MPT International 4/2018 (Sep)

Metallurgical Plant and Technology G 25074

ISSN 0935-7254

New slab plants start operations in Rizhao, China

September 2018

Metal powder production technology to feed 3D printing factories

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EDITORIAL

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Technology advances despite political obstacles This is the final editorial by Arnt Hannewald, who departs with our best wishes after more than 16 years as Editor-in-Chief of MPT International. Mr. Hannewald’s dedication has been integral to maintaining the journal as one of the iron and steel industry’s most influential. He leaves with our gratitude and hands his duties to MPT’s new Senior Editor, Alex Manford. One of the case studies in this issue covers the various new slab production plants commissioned in Rizhao, Shandong province, part of efforts by the Shandong Provincial Government to streamline its steel sector. While a giant amount of annual steelmaking capacity has been cut in the provincial capital, Jihan, by shutting down local steelmaking technology, a completely new Greenfield iron and steel complex has been set up in the coastal city of Rizhao. The impressive complex more than substitutes Jihan’s reduced capacity, and seems to reference a press statement made by Eurofer President Geert Van Poelvoorde earlier this year: “The challenge we face today, ultimately, has its roots in the global overcapacity the industry continues to wrestle with. It is more crucial than ever that governments act decisively to address the root causes. This includes the elimination of capacity and market-distorting subsidies and government support measures worldwide.” It is worth taking a close look at the flat steel technologies installed in Rizhao.

Dipl.-Ing. Arnt Hannewald

Meanwhile, MPT continues its series of articles about digitalization in the steel sector. Among the most promising technologies, additive manufacturing has now reached the shop floor. SMS Group has recently introduced a comprehensive technical solution for the complete process. This combines expertise from all fields involved – materials (including special alloys), metallurgy, melting, atomizing, powder handling, 3D printing etc – to form a seamless process chain with dedicated automation and contol, plus consistent quality assurance. This already dynamic development in additive manufacturing, which we have been observing recently, is likely to pick up momentum in the near future.

While the steel sector reports positive growth, the times are uncertain. Where you acquire your trusted industry analysis has never been more important. For this reason, we are carrying forward MPT International’s considerable 30 years’ legacy into a new era. While the print magazine will remain largely unchanged, as your most authoritative source for news and innovations in metallurgical technologies and plant engineering, we have plans to embrace the new digital possibilities and develop more content online. We hope you will join us on this journey towards providing you with even more valuable insights.

Alex Manford

MPT International 4 / 2018

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››› CONTENTS

Additive manufacturing 24

Metal powder production technology to feed 3D printing factories An AM demonstration centre is going to be built to demonstrate the complete process chain: powder production, 3D printing and finishing including a dedicated automation system

Safety 30

Improving safety at work with the help QH CTVKƂEKCN KPVGNNKIGPEG

Coverphoto: Revamped exhaust gas system with combustion chamber and movable connection piece from KSK GmbH for the 140 t electric arc furnace of Georgsmarienhütte GmbH info@k-s-k.de www.k-s-k.de

Nordic steel company SSAB has combined occupational safety data with artificial intelligence. The aim has been to find the hidden reasons behind workplace accidents

Continuous casting

Automation

New slab plants start operation in Rizhao, China Another thin-slab plant started production at Rizhao Steel earlier this year. Also, neighbouring Shandong Iron & Steel Group Rizhao recently commissioned new continuous slab casting capacity

Process-capable and robust length and speed measurement solutions Non-contact optical measurement systems are the ideal solution in harsh environments. Their reliable measurement data can be easily integrated into process control systems

Quality assurance

Surface treatment

Automatic eddy current inspection detects hard spots on the surface of heavy plate German steel company Dillinger has launched operation of yet another world first in its heavy plate rolling mill with its new eddy current testing system

Tata Steel Europe and POSCO exchange GZRGTVKUG KP VJG ƂGNF QH CFXCPEGF UVTKR EQCVKPIU The companies have partnered to develop innovative steels for the future. Carmakers and other manufacturers will have access to a whole new generation of steel products thanks to a new agreement

Strip processing

Material flow logistics

New grain-oriented electrical steel mill helps ensure nationwide power supply in India thyssenkrupp Electrical Steel is the first and currently only manufacturer of grain-oriented electrical steel strip in India

Intelligent furnace technology in continuous annealing and galvanizing lines Up to now fixed heat cycles have largely been used in the process control. The “I-Furnace” now takes into consideration the individual requirements of single coils or coil segments

MPT International 4 / 2018

High-speed production buffer for wire rod coils German steelmaking company Saarstahl AG has implemented a fully automatic high-bay warehouse for up to 665 steel wire rod coils at its Neunkirchen site

Columns 8

International industry news

Literature service

Technical innovations

In the next issue

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MPT International 4 / 2018

››› INTERNATIONAL INDUSTRY NEWS

The Americas Canada Lockheed Martin invests in development of metal powder atomization. Materials science company Equispheres has received a multi-million USD investment from Lockheed Martin. This investment enables Equispheres to accelerate its growth in the provision of high-quality materials required for advanced technologies such as additive manufacturing, 3D printing and cold spray deposition. Each of these technologies requires a unique spherical metal powder in the manufacturing process. Equispheres created a technology for producing perfectly spherical metal powder with specific characteristics desired within the aerospace and automotive industries. Lockheed Martin’s investment enables Equispheres to conduct the research, development and design work to build reactors that will produce powders of higher strength material such as inconel, steels and cobalt chrome.

Canada ArcelorMittal orders new reheating furnaces. ArcelorMittal Long Products Canada has ordered a made-to-measure, walking beam furnace with a capacity of 130 t/h to be supplied on a turnkey basis. The new furnace will supply the existing rebar and SBQ rolling mill at the West plant in Contrecoeur. The start-up is planned for June 2019. The second furnace, a Bendotti walking beam furnace also with a 130 t/h capacity, will be used to supply the existing wire rod rolling mill in the East plant. The start-up of the second furnace is planned for December 2019.

arc furnace in operation at its Ramos minimill. The system automatically identifies deviations in process-controlled variables, correcting them according to the best possible practice to avoid energy losses. Installation is planned to take place by June 2019.

USA Nucor orders reheating furnace for new merchant bar mill. Forni Industriali Bendotti has been awarded a contract by Nucor Steel Kankakee for a reheating furnace. The walking beam furnace will have a capacity of 91 t/h. It will supply the merchant bar mill that will be erected by SMS group in the Nucor Kankakee plant in the town of Bourbonnais, 100 km south of Chicago. The start-up is scheduled for late 2019.

USA Nucor to build new galvanizing line. Nucor is going to construct a galvanizing line at the company’s sheet mill in Arkansas to support Nucor’s growth into a wider and more diverse set of end-market applications. The new galvanizing line will have an annual capacity of approximately 500,000 t. It is expected to be operational in the first half of 2021. This project complements the investment currently underway to construct a specialty cold mill complex at Nucor Steel Arkansas. The galvanizing line will be coupled with Nucor’s new specialty cold mill complex.

Asia

News in brief Tata Steel Packaging, The Netherlands, has commenced operations of its continuous annealing line CA 12, which was modernized by Primetals Technologies with new electric and automation equipment.

Guangdong Guoxin Industrial, China, has awarded SMS group the final acceptance certificate after the successful commissioning of the two single-strand wire rod mills at its Jieyang works in the Guangdong Province.

Shaoguan Iron and Steel, China, has commissioned a Danieli service team to perform maintenance services on its breakdown mill and manipulator during a regular shutdown. The equipment had been operating without any overhauling since it was supplied by Danieli in 2012.

Columbus Stainless, South Africa, has commissioned its two 100 t AOD converters after installation of a new torque retainer by SMS group. The retainer, a compact electro-hydraulic unit, reduces vibrations and the force acting on the gearbox unit during operation of the AOD converters.

voestalpine, Austria, has started up the new CC8 slab caster, which was installed to replace slab caster CC3 at the LD Stahlwerk 3 in Linz. The new caster was built by Danieli.

China Mexico De Acero to upgrade EAF operation with automation package and scrap charging system. DeAcero has awarded Danieli an order for the supply of a Q-Melt® automation package and a new continuous scrap charging system for the electric MPT International 4 / 2018

Tangshan Iron & Steel to expand condition monitoring system. Tangshan Iron and Steel has awarded PrimetalsTechnologies an order to further expand the existing condition monitoring system (CMS) in cold rolling mill No. 2 at its Tangshan plant in Hebei Province. In future, the expanded system will also be used for condition

Commercial Metals Company, USA, has brought on stream its new micro mill located in Durant, Oklahoma. The micro mill, supplied by Danieli, produces spooled bars in coil in an endless casting rolling process.

KNOW-HOW FOR TOMORROW

››› INTERNATIONAL INDUSTRY NEWS

monitoring two new continuous galvanizing lines supplied by Primetals Technologies in addition to an existing galvanizing line, a continuous annealing line and a coupled tandem pickling line in cold rolling mill No. 2, as well as a hot strip mill. The CMS monitors not only the mechanical equipment but also the mechatronic systems, the technological controls, the process models and third-party systems. With cross-plant condition monitoring, Tangshan is taking an important step towards Industry 4.0. The expanded CMS is scheduled to come into operation at the end of 2018.

China Yongfeng Group invests in casting technology. Shandong Laigang Yongfeng Steel, based in Dezhou, has placed an order for two continuous casting machines with SMS Concast, a company of SMS group. The two continuous casters are part of a project aimed at the expansion of the existing plant, where a new, electric arc furnace-based minimill is going to replace the existing production facilities. The new plant will produce 870,000 t/ year of a large variety of demanding high-quality SBQ steel grades, including bearing steel which will be cast on continuous caster No. 1. Continuous caster No. 2 will be used for rebar grades and is aimed to cast 1 million t/year. The 165 mm square billets produced will be processed into bars and wire rod in the new rolling mill, which will also be supplied by SMS group.

degreasing section, the annealing furnace, the pickling section (including a neolyte recovery system and a Pyromars plant), the skin pass mill and leveller, the automation and electrical equipment, and the instrumentation systems.

China Ruifeng orders continuous hot-dip galvanizing line. Shandong Ruifeng Stainless Steel has selected SMS group to supply a continuous hot-dip galvanizing line for steel strip. The line is to be erected in Binzhou in the province of Shandong. Start of production is scheduled for the second half of 2019. The new line will enable Ruifeng to anneal and galvanize 350,000 t/year of cold strip produced on the company’s pickling line/ tandem mill. SMS group will supply all mechanical and process-technological components, including the furnace and air-knife system, and all electrical and automation systems. The strips to be processed in the line will first run through a cleaning section including an electrolytic cleaning segment. Subsequent heat treatment will be accomplished in a horizontal Drever furnace with a direct-fired zone and a radiant-tube zone. A DUMA-Bandzink air-knife system for a homogeneous and precise zinc layer thickness. To be able to coat the strips with both aluminium-zinc or zinc, it is planned to install a change system with two zinc pots. For post-treatment, the line will be equipped with a skin-pass stand, a tension leveller and two vertical roll coaters, as well as an oiling machine in the exit section.

China Fuxin Special Steel to build new cold strip annealing and pickling line. Andritz has received an order from stainless steel producer Fuxin Special Steel to supply a cold strip annealing and pickling line for its Fuxin plant, in the Fujian Province. The line will produce flat products in the 200, 300, and 400 stainless steel series and will have a total annual production capacity of 320,000 t. Production of the first coil is scheduled for the second quarter of 2020. The Andritz scope of supply includes the mechanical equipment, the MPT International 4 / 2018

Anda plans to use the RAW to manufacture jet engine rings made from titanium and nickel-based alloys for use in the aerospace industry. The machine can be operated with a maximum radial rolling force of 500 t and an axial force of up to 250 t. Anda already operates a type RAW 500/400-3000/700 ring rolling mill from SMS group.

China Avic Guizhou Anda Aviation orders ring rolling machine. Avic Guizhou Anda Aviation Forging has awarded SMS group the contract to supply a ring rolling machine of type RAW 400(500)/200(250)-2500/800 DM. Production start is scheduled for mid-2019. The new ring rolling machine will be able to produce seamless rings with diameters of up to 2,500 mm and a maximum height of 800 mm.

China Yongfeng to build EAF plants. Tenova has been contracted by Shandong Laigang Yongfeng Steel to supply two electric arc furnace and Consteel® Evolution plants. In this project, Tenova will introduce the new Consteerrer™ technology, a solution developed jointly by Tenova and ABB. This new technology enhances the Consteel Evolution process with ABB’s ArcSave® non-contact electromagnetic stirring of the furnace’s liquid bath.

India JSW Steel orders environmental technology for sinter plant. Primetals Technologies has received an order from JSW Steel to supply an offgas cleaning system with waste gas recirculation for its existing sinter plant No.4 at the Vijayanagar works in the Karnataka State. It will be designed as a special bag filter-based dry-gas cleaning system for sinter plants. The Meros (maximized emission reduction of sintering) system will treat up to 430,000 Nm³/h and will significantly reduce dust emissions to less than 5 mg/Nm³. Provisions will be made for the future installation of DeSOx, DeNOx, DeOrganic and heavy metals removal systems. With the installation of the sinter plant waste gas recirculation system, up to 50% of the off-gas will be recirculated within the sintering process. The new plant is expected to be started-up in the first quarter of 2019.

Indonesia PT. Sun Rise Mill orders new pickling and cold rolling lines.

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INTERNATIONAL INDUSTRY NEWS Galvalume sheet producer PT. Sun Rise Mill plans to extend its production by the installation of a new push-pull pickling line and a 6-high cold rolling reversing mill. The order for the supply of the mechanical, technological and automation equipment has been placed with Danieli. The reversing mill will be designed for the production of 200,000 t/year of high-quality strip with a minimum strip thickness of 0.2 mm at a maximum strip width of 1,250 mm and maximum tensile strength of 780 N/mm². The push-pull pickling line to be supplied by Danieli will be designed to be extended to a final production of 600,000 t/year. Both lines are scheduled to start operation in early 2020.

Japan JFE prolongs coal supply contract. JFE Steel and Mechel have prolonged their long-term deal for coal supplies by another three years. The agreement will be in force until June 2021. According to the agreement, Mechel will supply JFE Steel up to 1.5 million t/year of metallurgical coals, i.e. coking coal concentrate produced by Yakutugol Holding as well PCI produced by Southern Kuzbass Coal Company. The price will be determined based on the market situation.

