. The HKS series of safety couplings fulfils special demands, such as the flexibility to compensate mounting errors without overloading the ball bearings of the attached encoder. At the same time they are rigid enough to permanently withstand even the harshest of operating conditions. The requirements to be met in the design of safety couplings are defined in IEC standard 61800-5-2.

overloading, the additional safety claws guarantee continued availability. They take over a “drive” function to ensure the coupling and encoder continue to rotate and that the plant does not come to an unplanned standstill even in this worst case scenario.

The HKS series includes both single joint couplings to correct angular misalignments of flange attachments as well as double joint couplings with which it is possible to compensate shaft misalignments in conjunction with foot attachments. HKS and HKDS safety couplings operate flawlessly

Special marking machines

Number heads

XS Laser

Dot pin marking

Fatigue-resistant safety coupling

To comply with the standard it is absolutely essential that high fatigue resistance is designed into the safety couplings.

To verify fatigue resistance, extensive trials and tests were carried out in addition to the stipulated calculations. Amongst others these included shock tests, fatigue tests under operational stresses as well as a 96-hour salt spray test to verify corrosion resistance.

In contrast to durable couplings, whose service life is limited to a certain number of load variations, fatigue-resistant safety couplings are designed to withstand an infinite number of load variations; consequently, they had to undergo more than 106 load variations without any fault. Even in the event the spring washers made of special highstrength steel fractured as a result of

between -50°C up to a maximum of +120°C; the insulated HKSI and HKDSI product versions operate perfectly between -25°C and +85°C. The HKS series includes a variety of couplings with total lengths ranging between 36 mm and 120 mm as well as bore diameters of up to 22 mm. Johannes Hübner Giessen provides a Declaration of Conformity with every HKS safety coupling that guarantees fault exclusion when operating and assembly instructions are complied with. That means it is possible to deploy the couplings in safety applications up to SIL 3 (safety integrity level 3) / PL e (performance level e) and that they are classified in the risk analysis as a fault exclusion component.

Contact: www.huebner-giessen.com MPT International 3 / 2017

52

››› TECHNICAL INNOVATIONS

Optimization of dummy bar chains by maintenance-free slide bearings CONTINUOUS CASTING Slide bearings from Mangachoc require no lubrication at all. When used in dummy bar chains, they come as a bush with a hardened pin made of stainless steel. It is extremely important for a dummy bar chain to slide perfectly smoothly. Mangachoc slide bearings provide a very long life of the dummy bar chain without disruptions, as has already been proved in numerous continuous casting plants.

In contrast to this, connections between the chain elements by just a pin or a pin with a bush require regular, intensive and expensive lubrication. Another solution often found in dummy bar chains is a pin with an oil-impregnat-

ed sintered bush or with a bush made of bronze that contains solid lubricants. All those solutions have in common that they are not entirely wear-resistant. This is due to the fact that in lubricated bearings the lubricant will form a paste as it gets into contact with scale and/or other hard dirt particles. The result is wear due to abrasion. Moreover, there is the risk of seizing (adhesion) due to lubrication starvation.

All these problems are ruled out by the highly wear-resistant, maintenance-free Mangachoc slide bearings.

Contact: www.mangachoc.de

Titanium rotary hearth forging furnace THERMAL PROCESSING Can-Eng Furnaces International Limited was contracted to commission a turnkey 11 m diameter “Pancake” style rotary hearth furnace for a leading North American-based aerospace supplier. The open hearth configuration allows for flexible loading and uniform heating. The furnace sys-

Rotary hearth furnace

tem features an advanced low NOx combustion system designed to meet the most stringent environmental and temperature uniformity requirements. Special dual-door design provides the customer with significant flexibility for forging and press manipulation within their existing plant layout. The system is capable of processing up to 114 t load capacity in a 24/7 production environment. The furnace system complies with thermal performance requirements laid out in AMS2750E, integrates a low-shrinkage ceramic fibre lining, unique rotating hearth drive and sealing system. The system is scheduled to be commissioned to the United States in the third quarter of 2017. It will be used in the production of large closed-die forgings made of titanium and nickel-based alloy and used as structural parts in fixed wing aircrafts.

Contact: www.can-eng.com MPT International 3 / 2017

Dioxin abatement system

We are strong in know-how, engineering and service of long product rolling mills and guide systems.

g to new di n i m ll

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Dioxin abatement system installed at

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ENVIRONMENTAL PROTECTION Installed at the fume treatment plant of the ABS steelworks in Italy, the new dioxin abatement system developed

by Danieli Environment and More is able to keep the PCDD-F values permanently below 0.1 ng-TEQ/Nm³.