South Korea SeAH Besteel to install EAF melting control system. SeAH Besteel is going to upgrade its No. 3 electric arc furnace with the Danieli Q-Melt® automatic melting process control system. The system automatically identifies deviations in process-controlled variables and corrects them according to the best possible practice, to avoid losses or wasting of available energy sources. The suite is comprised of the Q-Reg Plus dynamic electrode regulator with arc coverage control and slag foaming detection, a Lindarc in-situ gas analyzer with laser spectrometer and the Melt-Model process control and optimizer. Installation is scheduled for September 2018.

Uzbekistan TMZ to build cold mill facility. Toshkent Metallurgiya Zavodi (TMZ) and MetProm have awarded Danieli the order to design and supply a new cold mill complex to be installed in Tashkent. The new complex will process 500,000 t/ year of cold rolled galvanized and painted material to meet the requirements of the automotive non-exposed panels, appliances, and construction markets. The mill will include a push-pull pickling section based on Danieli Turboflo technology, a two-stand reversing mill and a hot-dip galvanizing line for the production of CQ, DQ, DDQ, and HSLA coated grades in strip thicknesses from 0.3 to 1.2 mm and widths from 800 to 1,250 mm. The colour coating line will be designed for a capacity of 300,000 t/year. Turnkey construction will be undertaken by MetProm. The new complex is scheduled to come on stream in 2019.

Europe

‹‹‹

News in brief Magnitogorsk Iron and Steel Works (MMK), Russia, has opened a new metal service centre for in the special economic zone of Alabuga, Tatarstan. The centre is a joint project between MMK and Coskunoz-Alabuga, a producer of steel moulded parts for automobile manufacturers. Ilyich Iron and Steel, Ukraine, has put into operation the first phase of its new sinter plant gas cleaning system. The new gas cleaning system, provided by Termokimik, Italy, will allow dust emissions to be reduced by 90% and sulphur oxides by 43%. Nucor Steel, USA, has installed and commissioned a quad laser heads VeriFlex flatness measurement system from Shapeline at its facility in Winton, NC. The system is used at the heat treatment/leveling line.

Belgium ArcelorMittal to build conversion plant for blast-furnace gas. ArcelorMittal has begun construction of new premises at its site in Ghent to house a pioneering new installation which will convert carbon-containing gas from its blast furnaces into bioethanol. The technology was pioneered by Chicago-based company, LanzaTech, with whom ArcelorMittal has entered into a long-term partnership. The technology licensed by LanzaTech uses microbes that feed on carbon monoxide to produce bioethanol. The bioethanol will be used as transport fuel or potentially in the production of plastics. This is the first installation of its kind on an industrial scale in Europe and once complete, annual production of bioethanol at Ghent is expected to reach around 80 million litres. Commissioning and first production is expected by mid-2020.

France ArcelorMittal awards logistics and packaging orders. Harsco has renewed and extended two existing contracts with ArcelorMittal Atlantique

& Lorraine. Additionally four new logistics and packaging contracts have been awarded to Harsco. The six-year contracts are effective immediately.

Germany Schoeller Werk builds four new drawing lines. Schoeller Werk is expanding its production capacities for redrawn precision tubes while enhancing its production efficiency. The company recently commissioned four new continuous drawing lines. The integration of production steps such as cutting, tube surface cleaning and the winding of tubes into coils clearly improves efficiency. The new machines include numerous testing possibilities directly during the forming process. Schoeller Werk produces around 1.5 million m/month of drawn longitudinally welded stainless steel tubes every month. The new high-performance drawing lines will be used primarily to produce high-load control lines and chemical injection tubes for the offshore industry and fuel supply systems for the automotive industry. MPT International 4 / 2018

››› INTERNATIONAL INDUSTRY NEWS

Hungary Ózdi Acélmüvek to upgrade fume treatment plant. Ózdi Acélmüvek (Max Aicher Group) has selected Danieli for the revamping of the fume treatment plant at its facilities in Ózd. The new equipment will be designed to collect all the fumes and dust emissions from the primary and secondary suctions lines of the existing 67 t electrical and ladle furnaces. The project will consist of the design, manufacturing and supply of a new bag filter, axial cyclone, a new common dust collecting system as well as the electrical and automation system. The canopy hood and secondary ducts will also be upgraded. The project is scheduled to be implemented within twelve months.

Italy Arlenico to install wire rod finishing block. Arlenico, owned by Duferco Italia Holding (50%) and Feralpi Siderurgica (50%), has ordered

a four-stand MEERdrive®PLUS block from SMS group, which will be installed in the wire rod line at its Caleotto plant. This will allow the company to serve the market with products of the tightest tolerances and apply the thermomechanical rolling process. MEERdrive®PLUS is a drive concept for modern wire rod production. It uses individual drives with small low-voltage motors for each stand. All finished sizes can be rolled in the block. Thus it will be possible to implement “one-family rolling” in the rolling mill, reducing the otherwise required mill downtimes for size and ring changing.

Italy Feralpi orders wire rod block. Feralpi, producer of rebar and wire rod for construction, is investing in a fourstand MEERdrive®PLUS block to increase the rolling speed and production, be able to extend the size range produced and achieve enhanced final mechanical properties. The block will

be installed after an existing ten-pass block and roll wire rod diameters from 4.5 mm up to 27 mm at speeds up to 120 m/s - also at a temperature as low as 750°C. Excellent tolerances down to 0.05 mm and 50% ovality will be achievable. The new four-pass wire rod sizing block will be served by a sophisticated water cooling line.

Russia Ural Steel melt shop to be upgraded. JSC Ural Steel has contracted Tenova to install two Flexible Modular Furnaces® at the Novotroitsk facility. The objective of the project is to minimize the operating costs through flexible raw material charging and process operation. These furnaces can be operated with a raw material charge mix up to 85% hot metal without use of electric energy. They will replace the existing electric arc furnace operating with 100% solid charge. This modernisation project is an important stage of the integrated investment programme aimed at reorganizing production at Ural Steel.

ALUMINIUM 2018 12th World Trade Fair & Conference

9 – 11 October 2018 Messe Düsseldorf, Germany www.aluminium-messe.com

Organised by

Partners

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C O N V E Y

Q U A L I T Y

Hot Sinter Transport AUMUND Pan Conveyors • Applications upstream or downstream of the sinter cooler • Capacity up to 1,500 t/h and pan width up to 3,000 mm • Withstands material temperatures of up to 1,100 °C • Combined conveying and cooling – increase of cooling capacity • Replacement for vibratory feeders or belt conveyors

New build. Upgrade. Conversion.

AUMUND Foerdertechnik GmbH metallurgy@aumund.de · www.aumund.com

››› INTERNATIONAL INDUSTRY NEWS

Russia NLMK to boost quality and reduce cost of coke production. NLMK Group is designing equipment to implement stamp charging at Altai-Koks. This will boost coke quality and reduce the cost of its production through use of more cost-efficient grades of coking coals. The scope of the project includes an overhaul of the plant, construction of a storage bunker equipped with stamping machines, and installation of conveyors and machines for loading stamped charge into the oven. Instead of the conventional top charging method, stamped charging involves feeding of compacted coal briquettes into the oven horizontally. This ensures better quality of coke and a reduction in the share of expensive grades of coal, as stamped coke particles bake better. The upgraded coke plant will be equipped with highly efficient, advanced systems for capturing and treating off-gases. Operational start-up is planned for the second half of 2019.

Russia NLMK develops e-commerce. NLMK has been operating an e-commerce platform since 2012, based on the ‘Client-Info’ RMS system. Access to the platform is open to large clients that have long-term established relations with NLMK. Other buyers who did not previously have the opportunity to use the e-commerce service can now access the online store. The store is a fully functional online self-servicing system that enables buyers to place orders for products of up to 20 t, eliminating the need for additional processes outside the system. The e-marketplace offers the buyers a transparent pricing process based on the cost of delivery, additional services, and discounts. Both registered and non-registered customers can view product prices.

Russia NLMK to increase slab capacity. NLMK has launched a project to upgrade its continuous casting line (CCM-9) at its Lipetsk production site. MPT International 4 / 2018

SMS group was selected as the supplier of engineering and main process equipment for the project. The upgrade will enable an 80% boost in the capacity of the line to 1.8 t/year, and the production of heavy gauge slabs up to 400 mm thick and up to 2,800 mm wide, which will be rolled into plates used for the production of large-diameter pipes, wind turbines, sea vessels, and offshore drilling rigs. The reconstruction will improve process logistics and cut repair and maintenance costs.

ing mill will operate in hot charging mode and produce up to 915,000 t/year of wire rod from 5.5 to 20 mm dia. The mill, made up of 16 cantilever stands, will deliver superior finishing/sizing products via a TMB Twin-Module Block. Danieli Automation will supply all electrical equipment including substation, advanced process control and equipment control systems. Production is expected to start up by the second half of 2020.

Sweden Russia Severstal to modernize hot strip mill. Primetals Technologies has received an order from Severstal to modernize the company´s hot strip mill “HSM 2000” in its Cherepovets steel works. Main targets are to improve tolerances of product width and thickness as well as to improve overall production quality. Also, operational safety and working conditions will be enhanced. To these ends, an edger of the hot strip mill will be upgraded, short stroke HAGC (hydraulic gap control cylinders) will be installed in the finishing mill, and the cooling line will be outfitted with a power cooling unit. The existing level 2 system will be upgraded to extend lifetime and include present technological models. Profile and flatness control models will be added as new functions.

The Netherlands Van Merksteijn orders new green steel minimill. Van Merksteijn International has awarded Danieli the order to supply a scrap-based steel minimill for the production of 900,000 t/year of wire rod. The new 1 million t/year minimill and auxiliary plants will be built at the seaport of Eemshaven in the north of the Netherlands. It will be equipped with a 100 t EAF fed by an endless scrap charging system, a ladle furnace, fume treatment plant, and a three-strand continuous billet caster - with provision for a fourth strand for a production increase to up to 1.2 million t/year. Fed by 160mm square billets, the compact roll-

SSAB to upgrade strip leveller. SSAB is going to upgrade its pickle line tension leveller with two straightener sections from Fagor Arrasate. The new equipment will enhance flattening performance and reliability. It will be designed for levelling up to 1,650 mm wide and up to 12.7 mm thick hotrolled black or hot-rolled pickled and oiled strip. This is achieved by eight backed-up work rolls with a four over four roll configuration and a 150 mm roll diameter.

Turkey Kroman Çelik to enhance wire rod production. Kroman Çelik has selected Danieli for the modernization of its high-speed wire rod mill, supplied by Danieli 2006. The upgrade project will include the addition of a twin module block and a newly designed high-speed shear before the sizing block. The new systems will guarantee a size tolerance of ± 0.10 mm, and 60% out-of-roundness on 4.5 mm dia. wire rod at production speeds of up to 115 m/s. Kroman Çelik is going to expand its wire rod range from currently 5.5 – 20 mm to 4.5 – 26 mm dia. and widen its steel grade production to premium grades. This plant will perform thermo-mechanical rolling. It will be in operation by the summer of 2019.

Turkey Kardemir invests in off-gas cleaning technology for sinter plants.

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››› INTERNATIONAL INDUSTRY NEWS

Kardemir has placed an order with Primetals Technologies to supply two new Meros off-gas cleaning plants for sinter plants No. 1 and No. 2, and to upgrade a previously ordered Meros plant at sinter plant No. 3. Each Meros plant will be able to treat 400,000 Nm³/h of sinter off-gas, reducing SOx by more than 90% as well as delivering extremely low dust emissions. The two new Meros plants will be designed to use sodium bicarbonate as desulphurization agent, while the existing system installed at sinter plant No. 3 will be upgraded to employ sodium bicarbonate instead of lime in the future. Start-up of the equipment is to take place by the end of 2018.

United Kingdom Liberty receives first steel shipment from Australian sister plant. The first in a series of shipments from Liberty’s sister plant at Whyalla, South Australia, will enable the Newport mill in South Wales to begin ramping up production of hot rolled coil, as it waits for the installation of its own liquid steel making furnaces. Delivery of the 24,000 t cargo is a milestone in the development of a global integration strategy by the GFG Alliance, which includes Liberty. Whyalla will supply Newport with around 100,000 t of slab in the first year, allowing it to boost output of coil, initially by about a third, to meet growing UK and EU demand for steel from industries such as construction and heavy engineering. The Newport plant is also going to upgrade its rolling mill as part of a wider development plan that will eventually include the installation of an electric arc furnace to recycle scrap steel.

Companies Saarland’s steel industry takes stake in cyber security company. Along with other investors, SHS Ventures has acquired a stake in the hightech company Rhebo on behalf of the steel industry in the German state of Saarland. Rhebo, which is based in MPT International 4 / 2018

Leipzig, Germany, is specialized in safeguarding control networks of industrial facilities against disruption to operations and cyber attacks. Rhebo is listed by Gartner, global leader in IT market research, as the only German manufacturer of anomaly detection systems for industrial control networks.

Stelco acquires previously leased lands. Stelco has completed the acquisition of lands which are beneficially owned by Legacy Lands Limited Partnership and on which Stelco conducts its operations in Hamilton and Nanticoke, Ontario. These include lands that contain the Hamilton Works blast furnace and cast houses, as well as developable lands and port facilities. Existing lease arrangements have been terminated and the associated rental payments cancelled. The acquisition provides Stelco with more flexibility to utilize the lands for its existing and future operations.

Paul Wurth acquires cokemaking assets of Koch Industrieanlagen. Paul Wurth has purchased assets of the coke oven machine segment of DSD Koch Industrieanlagen, based in Saarlouis, Germany. Paul Wurth takes over the patents and property rights, references, drawings, licenses, brand name and know-how of the company, which is specialized in coke oven machines for stamp charged batteries. After the acquisition in 2014 of the Schalke coke oven machine technology for top charging batteries, this recent transaction completes Paul Wurth’s expertise and portfolio to include charging cars, charging-pusher machines, stamping systems and stamping-charging-pushing machines.

Cleveland-Cliffs sells assets in Australia. Cleveland-Cliffs has entered into a definitive agreement for the sale of substantially all of the assets of its Asia Pacific Iron Ore business to Australian mining services company Mineral Resources Limited. The sale of these assets to Mineral Resources marks Cliffs’ exit from the Australian iron ore business, and represents the

final step in the implementation of its US iron ore-centric strategy.

Sales agreement between Tenova and Polytec Robotics. Tenova and Polytec Robotics, a brand of BM S.p.A, have signed an agreement for the implementation and sale of robotics solutions for steel plants. Thanks to the collaboration with Polytec Robotics, Tenova is moving forward in the development of key technologies for Industry 4.0 solutions in the metals industry. The jointly offered PolyTEN range of solutions allows steelmakers to increase safety in the furnace area, along with improvements in productivity and cost reduction.

Increase in world DRI production. World DRI production increased by more than 14 million t over 2016, exceeding 87 million t in 2017, according to data collected by Midrex Technologies and audited by World Steel Dynamics. This significant increase is credited to the impact of new plants in Iran, Russia and USA, as well as improved conditions in Egypt and India.

Mannesmann Stainless Tubes acquires SOTEP. Mannesmann Stainless Tubes, Germany, a subsidiary of the Salzgitter Group, has acquired the stainless-steel tubes manufacturer SOTEP (Société Technique d’Etirage de Précision), based in Issoudun, France. SOTEP, specialist suppliers of cold finished seamless stainless-steel tubes, is positioned in the premium segment for sectors such as aerospace, power plants, oil and gas.

NSSMC integrates Nissin Steel and changes name. Nippon Steel & Sumitomo Metal Corporation (NSSMC) and Nisshin Steel have conducted a share exchange effective January 1, 2019. As a result of this transaction, Nisshin Steel will become a wholly owned subsidiary of NSSMC. NSSMC has also determined to adopt a new and more inclusive trade name befitting a

INTERNATIONAL INDUSTRY NEWS steelmaker with origins in Japan and an emphasis on continuing growth in global markets. The new trade name of NSSMC is Nippon Steel Corporation. For purposes of consistency in branding and the fostering of a sense of unity throughout the group, Nisshin Steel will be named Nippon Steel Nisshin. The name changes will become effective on April 1, 2019.

Outokumpu acquires Fagersta Stainless wire rod mill. Outokumpu and Sandvik have signed an agreement for Outokumpu to purchase full ownership of Fagersta Stainless wire rod mill in Sweden. Fagersta Stainless is currently a 50/50 joint venture owned by Outokumpu and Sandvik Materials Technology. Fagerstaâ&#x20AC;&#x2122;s product offering complements well Outokumpuâ&#x20AC;&#x2122;s ASR wire rod mill in Sheffield, UK.

Steel Dynamics completes acquisition of CSN Heartland flat roll operations. The acquisition of Heart-

land Steel Processing, formerly known as Companhia Siderurgica Nacional Heartland, by Steel Dynamics has been completed. Located in Terre Haute, Indiana, Heartland produces various types of higher-margin, flat rolled steel by further processing hot rolled coils into pickle and oil, cold roll, and galvanized products. The acquisition will expand Steel Dynamicsâ&#x20AC;&#x2122; annual shipping capacity and its value-added product portfolio through the addition of lighter-gauge and greater width steel strip.

Tata Steel Europe explores potential sales of non-core businesses. Tata Steel Europe has conducted a detailed portfolio review of all its businesses to assess the strategie fit and the future potential. Based on this review, Tata Steel Europe has begun a process of seeking buyers for business units which supply products to niche markets, allowing the company to continue to strengthen its focus on strategic strip products and markets. The sale process will cover five business units: Cogent, a manufacturer and processor

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of electrical steels based in Newport, South Wales (UK), Burlington, Canada and Surahammar, Sweden; Kalzip, an aluminium roofing and cladding business based primarily in Koblenz, Germany; Firsteel which coats steel for kitchen bakeware based in Walsall West Midlands, UK; Tata Steel Istanbul Metals, a coil coating company, based in Adapazari, Turkey; and Engineering Steels Service Centre, based in Wolverhampton, West Midlands, UK.

Outokumpu and BĂśllinghaus Steel widen partnership. Outokumpu Long Products and BĂśllinghaus Steel have entered into an agreement under which BĂśllinghaus Steel will act as a representative for Outokumpu cold drawn hexagon and square bars in Germany and UK. Outokumpuâ&#x20AC;&#x2122;s range of special shapes bars covers 8 mm â&#x20AC;&#x201C; 25 mm size range and will be sold by BĂśllinghaus Steel to the market in addition to their existing product range. This agreement adds to the longstanding partnership between the two companies, which has existed for some 20 years.

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››› INTERNATIONAL INDUSTRY NEWS

Personalities Appointment of new AIST president. James F. Dudek, vice president, asset revitalization and manufacturing excellence, United States Steel Corporation, has been appointed president of the Association for Iron & Steel Technology (AIST) for 2018–2019. James F. Dudek succeeds Randy C. Skagen, vice president and general manager, Nucor Steel Tuscaloosa. Dudek plans to focus on attracting young talent into the industry during his term as AIST president.

New general manager of Liberty Steel Georgetown. Revansidha “Rohit” Gulve joined Liberty Steel Georgetown as the new general manager. The Georgetown mill is preparing to get the previously shuttered melt shop, casters and rolling facilities ready for recommissioning. Gulve joined the operation from Gerdau Steel in Beaumont, Texas.

NLMK appoints new director. NLMK has appointed Dmitriy Kolomytsyn as director for investor relations and capital markets. Dmitriy Kolomystyn previously held the position of head of corporate development. Sergey Takhiev, who previously headed NLMK Group’s investor relations, has decided to continue his career in another company.

tlesworth, currently Big River Steel’s general manager of the Carbon Sales Group, will become the company’s new chief commercial officer.

New board chairman at voestalpine. Chairman of the management board of voestalpine, Wolfgang Eder, will renew his contract until July 3, 2019 (date of the Annual General Meeting) and subsequently step down from the management board. The supervisory board will recommend to the Annual General Meeting 2019 that it elect Eder to the supervisory board as the new shareholder representative. If elected, he could take over the chairmanship of the supervisory board from Joachim Lemppenau, after a two-year “cooling off period.” Herbert Eibensteiner is to become new chairman of the management board on July 3, 2019. Eibensteiner has served on the management board of voestalpine AG since 2012.

New general manager of Aumund Corporation. Simon Shipp has taken over from Geoffrey Conroy as general manager of Aumund Corporation USA, a subsidiary of Aumund Fördertechnik, based in Rheinberg, Germany. Geoffrey Conroy retires after twenty years as general manager of Aumund Corporation. He will remain on board in a consultant role. Simon Shipp (Photo: Aumund)

operations has taken over full responsibility for the operative sales business. Hendrik Schafstall and Michael Wohlmuth founded Simufact Engineering in 1995. Since 2015, Simufact is part of the US-based MSC Software family.

Executive appointment at NSSMC. Shinji Kido, currently general manager, head of the bar & wire rod division at the Yawata Works, has been appointed as executive officer.

Key executive appointments at ArcelorMittal. Robrecht Himpe has retired from his duties as a member of ArcelorMittal’s executive management committee and as CEO, ArcelorMittal North America, and CEO, AM/NS Calvert, after 37 years of service with the group. Brad Davey will succeed Robrecht Himpe as CEO, ArcelorMittal North America, and Howard MacNair will take up the position of CEO, AM/NS Calvert.

Messe Düsseldorf has new operative managing director. Wolfram Diener has been appointed as the new operative managing director of Messe Düsseldorf. He succeeds Joachim Schäfer, who is going to retire. Wolfram Diener will take over the divisions that Joachim Schäfer has been responsible for since 2006, including the trade fairs GIFA, METEC, THERMPROCESS, NEWCAST, Pump Summit, Valve World Expo, wire and Tube. Wolfram Diener

Dmitriy Kolomytsyn

New chief commercial officer at Big River Steel. Mark Bula, chief commercial officer of Big River Steel, will be exiting the company to pursue new entrepreneurial opportunities. Mark Bula was a member of the initial development team. Keith ShutMPT International 4 / 2018

CEO transition at Simufact Engineering. At Simufact Engineering, Michael Wohlmuth has handed over his positions as CEO and managing director to co-managing director and CTO Hendrik Schafstall. Michael Wohlmuth will take over responsibilities as vice-president for strategic business development. At the same time, Stefan Zimmer in his role as senior director global sales and

Events ›

25 – 27 September 2018 Vienna, Austria Organizers: The Austrian Society

PIONEERS AT HEART

Experience matters. We believe imagination matters too. Curious minds question everything to ďŹ nd groundbreaking solutions. There is still so much to discover. So many great opportunities. We love the heat and we love the cold. We love the glow and we love the dust. We love the quantum leaps and the small steps. We love to innovate and we love to be challenged. We love metals and we will change the way you produce it. We are pioneers at heart.

contact@primetals.com

››› INTERNATIONAL INDUSTRY NEWS for Metallurgy and Metals ASMET www.icsti2018.org ICSTI 2018. The International Congress on the Science and Technology of Ironmaking will bring together plant operators, plants suppliers and R&D experts. Topics discussed will include cokemaking, iron ore production and handling, sintering, steelmaking, recycling, as well as automation and digitalization in coke and ironmaking.

›

10 – 12 October 2018 Taranto, Italy Organizers: Italian Association for Metallurgy (AIM) www.aimnet.it/eosc2018

EOSC 2018. The 8th European Oxygen Steelmaking Conference will focus on the latest development in primary steelmaking, ladle metallurgy, plant operation experience, automotive and on-line process analyses, improving steel quality and environmental protection.

›

16 – 19 October 2018 Stockholm, Sweden Organizers: Jernkontoret www.icrf2018.com

ICRF 2018. The Ingot Casting, Rolling and Forging Conferences are organized by different European metallurgical societies and associations. ICRF 2018, held in Sweden, will include the following topics: metallurgy of ingot casting, casting technology, additives for ingot casting, remelting technologies, rolling and forging of ingots, heat treatment, simulation, etc.

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17 – 19 October 2018 Jakarta, Indonesia Organizers: Messe Düsseldorf Asia and WAKENI www.indometal.net

indometal 2018. At the international metal and steel trade fair for Southeast Asia, the show floor will be represented by: foundry plants and equipment, die-casting machines and MPT International 4 / 2018

melting operations, to plant manufacturers, suppliers of plant and equipment for iron making, steel making and non-ferrous metal production and as well as rolling and steel mills. Additionally, industrial furnaces, industrial heat treatment plants and thermal processes, casting machinery and pouring equipment can also be expected.

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23 – 26 October 2018 Hanover, Germany Organizers: Mack Brooks Exhibitions Ltd www.euroblech.com

EuroBLECH 2018. Industry experts, manufacturers and suppliers will come to Hanover to discover the latest technological developments in sheet metal working and processing, invest in new machinery for modern manufacturing and exchange expertise. Industry 4.0 will be one of the major focus points at the show as the industry is adjusting to the development towards smart manufacturing and digitalization.

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25 – 27 October 2018 Istanbul, Turkey Organizers: Hannover-Messe Ankiros Fuarcılık A.S. www.ankiros.com

ANKIROS 2018. 14th international trade fair for iron, steel and foundry technology, machinery and products. The leading event in the region is staged together with ANNOFER 2018 – trade fair for non-ferrous metals technology, machinery and products, and TURKCAST 2018 – foundry products trade fair. Together the trade-fair trio is one of the biggest metallurgy events in Eurasia.

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5 – 7 November 2018 Cartagena de Indias, Colombia Organizers: Alacero – Latin American Steel Association www.alacero.org

Alacero-59. The Latin American Steel Conference will bring together

INTERNATIONAL INDUSTRY NEWS the high-ranking representatives of the continent’s steel sector . The conference will be staged together with ExpoAlacero, the industry exhibition that brings together the most important companies of the steel value chain.

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21 – 23 November 2018 Vienna, Austria Organizers: The Austrian Society for Metallurgy and Materials www.mamc2018.org

Metal Additive Manufacturing Conference. The 3rd edition of the conference will again focus on industrial perspectives in additive technologies.

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27 – 29 November 2018 Mumbai, India Organizers: Messe Düsseldorf www.wire-india.com www.tube-india.com www.metallurgy-india.com

wire India, Tube India and Metallurgy India. This metal trade fair trio will cover plants and machinery for the metallurgy industry, the latest technologies and services from all segments of the wire and cable industry as well as pipe and tube processing and trade.

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29 – 30 November 2018 Bergamo, Italy Organizers: Italian Association for Metallurgy (AIM) www.aimnet.it/cleantech4.htm

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Clean Tech. The 4th European Conference on Clean Technologies in the Steel Industry will provide a forum for researchers and steel manufacturers to review recent developments on clean technology, energy efficiency and CO2 reduction, material efficiency and product life cycles.

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22 – 24 January 2019 Mumbai, India Organizers: FICCI www.ficci.in

India Steel 2019. Fourth international exhibition and conference on steel industry – an industry event to meet face-to-face with key individuals involved in the production and processing of iron and steel.

Setting The Standards For Highest Efficiency In Thermal Processing

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MPT International 4 / 2018

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş ADDITIVE MANUFACTURING

Metal powder production technology to feed 3D printing factories The powder atomization technology is the initial process in the value chain of additive manufacturing. SMS group has developed and successfully started up an industrial-scale pilot plant for the production of high-quality metal powder suited for 3D printing of metal parts. An demonstration centre is going to be built to demonstrate the complete SURFHVV FKDLQ SRZGHU SURGXFWLRQ DGGLWLYH PDQXIDFWXULQJ DQG Ć&#x201A;QLVKLQJ LQFOXGLQJ D dedicated automation system

3D design scheme of the metal powder plant

The fine, gray powder looks unspectacular, but it is characterized by some very demanding properties. The extremely homogeneous metal powder

Robert Bause, SMS group GmbH, MĂśnchengladbach, Germany Contact: www.sms-group.com E-mail: robert.bause@sms-group.com

MPT International 4 / 2018

is the basis of Additive Manufacturing â&#x20AC;&#x201C; the process of 3D printing of metal. The powder is made up of minute, perfectly spherical balls measuring only 15 to 45 micrometers (Îźm). Hard to imagine, these microscopic particles are produced in a 13 meters tall and highly complex plant involving an extremely sophisticated technique. SMS group has recently commissioned a pilot plant for the industrial-scale produc-

tion of this type of metal powder. It marks a milestone for SMS group because only a high-quality powder can make a high-quality 3D printed component. â&#x20AC;&#x153;Our objective is to master â&#x20AC;&#x201C; and allow our customers to master â&#x20AC;&#x201C; the complete process chain of this innovative technology,â&#x20AC;? says Norbert Gober, SMS group. â&#x20AC;&#x153;This is why we deliberately decided not to build a small-scale but an industrial-scale pilot plant. In this

3D image of a future Additive Manufacturing series production factory including atomizing plant and 3D printers

way we can develop the atomizing process under real conditions, i.e. at high temperatures and specific pressures and in long production cycles. We cooperate with Additive Industries who provide selective laser melting systems for 3D metal powder printing. We intend to set up a demonstration centre comprising all process steps of the value chain to manufacture AM parts.”