The installed activated carbon injection system is made up of two storage silos (each of 65 m³) with independent dosing units, two injection systems installed on board of each exhaust fume line and automation. It complies with ATEX directives. The use of adsorbents (e.g. activated carbon, pulverized activated lignite coke or mixtures of these

160 years ...

ABS Italy

Contact: www.danieli.com

RX G

es i r e u id e S

Branch Office:

Morgårdshammar AB SE-777 82 SMEDJEBACKEN, Sweden Phone: + 46 240 668500 Fax: +46 240 668501 E-mail: mh@morgardshammar.se www.morgardshammar.se

Morgårdshammar AB Sales office Krefeld P.O. Box 101552 D-47715 KREFELD, Germany Phone: +49 2151 81290 Fax: + 49 2151 611795 E-mail: office@mh-guides.de

www.mh-guides.com

www.gk-mas.de

with lime) to be dosed to the exhaust duct before the dust abatement, controls the emissions of polychlorinated dibenzo-p-dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs) in fumes sampled at the stack. To predict the adsorbents’ abatement efficiency, based on the previous adsorption steps, a specific computational fluid dynamics analysis has been performed. This kind of dioxin abatement system can be installed on any existing fume treatment plant on a turnkey basis in four months.

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â&#x20AC;ºâ&#x20AC;ºâ&#x20AC;º TECHNICAL INNOVATIONS

Turning, milling and drilling of extra large workpieces combined in one unit

Horizontal machining centre

MACHINING Doosan Å koda Power has recently put into operation a new horizontal machining centre for turbine rotors of up to 140 t weight. The machining centre, which combines turning, drilling, milling, grinding and meas-

uring of extremely large parts in one unit, was manufactured and supplied by Heinrich Georg Maschinenfabrik.

The Georg ultraturn MC is designed to handle workpieces with diameters of up to 3,500 mm and lengths of up to 12,000 mm.

In the past, Doosan Å koda Power used to machine the turbine rotors in three steps â&#x20AC;&#x201C; requiring three separate machines: first, all the rotorsâ&#x20AC;&#x2122; bearing journals were turned, then the fir-tree blade slots were milled and, finally, the balancing holes and the coupling holes were drilled. In contrast, the new machine performs all these three process steps in one sequence, i.e. the work pieces do not have to be re-clamped or transferred in any way. The ultraturn MC series are designed to measure extra large workpieces with highest precision directly in the machine.

The overall machining time for regular rotors has decreased from about 1,000 down to 550 h. 30% less time is needed for turning and 50% for drilling and milling.

Contact: www.georg.com

The motor for your metal production )RU D SXUH DQG IJDZOHVV PHOW 7KH 0)& PDVV IJRZ FRQWUROOHU LV GHVLJQHG ZLWK D PRWRU YDOYH IRU UHJXODWLRQ RI SUHVVXUHV XS WR EDU DQG UHOLDEOH RSHUDWLRQ HYHQ XQGHU WKH PRVW VWULQJHQW FRQGLWLRQV 7R HQVXUH KLJKHU SURFHVV UHOLDELOLW\ LQ WKH JDVbVXSSO\ WKH YDOYH FDQ EH UHJXODWHG DW IXOO GLijHUHQWLDO SUHVVXUH $QG WKH VHOI ORFNLQJ GULYH HQVXUHV WKDW WKH PRWRU YDOYH LV QRW DijHFWHG E\ SUHVVXUH IJXFWXDWLRQV ,Q DGGLWLRQ WKH 0)& IHDWXUHV WKH ODWHVW GLJLWDO WHFKQRORJ\ â&#x20AC;&#x201C; ZLWK WKH LQWHJUDWHG EXV LQWHUIDFH LW LV UHDG\ IRU ,QGXVWU\ High-pressure MFC Type 8746: 0RUH UHOLDELOLW\ LV QRW SRVVLEOH <RX FDQ GHSHQG RQ LW :H PDNH LGHDV É&#x2C6;RZ ZZZ EXUNHUW FRP

TECHNICAL INNOVATIONS

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Large motor-driven cable reels for Russian steelworks SPECIAL EQUIPMENT ConductixWampfler, manufacturers of systems for the transmission of energy and data to mobile consumers, has developed and supplied large motor-driven cable reels to Tulachermet Steel Company in Tula, Russia, for the steel ladle as well as scrap and slag transport cars.