Sophisticated process technology based on profound metallurgical know-how The function of the new pilot plant built by SMS group is to atomize powder. Its main components are a vacuum induction furnace with a crucible and a tundish, atomization equipment, vacuum pumps, cyclones, gas coolers, bag filters, air separators and screens for powder grading. First, the plant melts the raw material (i.e. base metals and the alloys) inductively under vacuum. The vacuum technology is key to achieving an ultra-clean product and reliably preventing the material from reacting with oxygen. Ultra-clean powder can only be produced under inert conditions. Otherwise oxide inclusions and other contaminations would result in spoilt powder. Especially in this area, SMS Mevac’s expertise and know-how

in secondary metallurgy technology has contributed largely to the successful development of the process. In the next step, the liquid metal is atomized in a jet nozzle of just a few millimeters by means of pure argon. This process produces spherical particles in the micrometer range. The particles cool down to microscopic spheres – the metal powder. The powder undergoes further treatment and is graded by grain sizes, resulting in fractions of high-purity product of perfect spherical shape, with defined grain sizes between 15 and 45 micrometers, an exact chemical analysis and free from inclusions and satellites (agglomerated material). The plant is capable of producing powder from various metals: superalloys, Ni-based alloys, Cobalt-Cromium alloys, special steels, maraging steels and copper alloys. Markus Hüllen, Vice President 3D Competence Centre at SMS group: “The plant allows us to develop new alloys with new properties under real production conditions. At the same time we are going to implement an automated, seamless quality control system covering the complete process chain to produce additively manufactured parts. This type of consistent documentation and 100 percent traceability are an absolute must, for example, for components produced for the aerospace industry.“

The core process of metal powder production: atomization of the liquid metal

Integrated production and logistics chain for powder production and Additive Manufacturing Markus Hüllen: “We think beyond the stage of powder production. In order to be able to produce high-end, high-performance components from the powder, it is essential that the powder does not get in contact with oxygen also in the downstream production processes. Therefore we have been developing solutions that ensure that the powder is safely protected by an inert atmosphere until it is proMPT International 4 / 2018

››› ADDITIVE MANUFACTURING

cessed in the 3D laser printer. This involves a great effort, but guarantees the high quality level as required, for example, for safety-critical components.“ SMS group is going to set up a demonstration centre comprising the complete process chain of: ▪ powder production, ▪ powder handling, ▪ additive manufacturing,

ers complete plants for Additive Manufacturing series production on a turnkey basis, by integrating the entire process chain from powder production down to the finished products while ensuring series production at a high, reproducible quality level. The pilot plant will allow us to optimize the processes so as to maximize productivity and minimize total costs. Our customers will receive

Metal powder for innovative, additively manufactured components

Agile project team for the promotion of Additive Manufacturing For many years, SMS group has been very active in the field of Additive Manufacturing. A young and dedicated research and development team is advancing and promoting this innovative technology within the company. The team members do not limit their activities to investigating which new and optimized components could possibly be produced by Additive Manufacturing (AM). They rather dedicate a great deal of their activities to introducing a new way of thinking in the design and engineering departments. Norbert Gober, initiator of SMS group’s AM team: “The AM team tests out new approaches, scrutinizes common manufacturing chains and acts very flexibly and agilely. Since shortly, we are equipped with a powerful 3D printer, which has been provided by our cooperation partner Additive Industries. With this metal-powder bed printer, we will in future be able to implement new concepts right here, in-house.” Being a manufacturer of plants and machinery for the steel and NF-metals industry, SMS group focuses on components made of metallic materials because the machines and equipment will be subjected to extremely high loads during operation. The performance potential of the materials are investigated and tested under field conditions. Besides metals, also alternative materials, such as plastics and ceramics, are examined.

Additive Manufacturing technologies at a glance

Additively manufactured CONTIROD® nozzles for copper-wire rod mills

▪ heat treatment and machining, ▪ inspection, quality checks, ▪ logistics and, last but not least, a dedicated automation system. Nobert Gober: “Being the leading partner in the world of metals, our objective is to offer our customMPT International 4 / 2018

modular, scalable solutions tailored to their individual requirements. With our world-spanning service and support network, we are always readily available for our customers to accompany them along their way into the world of series production by Additive Manufacturing.“

Additive Manufacturing means producing an object based on digital 3D design data by adding material layer by layer. There are various AM techniques available. However, for the time being a few main techniques are commonly used for plant and heavy machinery applications: selective laser melting in a powder bed and the laser melting deposition process. In selective laser melting (SLM), layer by layer of a high-purity homogeneous metal powder is selectively, i.e. at defined positions, melted by a laser. In this way, the component is gradually built up. With the powder bed technique it is possible to produce compo-

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››› ADDITIVE MANUFACTURING

nents of complex and unprecedented structures, which would not be feasible by conventional processes. In laser metal deposition (LMD), metallic powder or wire is fed via nozzles and melted by lasers at defined spots. The unit that accommodates the laser and the nozzle may be actuated by a robot. Laser metal deposition achieves high build-up rates, but it is limited in terms of fineness. For plastics-based components, the selective laser sintering (SLS) process is available. This technique is very similar to the powder bed process using metals, the only basic difference being that it uses a special powder of plastics material melted by a laser. AM promotes a new approach for the component design. Sarah Hornickel, member of the AM team at SMS group: “There are almost no restrictions by any manufacturing constraints. We neither have to consider the geometry of the input stock, nor the specific process limits during manufacturing by forging or milling or drilling. Therefore we can start out from the function the component is going to perform. We adopt a creative technological approach to designing. In other words: We develop the perfect shape for the function at hand ready to be additively manufactured.“

Components of less weight, higher speed and with integrated functions The AM team has already implemented a great number of innovative solutions, which impressively demonstrate what advantages Additive Manufacturing processes provide. Their most important benefits include: significant weight reduction of dynamically actuated components, functional features are directly manufactured into the part during the 3D printing process, improvement of energy efficiency as a result of optimized flow patterns and minimized weight, dramatically shortened delivery periods and the possibility to produce virtually any where in the world. Nina Uppenkamp, AM team member, describes a project which has benefited from the full range of advantages provided by Additive Manufacturing: “In a copper wire rod mill, annular gap nozzles are used for wire cooling and MPT International 4 / 2018

water removal. The conventional component consisted of several parts and the air gap adjustment required the use of a shim. Setting up and properly adjusting the component involved a great effort by our customer. Our task was twofold: First, the component design was to be simplified and, second, the adjustment was to be accomplishable without the aid of a shim. We pro-

er for wire rod mills featuring a contour-adapted design with integrated nozzles has been performing excellently. By using Alumide®, a blend of aluminium powder and polyamide powder, the AM version of the component is lighter and cheaper than the conventional solution. An example from EAF steelmaking: For SIS injectors used in steel melt-

Conventionally (left) and additively manufactured roll cooling headers

duced a nozzle by AM which requires only 35 mm of installation space – versus the previous 65 mm, weighs only 0.85 kg instead of 2.5 kg and is of monolithic design. The CONTIROD® nozzle no longer consists of six parts. It is now one piece which does not require preassembly or adjustment of the nozzle prior to its installation in the plant. The new nozzles are already successfully in operation at BIRLA COPPER in India. They are less noisy than the previous ones and meet or even exceed all performance specifications. As we have manufactured the nozzles from a high-strength, wear-resistant material, they can remain in service much longer than their predecessors.“

AM substitutes for conventionally manufactured parts Also the other projects implemented so far have provided extremely promising results: A new roll cooling head-

ing, the size of the component was reduced by 60%. The injectors now come in one piece. In the past they consisted of eight individual parts. Another example: Lubrication rings of tube welding plants can be made smaller – without compromising their performance capacity. Also, the Technical Service of SMS group benefits from the lower weight and dramatically reduced delivery times for various spare parts. The projects and examples mentioned above show where Additive Manufacturing is heading. Norbert Gober strongly believes that the development will still pick up momentum in the near future: “There are several driving forces. At the universities, future design engineers can nowadays avail themselves of printers to print the parts they design and immediately examine the result in the form of a real component. The growing demand for AM components will in turn spur the development in printer technology. We see several new printer tech-

ADDITIVE MANUFACTURING

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nologies pop up every year. Maybe, another energy source will soon appear on the scene in addition to the laser. The young people coming from the universities will bring with them new ideas, concepts and methods that will change attitudes and strategies in the companies. Nothing is backwards oriented, everything is moving forward at full vigour. I believe that conventional manufacturing will become increasingly open to this trend and that there will be many more links between conventional manufacturing and AM. “

Additively manufactured components are already used in a number of industries, including the aerospace industry, the automotive industry, medical engineering, prototype and tool making, and plant and mechanical engineering. Both, powder atomization technology and Additive Manufacturing provide a very promising market

Section through an additively manufactured SIS injector

potential. According to a study published in 2017 by Roland Berger Strategy Consultants, the market for Additive Manufacturing grew from 0.8 billion to 5.5 billion euros during the period 2004–2016. This corresponds to a CAGR (Compound Annual Growth

Rate) of about 20%. However, this is only the beginning. Based on several institutes’ forecasts, which the study has evaluated, the market growth is predicted to experience a sharp rise reaching a global level of 24.1 to 28.3 billion euros by 2022.

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MPT International 4 / 2018

››› SAFETY

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Five main causes of injury in the steel industry (Picture by courtesy of worldsteel)

Demonstrate your expertise with professional reprints Take advantage of the excellent reputation of MPT Metallurgical Plant and Technology

Have we reported about your company, your products or systems in one of our journals? Or have we published an article authored by yourself? Whatever may be the case: Why not produce a reprint (print and/or digital version) of the published article and use it as a highly effective marketing tool. We are happy to provide you with more detailed information and discuss individual design options with you.

Interested? Then visit our website www.mpt-international.com (About us) or talk directly to our staff. Katrin Küchler · Phone: +49 211 6707- 563 · katrin.kuechler@stahleisen.de

A brand of jbd Gesellschaft für Medien und Kommunikation mbH Graf-Recke-Straße 82 · 40239 Düsseldorf, Germany · Phone: +49 211 6707-563 · Fax: +49 211 6707-597

››› CONTINUOUS CASTING

New casting plants start slab production in Rizhao, China The fourth Arvedi ESP plant started production at Rizhao Steel in April this year. This new casting and rolling plant will produce 1.7 million t/year of high-quality, ultrathin hot strip with thicknesses down to 0.8 mm and widths of up to 1,300 mm. Also, neighbouring Shandong Iron & Steel Group Rizhao recently commissioned new continuous casting capacity, namely two 2-strand continuous thick slab casters designed to produce 4.6 million t/year of slabs.

Two-strand continuous slab caster from Primetals Technologies at Shandong Iron & Steel Group Rizhao Co. Ltd.

Shandong Iron and Steel Group Co Ltd, Jinan, China Contact: www.sdsteel.cc Rizhao Steel Holding Group Co Ltd, Rizhao, China Contact: www.rizhaosteel.com/en/ Primetals Technologies, Ltd., London, UK Contact: www.primetals.com SMS group, Düsseldorf, Germany Contact: www.sms-group.com

MPT International 4 / 2018

Rizhao is a prefecture-level city in the south of Shandong coastal province, China. It is situated on the coastline along the Yellow Sea, and features a major seaport. The city plays a major role in the plan by the Shandong provincial government to streamline its steel sector, one of the country’s largest and most fragmented. The province of Shandong has pledged to cut 150 million t of annual steel capacity by 2020 as part of the government’s efforts to tackle pollution and make the bloated steel sector more efficient.

Shandong Iron & Steel Group Rizhao (Shandong Rizhao Steel) China’s state-owned Shandong Iron & Steel Group – commonly known as Shandong Steel - was formed by the merger of the state-owned parent companies of Laiwu Steel and Jinan Iron and Steel. The companies are all located in the province of Shandong. Shandong Iron & Steel Group ranked twelfth in terms of steel output with crude steel production of 21.68 million t in 2017, according to worldsteel. In the past ten years, Shandong Iron & Steel Group has shut down the capacity of more than 6 million t at Jinan to make way for new capacity in Rizhao base. In 2017, after completing a year-long production upgrade, Shandong Iron & Steel Group Co Ltd concluded the shut-down of all production lines of its subsidiary Jinan Iron and Steel Group Co Ltd. Of the 5.7 million t steel capacity at Jinan, around 4 million t have been transferred to a new site at its Rizhao Quality Steel Products Base on the east coast. All 33,000 employees of Jinan Iron and Steel Group were facing relocation because of the move of the production to Rizhao. With total investment of 56.7 billion yuan ($8.34 billion), the Shandong Iron & Steel Group Rizhao plant will have iron-making capacity of 8.1 million t, rolled steel capacity of 8.5 million t and finished steel capacity of 7.9 million t. Shandong Rizhao Steel started up part of its production in the second half of 2017 and is to become fully operational during 2018, as part of a layout optimization and capacity upgrade plan at Shandong Iron & Steel Group.

CONTINUOUS CASTING Rizhao Steel Rizhao Steel Co., Ltd. (Rizhao Steel), a company of the Rizhao Steel Holding Group, is located around 30 km outside of the port of Rizhao in the south of Shandong province. The company has a production capacity of approximately 15 million t of crude steel. Rizhao Steel’s product portfolio includes hot-rolled coils, wire rod and small H-beams, which are mainly sold to Chinese customers. Rizhao Steel was founded by Billionaire Du Shuanghua. In 2003, Rizhao Steel started to be constructed on a stretch of seashore and only used 181 days to successfully go into operation, thereby creating a miracle in the industrial sector of metallurgy. During the years Rizhao Steel has become an integrated iron and steel works with a combination of iron ore sintering, ironmaking, steelmaking, rolling, and other well-equipped facilities. Up to now, Rizhao Steel has reached an annual production capacity of 15 million t of steel. In 2009, Shandong Iron & Steel Group signed an agreement to acquire a 67% stake in Rizhao Steel. Both companies agreed on asset restructuring, reorganization and cooperation. The agreement particularly indicated the strategy of Shandong’s industry shift from the inland cities to coastal sites.