The project involved six double-spiral

4QVCT[ ƂDTG QRVKE VTCPUOKVVGT

the cable manufacturer. With six shielded energy strands for frequency-controlled drives, 20 control strands, and two shielded twisted-pair control lines, this cable has been specifically adapted to the application and local regulations.

The steel plant solution developed by Conductix-Wampfler makes use of rotary fibre optic transmitters (TFO), which

Precise, Reliable, Repeatable

Too Hot to Handle?

No Problem with Polytec

Motorized cable reels

motor driven cable reels for cables of over 1,000 m in length and a hose reel for argon supply.

The reels, with their unusually long winding lengths, have been installed in protected areas above the working area.

The cables and hoses are suspended and guided by roller bearings every three metres. The reels are driven by AC motors – in combination with the MAG-Drive magnetic clutch developed by ConductixWampfler. The special reeling cable has been developed in collaboration with

are ideal for the transmission of large volumes of data over larger distances.

They can be equipped with single mode or multi-mode fibre optic cables, single mode or multi-mode damping, and in variants for 40, 80, or 120 turns and 6, 12, 18, or 24 fibres. The solution package uses standardized cable reel components for easy spare parts management.

Conductix-Wampfler had received the order from SMS group.

Contact: www.conductix.de

High-performance vacuum lubricants VACUUM TECHNOLOGY Developed specifically for applications that require low vapour pressure while working at high stresses and high temperatures, Edwards UltragradeTM Performance vacuum lubricants are ideal for industrial and high vacuum applications. They can be used in larger heavy-duty as well as in smaller vacuum pumps. The newly branded ‘UltragradeTM Performance’ oils benefit from improvements in formulation, handling and packaging that together result in a finer product for cus-

Come an see us on 26th – 29th June 2017, at ESTAD Vienna, Booth 49

tomers dependent on high grade lubrication for their oil sealed vacuum pumps.

UltragradeTM Performance base oils are refined without the uses of solvents for extreme purity. The base fluids are combined with selected additives to provide a formulation resilient to the stresses of mechanical pumping. Finally, fluids are blended to achieve a selection of products that can be exactly matched to different pump types and applications.

Contact: www.edwardsvacuum.com MPT International 3 / 2017

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!

Learn more: www.velocimeter.us

56

››› TECHNICAL INNOVATIONS

-DV TKSQ@RNMHB SDRSHMF TMHS ENQ RS@HMKDRR RSDDK A@QR QUALITY ASSURANCE French stainless steel producer Ugitech, as subsidiary of the Schmolz + Bickenbach group, has invested in a new ultrasonic testing unit at its Ugine site. With the new system, Ugitech can now inspect almost 35,000 t/year of steel bar for internal and surface defects in accordance with the highest technical standards, giving the company around 50% more capacity in quality assurance. The non-destructive testing unit is used mainly for quality control and assurance of steel bar intended for use in the automotive industry. Following machining of the steel bar, the part’s thickness in some cases is less than 0.5 mm. Consistently flawless quality of the core and surface is essential for reliable component stability.

Contact: www.ugitech.com

Ultrasonic testing unit

/QNÖKD LD@RTQHMF RXRSDL QUALITY ASSURANCE ShanDong ShiHeng Special Steel, China, operates Profilemaster® SPS series measuring systems from Zumbach Electronics. The latest unit is equipped with four CMOS camera/laser modules and mainly used for measuring L and Omega-type profiles. The system is an important step to guarantee a high quality standard for the manufactured profiles. It has helped to

BRAUN Innovations tions for Steel Cutting-edge technology chnology for cutting and grinding ding

B

office@braun-steel.com

• High-performance cut-off machines • Multi-functional grinding machines • Automated turn-key solutions • Technical consulting • Life-time service support

INNOVATIONS FOR STEEL

www.b raun- steel. c o m

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

MPT International 3 / 2017

Inline measuring gauge

TECHNICAL INNOVATIONS solve previously existing measuring problems in the production line.

Zumbach Electronics offers a comprehensive range of non-contact, inline measuring and control instruments for diameter, thickness, eccentricity and out-of-roundness

‹‹‹

57

measurements and for physical or electrical parameters like expansion, capacitance, dielectric strength, and more.

Contact: www.zumbach.com

Thermal energy storage to reduce carbon footprint ENVIRONMENTAL PROTECTION Tata Steel is constantly aiming to improve its carbon footprint. In order to use its energy most environmentally friendly, at a facility in IJmuiden Tata intends to utilize the exhaust gas energy from production to cover some of its own energy demand. The plan also includes the creation of an energy storage facility, based on technology from EnergyNest. The company’s thermal energy storage (TES) solution allows to capture waste heat and make

it available for later uses. The resulting economic benefit relates mainly to savings in natural gas consumption and consequently CO2 emission reduction.