4th Arvedi casting-rolling plant starts up at Rizhao Steel At Rizhao Steel, the fourth Arvedi ESP (Endless Strip Production) plant supplied by Primetals Technologies was started up in April 2018. The new Arvedi ESP plants enables Rizhao Steel to further expand its production capacities for high-grade thin strip products and production of cold-rolled substitutes. The casting and rolling plant will produce 1.7 million t of high-quality, ultra-thin hot strip with thicknesses of down to 0.8 mm and widths of up to 1,300 mm. The product portfolio ranges from carbon steel to HSLA (highstrength low alloyed) grades. In contrary to the lines No. 1, 2, 3 constructed earlier [1], the 4th Arvedi ESP plant was adapted to changes in liquid steel production and space availability during the ongoing project. To cater to capacity shifts of Rizhao´s liquid steel production and a change in plant setup, the Arvedi ESP plant was reengineered for the use of

larger ladles as well as for decreased space availability during the ongoing project. The plant features a Through-Process Optimization solution (TPO) and Industry 4.0. The order was placed with Primetals Technologies in 2014. Primetals Technologies was responsible for the engineering of the Arvedi ESP plant and supplied the mechanical equipment, the media systems, technology packages and the automation technology. The casting and rolling lines are controlled with the aid of consistent and integrated basic (level 1) and process automation (level 2). This ensures a finely coordinated interaction of the casting and rolling process. The installed Through-Process Optimization solution (TPO) compromises the intelligent Through-Process Quality Control System (TPQC), a newly developed Industry 4.0 IT system and Through-Process Know-How (TPKH) modules. The TPO system will continuously monitor and manage product quality by recording all process parameters as well as measured production and product data, starting from the liquid phase up to the final processing lines. The Arvedi ESP system produces hot strip directly from liquid steel in a continuous and uninterrupted production process in a linked casting and rolling plant. In this type of plant the power consumption and the related costs are up to 45% less than in the case of a conventional plant with separate casting and rolling processes. It also means a significant reduction in CO2 emissions. Furthermore, with a length of only 155 m, the dimensions of these plants are clearly more compact than those of conventional casting and rolling plants.

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cluding mould level control with automatic casting start and the level 2 systems – were ready from the very first charge of the fully automated operation. And even during the run-up phase in the first week of operation over 40,000 t of slabs were produced for commercial use. The casting plants are designed to produce 4.6 million t/year of slabs. A number of technology packages ensure high surface and interior quality, even under fluctuating production conditions, and facilitate a flexible casting operation.

5JCMKPI JCPFU KP HTQPV QH VJG ƂTUV coil produced on the fourth Arvedi ESP line at Rizhao Steel: Yu Yao, Plant Manager ESP lines, Rizhao Steel; Harald Monn-Weiss, Site Manager Primetals

Two thick slab casters start operation at Shandong Rizhao Steel In April, Primetals Technologies received the Final Acceptance Certificates (FAC) for two 2-strand continuous slab casters installed in a new production plant for high-quality steel at Shandong Rizhao Steel. The casters were hot commissioned within two days in December 2017. Installation of the equipment and technology packages was based on the Primetals Technologies “Connect&Cast” principle. This ensured that all functions and systems of the plant – in-

Technologies; Xie Jibiao, Overall Plant Manager ESP Melt shop, Rizhao Steel (from left to right).

The steel for the two continuous casting plants is produced in basic oxygen steel converters with a total capacity of 5 million t/year. The casting plants are equipped with LevCon mould level control, straight, cassette-type Smart Molds, DynaWidth for automatically adjusting the width of the slabs, and hydraulic DynaFlex mold oscillators. Smart Segments, I-Star Rollers and DynaJet spray nozzles are installed in the MPT International 4 / 2018

››› CONTINUOUS CASTING

strand-guide system. DynaGap Soft Reduction ensures that the slabs have a high interior quality. The secondary cooling system uses Dynacs 3D with eleven spray cooling zones. The packages “CC Control” and “CC Optimization” handle the basic automation and the process automation, respectively. The two continuous thick-slab casters have a machine radius of 9.5 m and a metallurgical length of around 32 m. They produce slabs with a thickness of 230 mm in widths ranging from 1,000 to 1,950 mm. The casting speed ranges up to 1.7 m/min. The plants process a wide range of carbon steels, peritectic grades, structural steel, HSLA steels, deep-drawing grades, and various alloys for pipes. Primetals Technologies was responsible for the detailed engineering of the casting platform and strand-guide system, the basic engineering of the caster run-out and discharge and the basic and detailed engineering for the maintenance area as well as for configuring the automation and the associated software. Primetals Technologies also supplied core components, hydraulic cylinders, drives, spray nozzles, and electrical and automation equipment.

Continuous caster for ultrawide medium slabs currently under erection at Shandong Rizhao Steel Shandong Rizhao Steel also placed an order with SMS group for the supply of a continuous caster for ultra-wide slabs. The single-strand caster is designed for an annual production of 1.5 million t of steel slabs with widths of up to 3,250 mm and 150 mm thickness. It is going to process structural steel grades as well as micro and low-alloy steel grades. Peritectic grades will account for more than 45% of the overall production. Commissioning is scheduled for the end of 2018. In the future, Shandong Rizhao Steel will measure and align moulds and segments using the HD LASr assistant system developed by SMS group. Perfect alignment between moulds and segments has a strong influence on the slab quality. Thanks to its three-dimensional laser measuring system and an intuitive operating concept, HD LASr ensures precise and reliable recording as well as a meaningful evaluation of the measured objects. The moulds will be treated with MPT International 4 / 2018

UNIGUARD™, a plasma-ceramic coating which provides for a mould service life four times longer than conventional coatings. For the new caster, SMS group will supply an HD moldTC (TC – thermocouples). Furthermore, the narrow mould sides will be equipped with HD moldFO (FO – Fiber Optical sensors) and the Breakout Prevention Assist and Mold Temperature Assist systems. SMS group will supply the entire X-Pact® electrical and automation systems for the continuous caster, the technological control systems (level 1) and the technological process models (level 2). Furthermore, the plant will be equipped with Internet of things (Industry 4.0) technologies newly developed by SMS group for intelligent processing of plant data and automation of processes. The X-Pact® TechAssist system automatically selects the optimum technological parameter settings for the metallurgical process based on the steel grades to be produced. X-Pact® Process Guidance provides all relevant process information and prompts them on operator screens perfectly timed. X-Pact® Business Intelligence summarizes relevant data from different systems and enables interaction with dynamic applications and dashboards.

New Steckel/plate mill for Shandong Rizhao Steel In early 2017, the company placed an order with SMS group for the supply of a Steckel/plate mill. The new plant is scheduled to go on stream in 2019. The order comprises the complete engineering package, mechanical key equipment, all electrical and automation systems as well as process know-how. The Steckel/plate 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 product range will include carbon steels, quality steels, low-alloy steels, grades for shipbuilding, bridge and pressure vessel construction, for weath-

erproof and wear-resistant plates as well as tube/pipe grades to API standard. The slabs used as feedstock for the rolling mill will be produced by the new continuous caster also to be supplied by SMS group and described above. Thanks to the high slab weight of 57 t, 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 first passes are simple reversing flat passes. Rolling stock of a thickness of 25 mm or less will be coiled in the Steckel furnaces to keep the specified temperature. The mill stand 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 meters by a “flying” cross-cut shear. The four-high reversing stand will have a rolling force of 90 MN. To set the desired strip geometry, the mill stand will be equipped with state-of-the-art actuators. These will include, in addition to hydraulic roll adjustment, CVC®plus equipment with integrated work roll bending. The vertical edger will feature fully hydraulic roll adjustment with integrated width control (AWC). During the coiling operation in the furnace, Steckel loopers will keep the strip tension constant, ensuring high process stability. For plate cutting, the mill will be equipped with two shear lines, each comprising one double-side trimming shear and one cross-cut shear. One line will be designed to cut plates up to 50 mm thick, the other one for plates up to 25 mm thick. SMS group will also supply X-Pact® electrical and automation systems for the entire plant. Prior to shipment, the X-Pact® electrical and automation systems will be prepared in a Plug & Work integration test to speed up the commissioning process on site. The supply package furthermore includes a product quality analyzer (PQA) to be provided by MET/Con, a company of SMS group.

References [1] A. Jungbauer, B. Linzer, A. Viehböck: Rizhao Steel counts on thin slab technology for high-quality production. MPT International, 3/2015, 118-121 [2] Rizhao Steel operates one of the most productive continuous pickling lines. MPT International, 3/2017, 44 [3] T. Schilling, H. Höfer: State-of-the-art rolling and strip processing technologies for the Rhizaho Greenfield project in China. MPT International, 2/2016, 68-71

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Process-capable and robust length and speed measurement solutions Non-contact optical measurement systems are the ideal solution for high-precision length and speed measurement in most different areas of application. Polytecâ&#x20AC;&#x2122;s Laser Surface Velocimeters (LSV), especially designed for use in harsh environments, are a good example of this. Their reliable measurement data can be easily integrated into process control systems. Reliable measurement of product speed and length is essential for production processes in many areas. And the measuring system requirements are as diverse as their applications. For example, in the steel industry, ambient temperatures of 200Â°C as well as dust and oil vapours are quite common. Under these ambient conditions, the measurement system must meet the highest standards of accuracy and reproducibility. Non-contact optical measurement systems are the ideal solution for high-precision, non-invasive length and speed measurement in the most different areas of application. Polytecâ&#x20AC;&#x2122;s Laser Surface Velocimeters (LSV), especially designed for use in harsh environments, are a good example of this. Their non-contact working principle does not show wear or tear, leading to maintenance-free, continuous operation. Their reliable measurement data can easily be integrated into process control systems. The basic function is simple: Using the differential laser Doppler principle, they evaluate the laser light scattered back from a moving object. The LSV measures during standstill and reliably detects the direction of movement. This is why non-contact, optical measurement technology has more and more become the first choice in many applications.

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Two LSVs simultaneously record both the longitudinal movement of the tube in feed direction and the rotary motion perpendicular to it

+PETGCUKPI RTQĆ&#x201A;VCDKNKV[ KP EQPVKPWQWU ECUVKPI In continuous casting of steel, it is important to keep material losses to a minimum to ensure economical production. Measurement systems for cutto-length control are therefore obligatory. But often the inherent inaccuracy of conventional contacting methods â&#x20AC;&#x201C; caused, for example, by slippage or wear â&#x20AC;&#x201C; means that a considerable amount must be added to the minimum length guaranteed to the customer; so manufacturers give away material for free with every cut. The exact knowledge of the speed and length of the strand is the key to optimize the process and the costs. Here, due to their laser precision and reproducibility, non-contact LSVs offer the most practical solution, improving quality and increasing yield. This pays off quickly for the user. If the extra length of each cut is reduced by only a few millimeters, the investment can be paid off in less than one year. In addition, mounting and start-up of this optical measurement system are

easy. It is mounted at a height of 1.5 m above the strand and is ready for use immediately after entering the application-related parameters. Another advantage is its resilience to demanding ambient conditions. In spite of the hot environment, there is no need for the user to protect the measurement system with additional cooling measures. The protective cooling housing, made of aluminium, with cast-in cooling water pipes made of stainless steel, has such an effective cooling performance that additional enclosing is unnecessary. This saves further costs and effort.

/CUU Ć&#x192;QY EQPVTQN KP TQNNKPI OKNNU Rolling mills have similar requirements. The processing industry demands highest accuracy and quality of todayâ&#x20AC;&#x2122;s steel and aluminium products. In order to continuously reduce thickness tolerances of rolled strips, modern rolling mills are controlled according to the mass flow principle. The mass

AUTOMATION flow relationship allows the roll gap to be calculated for the required strip thickness. It requires speed and thickness measuring before the roll stand and speed measuring again after the roll stand. This way the roll gap can be adjusted fast and very precisely. The strip thickness is usually determined by x-ray or optical measuring instruments; Laser Surface Velocimeters are perfect for reliably measuring speed here, because the sensors are easy to integrate and â&#x20AC;&#x201C; in contrast to traditional contacting speed measurement techniques (e.g. measuring wheels) â&#x20AC;&#x201C; LSVs work without slippage and wear, avoiding measurement errors. In addition, the different available stand-off distances (300 to 3,000 mm) offer flexibility, simplifying the mounting as well as retrofits.

0QP FGUVTWEVKXG OCVGTKCN VGUVKPI Various non-destructive measurement procedures are combined in the quality control of seamless steel tubes. Most important are longitudinal and transverse defect testing as well as wall thickness and lamination measurement. For exact localization of defects, the actual test procedure is combined with Polytec velocimeters. Using the laser Doppler principle, they can determine the precise movement of the tube and the current tube position in the test system based on the backscattered laser light. The use of several LSVs is common in ultrasonic testing equipment. Typically, the tubes rotate around their longitudinal axis at 2 m/s. Two LSVs simultaneously record both the longitudinal movement of the tube in feed direction and the rotary motion perpendicular to it. This provides unambiguous position data during the entire test. With the LSV position data, defects can be located precisely and marked in colour for further post-processing.

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vP s Laser Doppler Velocimetry functional diagram (ÂŠ All pictures by courtesy of Polytec)

stant that depends on the laser wavelength h and the angle between the laser beams 2q. The following applies: Î&#x201D;s = h/(2 sin q). If a particle moves through the fringe pattern, the intensity of the backscattered light is modulated. Consequently, a photodetector in the sensor head generates an AC signal with a frequency f D directly proportional to the velocity component of the surface in the

measurement direction v p and the following applies: f D = v p/Î&#x201D;s = (2v p/h) sin q (where f D is the Doppler frequency, v p the velocity component in the measurement direction and Î&#x201D;s the fringe spacing in the measurement volume). The value h/sin q represents the material measure for the velocity and length measurement. It is measured precisely for every sensor head and is printed on the identification label. MPT International 4 / 2018

››› QUALITY ASSURANCE

Automatic eddy current inspection detects hard spots on the surface of heavy plate *HUPDQ VWHHO FRPSDQ\ 'LOOLQJHU KDV ODXQFKHG RSHUDWLRQ RI \HW DQRWKHU ZRUOGŒV Ƃ UVW LQ LWV KHDY\ plate rolling mill with its new eddy current testing system. Henceforth, with this unique system eddy FXUUHQW ZLOO EH XVHG WR DXWRPDWLFDOO\ LQVSHFW WKH VXUIDFH RI KHDY\ SODWH IRU ORFDOL]HG KDUG VSRWV

AG der Dillinger Hüttenwerke (Dillinger), Dillingen, Germany Contact: www.dillinger.de

use of highly advanced probes and exact documentation of the inspection, which simultaneously checks both surfaces of the plate. This means shorter delivery times and an unsurpassed level of security for the customer. The inspection system detects these hardened areas and, since they have a thickness of only a few tenths of a millimeter, they can be removed with a light grinding. As a result, the new eddy current system ensures the delivery of plate that is 100% tested to be free of hard spots. This technology was developed by Dillinger. It is currently being validated by major oil and gas companies and will lead to Dillinger’s approval as a supplier of this plate. Dillinger’s aim is to incorporate this technology into the standards as the definitive method. This makes Dillinger a world leader in testing technology and quality assurance for this burden on the material side. To underscore its unique nature, a new brand was created for the introduction of the method: all Dillinger plate tested with this method is marketed under the additional “D-TECT”

ELOTEST HST Heavy Plate Hard Spot Tester

MPT International 4 / 2018 23 • 67227 Frankenthal • GERMANY Rohmann GmbH • Carl-Benz-Str. Phone +49(0)62 33 - 3789-0 • www.rohmann.de • E-Mail: info@rohmann.de

Eddy Current Test Instruments and Systems

The inspection technology was developed by Dillinger to meet new requirements from oil and gas companies for the ability to detect and remove hard spots on plate used for special pipelines. These pipelines transport an extremely corrosive medium called sour gas. Since the steel plate for these pipelines represents an important product for the company, Dillinger plates were previously first inspected for hard spots during a development phase using a trolley. Now the new system is fully integrated into the production flow and represents a significant improvement over the previous labor-intensive and time-consuming method of inspection via trolley. This requires no additional waiting times for the inspection during production and in addition makes the test result more precise through the

Eddy-current inspection system installed at the heavy plate mill of Dillinger, Germany

brand. This abbreviation stands for the initials in Dillinger -Totally Eddy Current Tested. The local team calls the system, quite aptly, the “D-TECTor.”

Study on the cooling of heavy plate Continuing a partnership with the University of Saarland, Dillinger is supporting an ambitious research project: The Department of Numer-

HST Tester with EDDY+ method

QUALITY ASSURANCE

‹‹‹

ical Mathematics at the university is data that reflects the experience getting started, a mathematical bastudying and modelling the cooling of the experts, the cooling process sis is to be developed with which the process of premium heavy plate at could be tailored much more pre- cooling can be controlled so preciseDillinger. The focus is on the cool- cisely to customer specifications. ly – depending on the water load and ing from rolling heat. This is a deciIn a first step, a mathematical the speed at which the cooling plate sive factor in adjusting the material model in the form of a non-line- passes through – that the desired properties of the steel and therefore ar heat conduction equation was product properties can be adjusted in meeting the diverse requirements developed. With this equation it much more precisely. The funding customers have for the material. is possible to describe the cooling for the research project, which will Therefore mathematical models process mathematically along the run until September 2019, will more are needed to meet increasing cus- entire cooling line, depending on than pay for itself if the mathematitomer requirements and to further the speed and position in the cool- cians can complete the project sucautomate production. Dillinger is ing line. In the second phase now cessfully. supporting the research project with a total of 300,000 euros. Initially the project started already in 2015. Now, the second project phase was kicked off on 1 April 2018. Dr. Bernd Münnich, Chief Technology Officer at Dillinger, emphasizes the importance of an optimal cooling process for Europe’s leading heavy plate manufacturer: “The demands, properties and combinations of properties placed on our steels are becoming more complex all the time. Intelligent cooling can reduce the use of expensive alloying agents – and is therefore also more economical while offering high quality assurance.” Münnich therefore sees a better understanding of the cooling process as an innovation boost for Dillinger. Up to now, the experts at Dillinger have used a very extensive database to control the cooling system. It contains process parameters that, however, The long standing problem of flatness measurement and control in aluminum do not always exactly hot rolling mills is now solved by ABB. Achievements in the field show yield improvements of 2 % and rolling speed improvements of 10%. Altogether this match the prevailing corresponds to millions of dollars on the bottom line. One reason for this is, conditions in the coolas one of our customers put it, ”Good tail-out from the hot rolling mill results in high quality head-in to the cold rolling mill”. The range of applications where ing system. If a mathethe Stressometer system sustainably improves your business includes all kinds of cold rolling mills; and now also aluminium hot rolling mills. matical model can now Stressometer Systems. abb.com/stressometer be developed based on production and test

— Stressometer® Systems From hot to cold Measurement made easy

MPT International 4 / 2018

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş SURFACE TREATMENT

'ZGEWVKXG QHĆ&#x201A;EGTU QH 6CVC 5VGGN 'WTQRG CPF 215%1 UKIPKPI VJG ETQUU NKEGPUKPI CITGGOGPV QP ,WPG

Tata Steel Europe and POSCO GZEJCPIG GZRGTVKUG KP VJG Ć&#x201A;GNF of advanced strip coatings Tata Steel Europe and South Korean steelmaker POSCO have partnered to develop innovative steels for the future. Carmakers and other manufacturers will have access to a whole new generation of steel products thanks to a new agreement. Tata Steel Europe and POSCO signed a cross-licensing agreement, which will allow the companies to increase the range of advanced products to key markets including the automotive and construction sectors. Tata Steel Europe will gain access to the PVD technology for steel coils. POSCO will benefit from using the MagiZincÂŽ technology. Seoung Yu, POSCO Chief Technology Officer, said: â&#x20AC;&#x153;This is a mutually beneficial agreement which will help both companies to provide customers with access to innovative, value-added products.â&#x20AC;?

PVD technology for coils The deal will allow Tata Steel Europe to access Physical Vapour Deposition (PVD) technology, an innovative process allowing steels to be given anti-corrosion coatings without the current requirement to heat them during

Tata Steel Europe, London, UK Contact: www.tatasteeleurope.com

MPT International 4 / 2018

the hot-dip galvanising process. This has the potential to allow for an increase in the number of steel products on which specific anti-corrosion coatings can be used. The new PVD technology developed and patented by POSCO is already adopted in the electronics industry but needs further development for automotive and construction applications. The technology will help Tata Steel Europe meet the emerging need for sustainable steel products for next-generation cars and buildings and will allow the development and production of high-performing steels demanded by global customers. Hans Fischer, Chief Executive Officer, Tata Steel Europe, said: â&#x20AC;&#x153;Tata Steel Europe and POSCO are both recognised as leaders in technological advancement and the two companies have a history of collaboration. By pooling our technical know-how, we will be able to develop and promote market innovation, strengthen our offering and give our customers in several key markets the innovative products they need to be successful.â&#x20AC;?

Innovative galvanized strip with enhanced corrosion protection On the other side, POSCO will be able to produce Tata Steel Europeâ&#x20AC;&#x2122;s patented MagiZincÂŽ. MagiZincÂŽ is an innovative hot-dipped galvanized coating providing enhanced corrosion protection even in harsh environments. Its formulation allows it to outperform conventional galvanised steel, which is why the coating has been widely adopted by the EU automotive and construction industry since its market introduction in 2009. The collaboration with POSCO represents the next phase in Tata Steel Europeâ&#x20AC;&#x2122;s ambition to support customers by making the MagiZincÂŽ product available globally. Seoung Yu, POSCO Chief Technology Officer, said: â&#x20AC;&#x153;We have experienced considerable benefits in using PVD technology, while MagiZincÂŽ will help to bolster our offering by providing enhanced corrosion protection. We expect both PVD and MagiZincÂŽ to gain wider presence in the global market through this partnership which will continue as an exemplary model of collaboration between the two leading global steelmakers.â&#x20AC;?

STRIP PROCESSING

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New grain-oriented electrical steel mill helps ensure nationwide power supply in India WK\VVHQNUXSS (OHFWULFDO 6WHHO LV WKH Ć&#x201A;UVW DQG FXUUHQWO\ RQO\ PDQXIDFWXUHU RI JUDLQ RULHQWHG HOHFWULFDO VWHHO VWULS LQ ,QGLD 7KH QHZ HOHFWULFDO VWHHO SURGXFWLRQ OLQH KDV VWDUWHG RSHUDWLRQV LQ 1DVKLN 0DKDUDVKWUD 7KH PRGHUQ SURGXFWLRQ IDFLOLW\ SURYLGHV FRPSHWLWLYH HGJH LQ D IDVW JURZLQJ PDUNHW L H SRZHU GLVWULEXWLRQ DQG SRZHU WUDQVIRUPHUV In India thyssenkrupp has now start- tures of the new 35,000 ton-per-year make this task even more complex in ed operation of a new line for the pro- line are the magnesium oxide coating the future. Grain-oriented electrical duction of grain-oriented electrical line and the laser system for high-qual- steel is needed wherever electrical ensteel in Nashik, 160 kilometers north- ity surface treatment. Numerous orders ergy is efficiently converted, transporteast of Mumbai. The material is used have already been received, two thirds ed and used, such as in distribution and wherever electrical energy is efficiently converted, transported and used, such as in distribution and power transformers. The feedstock for the production of grain-oriented electrical steel strip is sourced from thyssenkruppâ&#x20AC;&#x2122;s steelmaking operations in Duisburg, Germany. â&#x20AC;&#x153;The local production of grain-oriented electrical steel is a milestone for the Indian steel market. With our decades of expertise in the production of this efficient steel for power transmission, we are helping meet the strong demand for a nationwide and environmentally friendly power supply in India,â&#x20AC;? says Dr. Jens Overrath, CEO of thyssenkrupp Elec- Central components of the new line are the magnesium oxide coating unit and the laser system for trical Steel. At the open- high-quality surface treatment ing, the state-of-the-art production line was put into operation of them from customers in India. The power transformers: To transport elecin the presence of Dr. Aruna Sharma Nashik site employs 500 people. tricity over long distances, it needs a (Secretary Steel, Ministry of Steel Govhigher voltage than it has when it is ernment of India) and Dr. Peter Kern generated. The voltage for transporta(representative at the German ConsuElectrical steel is important tion is around a thousand times higher late General in Mumbai). Central feathan in domestic wall sockets. For use for the energy transition Electrical steel plays a key role in the in households and industry the voltage energy supply and thus for the success needs to be transformed again. As a preof the energy transition. It is already mium manufacturer of efficient electhyssenkrupp Steel Europe AG, Duisburg, necessary to manage and balance fluc- trical steel, thyssenkrupp is contribGermany tuations in electricity demand. In- uting to the sustainable use of energy Contact: www.thyssenkrupp-steel.com creased use of renewable energies will resources. MPT International 4 / 2018

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STRIP PROCESSING

Intelligent furnace technology in continuous annealing and galvanizing lines 8S WR QRZ Ć&#x201A;[HG KHDW F\FOHV KDYH ODUJHO\ EHHQ XVHG LQ WKH FRQWLQXRXV DQQHDOLQJ SURFHVV ZLWKRXW WDNLQJ LQWR FRQVLGHUDWLRQ WKH LQGLYLGXDO UHTXLUHPHQWV RI VLQJOH FRLOV RU FRLO VHJPHQWV 7KH ,QWHOOLJHQW )XUQDFH , )XUQDFH FRPELQHV WKUHH PDMRU FRPSRQHQWV WR HOLPLQDWH WKLV GUDZEDFN

The Intelligent Furnace (I-Furnace) uses innovative digital solutions to optimize throughput and increases the yield of strip with a consistently high quality level

C. A. Klein, U. Sommers, F. BrĂźhl, C. Sasse, SMS group GmbH, DĂźsseldorf, Germany; A. Lhoest, Drever International S.A., Angleur, LiĂ¨ge, Belgium; E. Montagna, Tata Steel SEGAL S.A., Ivoz-Ramet, Belgium; D. Fintelmann, Tata Steel Ijmuiden, The Netherlands; M. BĂ¤rwald, EMG Automation GmbH, Wenden, Germany Contact: www.sms-group.com E-mail: communications@sms-group.com

MPT International 4 / 2018

The share of complex materials produced on continuous annealing and hot-dip galvanizing lines has been continuously rising in recent years. Numerous studies have also forecast further growth for advanced and higher-strength materials [1]. Alongside grades that are already well-established on the market, such as dual-phase or complex-phase steels, technology concepts must also cover material developments, such as quench and parti-

tioning steels or medium manganese steels. Despite the greater material complexity of such multi-phase steels, only minimal variations in the properties of a strip over the strip length and from one coil to the next are tolerated. Typical consumers of such kinds of strip are car manufacturers and their suppliers. The forming processes applied can also be seen as numerous mechanical tests of the strip material, while in the strip

STRIP PROCESSING

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Schematic view of the I-Furnace concept with EMG IMPOC system, mathematical furnace model, and annealing datadriven model

production process only very few samples are tested. Nowadays, however, a strip’s strength properties can in principle be determined continuously over its whole length. Since the annealing and galvanizing process is usually the last step to have any appreciable influence on the strip’s properties before it leaves the plant and is shipped off for further processing, an excellent process control is absolutely essential. The need to run such a plant at maximum cost efficiency restricts the scope for designing and organizing the processes, even in areas where this would be possible from a materials technology point of view. The material properties of annealed cold strip are influenced by a variety of factors. The annealing process in the continuous annealing line or in the galvanizing line plays a key role here. Besides that, skin-pass mills and tension levelers, which also affect the final properties, are used in these types of production lines. In addition to these influences, which can be directly adapted to the annealing and galvanizing lines, the chemical composition and the initial state of the strip are also of great importance. Looking at multi-phase steels in particular – i.e. those types of steel which undergo phase transformation processes during heat treatment – we know from the field of materials science that the relevant temperatures and times or rates during phase transformation depend on the alloying elements. But also the microstructural properties, such as e.g. the grain size, dislocation density, and precipitation state, are important for the transformation behavior – and this is where upstream processes, such as hot rolling or cold rolling play a crucial role. Up to now, most annealing lines worldwide have been operated using fixed annealing curves. These are recipes which stipulate the temperature that a strip made of a certain material