The EnergyNest TES is easy to integrate and operate, since it contains no moving parts. The storage technology is based on a special concrete, Heatcrete®, which can store large amounts of thermal energy over a long period of time with little heat loss (1% per day).

Graphic illustration of a thermal energy storage facility

Contact: www.energy-nest.com

© Utz Peter Greis, Düsseldorf

Cartoon

Are we going back to medieval times? The growing propensity for some states to impose protectionist measures is also going to be felt in the steel industry.

MPT International 3 / 2017

58

››› LITERATURE SERVICE Scanning detector for hot metals 6 pages, English A brochure featuring scanning sensor equipment from Delta. The Rota-Sonde DC4500 scanner is designed for rolling mill and continuous caster applications. It scans the infrared radiation emitted by hot products. The brochure describes the operating principle, special features and the technical data of all available models.

Contact: E-mail:

www.deltasensor.eu info@deltasensor.eu

Protection against laser radiation 8 pages, English A brochure setting out the range of laser protection clothing offered by Jutec for applications involving hand-held laser devices. The items of protective clothing are available for different levels of laser radiation depending on the application and the distance from the laser source.

Contact: E-mail:

www.jutec.com info@jutec.com

70 years of 3-roll technology 60 pages, English The anniversary edition of the Kocks magazine provides a reflection of the 70-year company history and milestones in 3-roll technology. The magazine contains case studies, interviews, articles featuring topics like the future role of high-strength steel, thermomechanical rolling, etc.

Contact: E-mail:

SENS OR S M A DE IN GER M A N Y

www.kocks.de marketing@kocks.de

Hot metal detector 2 pages, English

HMD 4.0

The new Proxitron Hot Metal Detectors

A flyer featuring the new Proxitron hot metal detector HMD 4.0. With a software-based configuration this latest model is programmable and adjustable over a wider range than previous versions. Other advantages include reduced interference, fully parameterizable outputs, teachin function, etc.

Contact: E-mail:

www.proxitron.com info@proxitron.de

Tapping technology 8 pages, English, Spanish, Portuguese, Russian, Chinese This brochure provides an overview of taphole technology provided by TMT, a joint venture company combining the expertise of Dango & Dienenthal and Paul Wurth. Equipment presented in the brochure includes clay guns, taphole drills, rodding and cleaning devices, slag stoppers, etc.

Contact: E-mail:

MPT International 3 / 2017

www.tmt.com contact@tmt.com

IN THE NEXT ISSUE…

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59

Special equipment Alternatives to mineral-based hydraulic fluids in steel production Fire hazards are constantly present in the steel industry with operations involving heavy equipment and liquid or red hot steel, and when mineral oil based hydraulic fluids are being used. However, there are alternatives that can be utilized without jeopardizing the performance or productivity of the steel production line.

Raw materials Radial flow fans installed at China’s largest sinter plant At Baosteel’s large ironmaking site in Shanghai, the sintering of iron ore requires sufficient process air to be drawn through the sinter strand sized 600 m². For the new sinter plant the old induced draught fans were too small to generate the negative pressure necessary for the sinter bed. Baosteel modernized the plant using two induced draught fans dimensioned according to the requirements. The radial flow fans delivered in December 2016 with a drive power of 12,300 kW belong to the largest fans in the world, entailing various challenges to construction.

Automation MES implemented at steel production sites of MMK Metalurji, Turkey Turkish steelmaker MMK Metalurji has implemented a state-of-the-art manufacturing execution system (MES) solution for the integrated mini-mill in Iskenderum and the cold strip complex in Istanbul. The plants’ size and complexity forced MMK Metalurji to seek the best available solutions for achieving excellence in manufacturing and data transparency from the shop floor to the management level. Full support of optimization and tracking of production, quality and storage are vital for efficient management and ensure optimum visibility of the various plant processes.

Improved safety in meltshops thanks to machine intelligence Various new technologies have been successfully implemented to increase safety, reduce the manpower needed in dangerous areas, increase the traceability and reduce the risk of mistakes in production. Implemented in different steps in both automation and robotics, the integration has introduced the concept of the Industry 4.0. The digitalization of information shared with the existing automation landscape and the efficient and user-friendly interface allow productivity to be increased and human presence outside the control pulpit to be reduced.

This preview may be subject to change.

Metallurgical Plant and Technology

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

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MPT International 3 / 2017

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