The I-Furnace uses information from EMG’s IMPOC system for non-destructive measurement of yield and tensile strength to optimize the annealing process

Overview of the automatic coil transition management with Drever’s mathematical model MPT International 4 / 2018

››› STRIP PROCESSING

Schematic view of the annealing model

Tata Steel Segal’s continuous ICNXCPK\KPI NKPG CEJKGXGF UKIPKƂECPV KORTQXGOGPVU KP [KGNF CPF ƂPCN RTQFWEV quality thanks to modern sensor technology (EMG) and intelligent control systems (Drever, SMS group)

variations in upstream processes that can also arise from time to time, nor the resulting consequences for the microstructure. To meet the requirements of hightech, state-of-the-art annealing and galvanizing lines, SMS group has developed the Intelligent Furnace (I-Furnace) concept. This enables the annealing process to be optimized by using upstream process and line automation data and linking three essential components: ▪ The IMPOC system, with which online, non-destructive measurements of the tensile strength and yield point over the entire strip length can be taken. ▪ The mathematical model for annealing and galvanizing furnace automation. This model specifies setpoint values for the furnace, optimizes temperature control in strip transition areas, and determines an efficient strip sequence for production. ▪ The annealing data driven model (ADM) is able to describe the relationship between the initial conditions, process parameters, and resulting material properties, in such way that a forecast of the properties can be made. It also allows information to be inferred on the heat treatment adjustments required.

izing coil, the steel strip is periodically magnetized to saturation as it passes through the line [2]. The gradient of the residual magnetic flux density, or remanence, is then measured with a magnetic field sensor. This largely depends on the microstructural properties, such as the grain size and phase fractions, which at the same time are key influencing variables with regard to the material strength. As a result, statistical methods can be used to calculate a regression between both variables and thus determine the material properties of the strip in real time based on the remanence measurement. Real time in this context means that a value for the tensile strength and yield point is available for each segment, typically two meters long, after it has passed the measuring device. Consequently, this enables functions for releasing the produced strip to be defined, for example, which may well result in a reduction in the number of additional samples, or allow defects which cannot be detected by mechanical testing to be dealt with. In addition, IMPOC can be used as a supporting tool when developing new materials [3].

Mathematical model The mathematical model simulates strip heating and cooling in the furnace and generates the setpoints for the furnace based on this. It automatically manages transitions between strips, which have different thicknesses and thus require different heating power or consist of different material grades and require temperatures within their respective limits [5]. The model especially manages to stay in the relevant quality limits during every part of coil processing. Furthermore, it allows to stay in the lower part of the quality window to save energy and/or increase speed. Such optimization and precise furnace control cannot be achieved manually.

Annealing model should have at a certain position within the processing line. However, these fixed annealing curves do not take into account the deviations in the chemical composition that can always occur, even with good process control in the steel mill. Neither do they consider the MPT International 4 / 2018

EMG IMPOC system The IMPOC measuring device enables online, non-destructive measurements of the yield point and tensile strength of ferromagnetic steel strip to be taken in real time. Using a magnet-

The newly developed annealing model enables the process to be perfectly controlled in line with the individual requirements of each strip. Two approaches are taken for this. A metallurgy/physics-based approach is used for process design and development.

STRIP PROCESSING By contrast, a data-driven model is used for the online-implementation on the plant itself. Advanced methods from the field of general statistics as well as machine learning are used to analyze the dependencies and build the regression models. In both cases the process parameters are individually optimized using numerical methods, based on the plant data, product data, and information on the upstream processes. Consequently, consistently high quality levels in the manufactured strip can be achieved and the plant can be operated at maximum efficiency. The focus here is on the material properties attained, while the temperature, as an auxiliary variable, can be varied. Depending on the relevant requirements, the emphasis can be placed on the homogenization of properties within the strip, or on a reduction in the variations from one strip to the next.

Intelligent Furnace As part of a cooperation project between Tata Steel IJmuiden, Tata Steel Segal, Drever International S.A., EMG Automation GmbH, and SMS group, various measures to improve the annealing process were implemented on the hot-dip galvanizing line at Segal [6]. For example, an EMG IMPOC measuring device, which provides high-resolution information on the effects of the annealing process, was installed downstream of the furnace. A mathematical

‹‹‹

Examples of strength progression on the basis of IMPOC values

model was also installed to ensure better process control. A variety of data was processed and analyzed and the findings used to optimize the processes. The strength progression of various strips over their length based on the unconditioned data from the IMPOC, where no process optimization had yet taken place, has been analyzed. It was found out, that even strips which are nominally from the same material – in this case DP 600 – have strength deviations from one strip to another. This can be attributed to fluctuations in the chemical composition, for example, or to the way the temperature is controlled in upstream processes. It is also possible, that strips have different strength conditions over the

strip length due to deviations in the upstream process. These are for example the result of the slightly different temperature progression of the slab at the support positions in the reheating furnace in the hot rolling mill. Nevertheless, the influence can still be seen from the continuous measurement, even in the fully annealed cold strip. This cannot be detected by the existing practice of mechanically testing a few individual samples at the tail end of the strip. Furthermore, the deviations within a coil can be caused by deviations within the annealing process, for example when the strip speed in the galvanizing line is reduced considerably. This results in a change in the annealing cycle of various sections of the strip. With some delay the

MPT International 4 / 2018

â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STRIP PROCESSING Comparison between measured (IMPOC) and simulated (annealing data-driven model) strength of a DP 800 strip

Compensation of deviations in strip strength due to upstream process variations via adjustment of the strip temperature after slow cooling

reaction of the material to this change of heat treatment conditions can be seen in the strength values which deviate. Finally, some coils did show characteristics, which are the result of a combination of all influencing parameters, upstream process parameters, and annealing conditions. An impressive example of improvement was the achieved increase in throughput for some grades. By conducting an analysis as part of the project, potential for increasing the throughput was identified for some products. Using the mathematical model, it was possible to realize this potential without transgressing the

temperature limits. By performing checks using the IMPOC device, it was ensured that the desired mechanical properties of the material were attained. For lots of material grades increases between 13 and 15 percent could be realized and documented. As part of the analyses, characteristic curved trends in the material strength over the length of the strip were found for certain materials, even under steady-state conditions in the furnace. These are a consequence of the preceding process stages. Driven by theoretical considerations, trials were carried out to analyze the influence of changes in the process parameters on the strength, in this case, for example, the effect of the strip temperature after slow cooling. As the IMPOC measured value curve shows, the strength of the strip is well in line with the temperature. A third step was to define com-

pensation patterns and implement them on the line, such that the final strength profile remains almost constant. This proved that it is possible to compensate for deviations in the properties resulting from upstream process variations. On the one hand, closely linking the strip temperatures to the mechanical properties is the basis on which annealing processes are frequently automated using temperature control systems. On the other hand, the full potential can only be utilized if the information on each individual strip is used. This is the central idea behind the I-Furnace. The IMPOC system is able to determine where variations in the material properties occur. The mathematical model is the perfect tool for implementing all the necessary changes to the process; the annealing data driven model can also establish very precisely what action is required to achieve a consistently high level of quality. Based on the data from the galvanizing line itself and on data from the hot-rolling mill, an excellent forecast of the actual properties can be made.

I-Furnace implemented at Big River Steel

Furnace of the new universal annealing and galvanizing line at Big River Steel, USA, VJG Ć&#x201A;TUV GXGT KORNGOGPVCVKQP QH VJG EQORNGVG + (WTPCEG EQPEGRV MPT International 4 / 2018

The linking of the three I-Furnace components is also part of the universal hot-dip galvanizing and annealing line, which SMS group supplied to Big River Steel, USA. The line is part of a completely new steelmaking and rolling mill complex which SMS supplied as a full-liner. Since the automation of the BRS plant is also supplied by SMS, the availability of the required upstream process data does not pose any

STRIP PROCESSING problems. The line produces galvanized and annealed hot and cold strip, including DP steels. The implementation takes place in several stages. The steel producer benefits already from the first stage, but the benefits increase with every step. Production is monitored in the first stage and the relevant data validated. This step is required for any form of modelling. Yet even in this early phase abnormalities or irregularities in the curves can be detected, and potential sources of faults can be eliminated either in the upstream processes or in the annealing line itself. In the second stage the data is used to train the machine learning models, with which the correlations between the parameters of all relevant processes and the final properties are formulated. Quantitative information on process improvements can also be obtained in this way. In the third stage, the automatic corrective measures are activated in the plant automation system, which results in the adjustment of set values and leads to the desired increases in

output and improvements in energy efficiency.

Summary The I-Furnace results in increased yield thanks to consistently high strip quality, enables throughput levels to

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be increased on existing plant and machinery, reduces strip repair costs, and, with improved process control, offers the potential to enhance the energy efficiency or boost throughput even further by adapting the target temperatures within the relevant process windows.

References [1] Keeler, S.; Kimchi, M.: Advanced High-Strength Steels Application Guidelines Version 5.0, WorldAutoSteel, 2014. [2] Dürr, W.; Irle, M.: Magnetic inductive on-line measurement system for mechanical properties within a hot-dip galvanizing line, Stahl und Eisen Vol. 123 (2003), No. 10, pp. 73-77 [3] EMG Automation GmbH: Broschüre IMPOCpro DE, URL: http://www.emg-automation.com/automation/qs-systeme/online-messung-von-zugfestigkeit-und-streckgrenze-IMPOCpro [4] Lhoest, A.; Martins, D.: Recent advances in continuous galvanizing line control by furnace mathematical model, Galvatech, International Conference on Zinc and Zinc Alloy Coated Steel Sheet, 9th, Beijing, 2013 [5] Lhoest, A.; Butzbach, K.: Mathematisches Modell ermöglicht höhere Anlagenproduktivität und bessere Bandqualität, Stahl und Eisen Vol. 129 (2009), No. 11, pp. 79-89 [6] Bärwald, M.; Sommers, U.; Biglari, M.; Montagna, E.; Beugeling, W.; Lhoest, A.: On-

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

line monitoring of IF and high-strength steels on continuous galvanizing lines controlled by furnace mathematical model. Galvatech, International Conference on Zinc and Zinc Alloy Coated Steel Sheet, 10th, Toronto, 2015

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MPT International 4 / 2018

››› MATERIAL FLOW LOGISTICS

High-speed production buffer for steel wire coils German steelmaking company Saarstahl AG has implemented a fully automatic highbay warehouse for up to 665 steel wire coils at its Neunkirchen site. The high-bay warehouse erected by Vollert operates with very short cycles. Bundles weighing up to 4.5 t are transferred directly from the stacker crane to the pallet truck and onwards to the dispatch area.

Transfer point for incoming or outgoing coils with coil lifting truck outside

German Saarstahl AG operates a most modern single-strand wire rod mill at its Neunkirchen production site. The range of products covers wire in various material conditions including fullhard, thermo-mechanically rolled, annealed and tempered. In order to keep the different types of wire, qualities and lengths available for on-call delivery, the company awarded Vollert the order to set up a fully automated highbay warehouse between the production line and the truck loading area. It replaces the previous open space warehouse and has a capacity of up to 665 wire coils on 12 storeys, with a total

Vollert Anlagenbau GmbH, Weinsberg/ Germany Contact: www.vollert.de E-mail: info@vollert.de

MPT International 4 / 2018

weight of about 3,000 t. The bundles vary in diameter up to a maximum of 1.5 m. The new coil storage facility has a length of 58 m and a height of 28 m.

age, the coils are automatically measured and gently lifted up by the stacker crane and later on made available for dispatch by the high-bay warehouse. Despite the heavy weight of up to 4.5 t per wire coil, the stacker crane only needs 190 seconds for a storage and retrieval double cycle. The transfer takes place at a common transfer point directly from the stacker crane to the manual forklift for loading onto the trucks. “This interface between automatic and manual transport is challenging since inaccuracies in the manual approach must be taken into account,” explains Lars Strobel, project manager at Vollert, “but we have solved the problem by combining mechanical barriers with optical sensors and signal transmitters.” As a result, the new high-bay warehouse is a significantly faster, weather-resistant and space-saving overall solution compared to the open space warehouse. Thanks to the very good preparations by Saarstahl and optimal coordination, the plant went into operation after only ten months of project time.

Safe storage retrieval in 190 seconds

425 years of tradition and state-of-the-art production in Neunkirchen

In addition to consulting, planning and construction, Vollert’s team also took care of the entire implementation, from steel construction to control and warehouse management. At the end of the production line the different bundles of wire are transported to a pallet truck by a forklift, and from there, they are transferred fully automatically to the high-bay warehouse. A single-acting stacker crane with telescopic forks takes over the wire coils and stores them. The low dimensional stability and the different diameters of the bundles are demanding features. Therefore, before stor-

The Neunkirchen plant, with around 900 employees, is one of the most traditional steel locations in the Saar region, Germany – with roots dating back to 1593. Today, it is one of the world’s leading producers of long products and Saarstahl AG continues to invest in quality leadership. In 2016, the wire rod mill at the Neunkirchen site was completely modernized for around 30 million euros. The single-strand wire rod mill has an annual capacity of 600,000 t of fully continuously rolled, highest precision wire in diameters between 7.0 and 27 mm.

TECHNICAL INNOVATIONS

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Productivity improvement through plant data analysis ANNEALING AND PICKLING Andritz has successfully improved the performance of the annealing and pickling line for stainless steel strip at Fuxin Special Steel in China. Based on proven software and algorithms developed by Andritz, the operating and process data of the plant were analyzed, and some bottlenecks identified. After implementing the necessary changes, the capacity of the line increased by 15%, with virtually no additional capital investment.

Andritz has combined all of its digitalization activities under the Metris umbrella brand. Metris encompasses innovative IIoT products largely relating to optimization of plants and processes by combining sensors, complex data analysis, and augmented reality.

Contact: www.andritz.com

MMK continues Big Data strategic initiative DIGITALIZATION At the end of 2015, Magnitogorsk Iron & Steel Works adopted a new development strategy for the period through 2025 that included, among other things, a Big Data strategic initiative calling for comprehensive modelling and mathematical optimization of key production processes. As part of the

implementation of its initiative, MMK is planning to complete five projects in 2018. These cover the blast furnace plant, rolling mill No. 10, the oxygen converter plant and MMK’s thermal power station. Work on a total of 16 projects will continue in 2018-2019. The company is currently preparing a programme for scaling

its Big Data strategic initiative for another strategic initiative: MMK-Industry 4.0, which includes not only Big Data projects but also projects related to predictive technologies, the Internet of things and the robotization of production. Contact: www.mmk.ru

THE AUTOMATION FOR YOUR PRODUCTION. EISENHÜTTENSTADT • WIEHL • DUBAI www.unitechnik-eh.de

METALLURGY // AUTOMATION - FROM RAW IRON TO STEEL TAPE PRODUCTION AUTOMATION // PRODUCTION CONTROL AND ROBOTICS LOGISTIC SYSTEMS // STORAGE AND TRANSPORT SYSTEMS MACHINE SAFETY // NEW CONSTRUCTION AND RETROFIT DRIVE TECHNOLOGY // AC AND DC DRIVES INDUSTRIAL SERVICES // MC TECHNOLOGY, INDUSTRIAL RADIO AND VIDEO SYSTEMS

UNITECHNIK AUTOMATISIERUNGS GMBH Seeplanstraße 1 I D-15890 Eisenhüttenstadt Fon: +49 3364 501 - 0 I www.unitechnik-eh.de

››› TECHNICAL INNOVATIONS

Thermal process technology COIL PROCESSING LINES Drying and thermal processes play very important roles in coil coating, galvanizing, pickling and other coil processing applications. adphos Thermal Processing has introduced its adphosNIR-BAT technology, which allows very high speed, ef-

Thermal treatment in process

ficiency and profitability in coil processing lines. It surpasses infrared based systems and hot air convection ovens in terms of flexibility and energy efficiency. All this results in very low operation costs and reduces CO2 emissions. The adphosNIR-BAT technology is suited for upgrades, replacements and greenfield installations. It is used for rinse water drying, primer and water based pretreatments, organic wet or powder-based coatings, thermal treatment in galvanizing, annealing or pickling lines. Contact: www.adphos.com

Compact linear displacement transducer for hydraulic cylinders

CRANEFRIGOR™ crane and crane cabin air-conditioning devices for steel works.

SPECIAL EQUIPMENT Ametek Factory Automation has introduced a rugged, high-accuracy linear displacement transducer in a compact rod-style package. The new compact-housing GEMCO® 958A is just 3 cm in depth, making it appropriate for hydraulic cylinder applications where traditional rod-style transducers will not fit. It is simpler to install and service than embedded-style sensors. Industry-leading tolerances assure long operating life in the most demanding applications. The transducers are made entirely from stainless steel. High accuracy combined with 16-bit output resolution provides reliable, absolute position feedback to help automate today’s sophisticated machinery. Programmable zero and span points allow users to adjust the output to exactly match their requirements. Magnetostrictive technology gives absolute analog position feedback, accurate to 0.04% of the programmable sensing distance. It can withstand the conditions traditionally associated with hydraulic cylinders: operating pressures up to 5,000 PSI and spikes to 10,000 PSI with response times in the milliseconds. Contact: www.ametekfactoryautomation.com

Displacement transducer in hydraulic cylinder application FrigorTec GmbH • info@frigortec.de • www.frigortec.com

MPT International 4 / 2018

TECHNICAL INNOVATIONS

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Radiometric mould level detector CONTINUOUS CASTING The new Congauge LB 6755 from Berthold Technologies, designed in cooperation with SMS Concast, is a high-tech radiometric detector, utilizing latest sensing technology to continuously measure both the liquid steel level and the thickness of the casting powder layer in a mould during continuous casting. The detector controls the automatic casting powder feeders, reducing human intervention in a dangerous area. The excellent performance of this new detector has been extensively tested under real casting conditions. A third-party institute has verified its qualification for extreme shock, vibration, and temperature environments. Contact: www.berthold.com

Device for mould level measurement

Flexible, robust and low-maintenance vacuum pumps SPECIAL EQUIPMENT With the air-cooled SCROLLVAC plus, Leybold offers a new uncomplicated, reliable vacuum pump. Suitable for a wide application range, the oil-free, dry running fore vacuum pump qualifies for a variety of demanding applications in the laboratory, in large research facilities or in vacuum furnaces. Thanks to its very lightweight, compact design, it occupies only minimal space in plants and equipment. This makes integration also into existing vacuum systems easy. Vibrations and noise are very low (less than 55 dB (A)) . The hermetic sealing of the rotating parts of the pump chamber reduces the risk of contamination. There are no wear-resistant shaft seals, making for very high leak tightness. The product family is available in four versions with the pump speed stages 7, 10, 15 and 18 m³/h. The SCROLLVAC C plus variant is designed for pumping aggressive media and chemicals. Contact: www.leyboldproducts.com

Fore vacuum pump MPT International 4 / 2018

››› TECHNICAL INNOVATIONS

Sturdy infrared thermometer for steelworks

Pyrometer for temperatures from 250 to 3,200°C

MEASURING INSTRUMENTS The pyrometers of the Endurance series offered by Fluke Process Instruments provide high reliability and usability in demanding primary and secondary metals production applications. The rugged infrared thermometers take non-contact measurements and are used to control process stability, product quality, and fuel efficiency. Featuring a 1 μm, 1.6 μm, or 2.4 μm spectral

response, the sensors achieve significantly higher accuracies than longer-wavelength sensors. The Endurance series covers measured temperatures from 50°C to 3,200°C with just a few models. Therefore, it takes fewer units to monitor entire processes. Models with one-colour and two-colour (ratio pyrometer) operating modes are available, the latter for measured temperatures as low as 250°C. Ratio pyrometers ensure correct readings even in dust-saturated or steamed-up surroundings. The series is designed for comfortable operation. A backlit rear-panel with tactile feedback allows for easy, intuitive on-site configuration and read-out. Furthermore, the sensors can be remotely operated. Profinet, RS-485, and Industrial Ethernet interfaces are available. What is more, Fluke Process Instruments has integrated a range of sighting options and offers a high-resolution on-board video camera for remote monitoring of the application and sensor alignment via Industrial Ethernet. Depending on visibility in the particular application, laser or LED sighting can be used to mark the position and size of the measurement spot. The sensors are enabled for the harshest industrial environments. They feature galvanically isolated I/Os and a stainless steel IP65 housing and withstand ambient temperatures up to 315°C using cooling accessories. The manufacturer provides a four-year warranty. Contact: www.fluke.com

Temperature monitoring in the metals industry MEASURING TECHNOLOGY Precise temperature monitoring of metals during production is a critical quality factor. The thermoIMAGER TIM M1 thermal imaging camera offered by Micro-Epsilon is designed for temperature monitoring tasks in the metals processing industry. As it is a non-contact procedure, the camera does not affect the target. The short-wave spectral range of 1 μm is particularly suitable for temperature measurements of metals whose surfaces have a higher radiation intensity and emissivity with shorter measuring wavelengths. Laser welding applications require a laser blocking filter that suppresses the laser wavelength. The TIM M1-N1064 is equipped with a notch filter at 1,064 nm with a bandwidth of 44 nm. Diode laser types that operate in this exact wavelength range are therefore blocked by this filter. Other wavelengths pass through and are detected by the thermal imaging camera. This filter is primarily used in laser powder welding applications and for process optimization of 3D printing processes. The TIM M1 B880 uses a bandpass filter that only passes light with a wavelength of 880 nm at a bandwidth of 70 nm. The laser line of kW laser types operates exactly in this range, which is why the laser line can be perfectly displayed and monitored. This filter is mainly used in laser processing, laser welding with wavelengths of 950 nm and applications involving diode and fibre laser applications. MPT International 4 / 2018

Temperature measuring device

The TIMConnect real-time software for parameter set-up of the camera and visualization of infrared thermal images completes the scope of services available with Micro-Epsilon thermal imagers.

Contact: www.micro-epsilon.com

TECHNICAL INNOVATIONS

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Platform for maintenance of heat treatment plants SERVICE An internet-based customer portal for the structure, integrating it with the new Aichelin software maintenance and upkeep of furnaces has been devel- for process documentation. Future scenarios such as exoped by Aichelin Service, provider of services for heat penditure data and fault probability can be determined treatment plants. The digital service platform “my- and made available for the customer in real time. Aichelin” offers the company’s customers extensive and unprecedented real-time information about their Contact: www.aichelin.com furnaces. This optimizes maintenance and continuous service and considerably increases efficiency. The new platform enables deep insight into plants in the heat treatment industry. Not only all furnaces under the umbrella of Aichelin-Holding, but also furnaces from other manufacturers can be serviced through the customer portal, which provides all relevant data, such as lifecycle, defect probability, delivery times, availability, prices, extensive documentation, technical drawings, and much more. Thanks to the 1:1 presentation, customers can comfortably oversee all processes and follow them through a 360-degree tour of the entire plant. This also includes maintenance status and, in the future, condition diagnosis. Video documentation and checkAIC has more than 40 years of experience in this market which allows us to listen and lists serve as additional solve every customer’s needs. guidance. The platform supports We offer state-of-art systems, specially designed for long-product rolling mill, meltshop and caster, supplying technological solutions and taking care of every detailed step, from Power control, PLC & businesses with autoHMI software up to innovative solutions, level 2, commissioning and advanced services. mated suggestion lists in The result leads to a better performing, safer and more efﬁcient production process. spare parts stocking and maintenance planning. Our results are constantly confirmed by the loyalty of our best Clients. The innovative shopping cart function and quoAIC Automazioni Industriali Capitanio sites: tation generation at the ® Italy (Headquarters & Workshop) - Phone +39 0365 826333 ® United States of America (Sales & Service) touch of a button make ® India (Sales & Service) the procurement process ® Brasil (Sales & Service) extremely simple. The aic@aicnet.it - www.aicnet.it platform has a modular

The worldwide experience in engineering metal automation process is all in your hands.

››› TECHNICAL INNOVATIONS

Carbon and sulphur analysis VHSG ×DWHAKD LD@RTQHMF Q@MFD

Analyzer for carbon and sulphur

ANALYTICAL INSTRUMENTS A new analysis system for accurate and reliable analysis of carbon and sulphur

in inorganic materials like steel, cast iron, copper, ore, cement, ceramics or glass has been developed by Eltra. The robust system, traded under the name ELEMENTRAC CS-i, uses an induction furnace for sample combustion as well as highly sensitive IR cells to determine carbon and sulphur concentrations. The measuring range may be adapted to the user’s specific requirements. The system comes with freely selectable configuration of each IR cell, a new vacuum system for high-

er measurement precision and stability, a heated dust trap for improved sulphur detection, an optimized catalyst reactor for extremely accurate carbon detection and with comprehensive diagnosis and analysis tools. It may be equipped with IR cells of different sensitivity for carbon and sulphur, according to the customer’s requirements.

Contact: www.eltra.org

Surface inspection for tubes QUALITY ASSURANCE In tube production, surface defects often continue through the complete process chain. Non-stop surface inspection from the bloom to the finished tube is therefore critical for the quality of the final product. The X-3Division tube surface inspection offered by IMS automatically detects and classifies defects and their positions in hot and cold applications. The key to a very high measurement accuracy is the geometric stability of all components concerned. IMS has developed high power lasers in combination with newest high speed 3D cameras. While each laser camera system operates individually, all systems remain in constant alignment to each other within tight tolerances. The laser camera systems are arranged circularly for a complete and simultaneous measurement. Four to eight sets are typically used, depending on the complexity of the product. Also the minimum and maximum product dimensions are taken into consideration.

Gauging system for tubes

Contact: www.ims-gmbh.de

High-sensitivity scrap metal detector MEASURING INSTRUMENTS Belt conveyor operators at mining, mineral, steel, cement and other industrial manufacturing sites can now install a new, highly-sensitive scrap metal detector designed to optimize production time, protect process equipment and reduce false alarm rates. The Thermo Scientific Ramsey Oretronic IV tramp metal detector builds upon the existing line of tramp metal detectors by increasing sensitivity for improved detection capabilities. Thermo Fisher designed the new detector to work with belt conveyors that move minerals, iron pellets, MPT International 4 / 2018

coal, aggregates and other bulk materials, to better detect all types of metallic scrap. The increased sensitivity in the Oretronic IV detector allows it to identify tramp metal buried in wet conductive materials quickly and accurately. The detector is available in two versions with two levels of sensitivity, includes a microprocessor-based control unit, a receiver coil, a transmitter coil and a support frame. Existing instruments in the Oretronic tramp metal detector line can be easily upgraded with the new device. Contact: www.thermofisher.com

Detector with support frame

TECHNICAL INNOVATIONS

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Compressor technology for furnace blowers IRON AND STEELMAKING The MAX1 axial compressor technology from MAN Diesel & Turbo is going to be used at steelmaking facilities of Tata, JSW and SSAB. JSW Steel has ordered two MAX1 compressor trains as blast furnace blowers for the expansion of its steel works in Dolvi, India. Each system will comprise a highly efficient axial compressor with an electrical motor, as well as auxiliaries and supply units. Tata will use the compressor technology from MAN Diesel & Turbo as blast furnace blower at its IJmuiden site in the Netherlands. SSAB has ordered the MAX1 compressor technology to improve the cold blast supply at its steelworks in Luleå. These orders demonstrate that this compressor technology has become well accepted in the iron and steel industry. The axial compressors and the related blading technology provide greatly enhanced power density, performance and reliability. Technology-wise, this was achieved by combining compression technology of modern gas turbines with the technology of industrial large-volume compressors. The result is significantly lower power consumption.

Design of blast furnace blower

Contact: www.dieselturbo.man.eu

Cartoon

MPT International 4 / 2018

››› LITERATURE SERVICE Coke oven machine technology 8 pages, English In this brochure, JMH John M Henderson provides a digest of its expertise in engineering machinery for coke ovens. Machinery designed by the company includes charge, quench and transfer cars, pusher machines, locomotives, water jet door cleaners and door extractors, and associated emission control systems. Contact: www.johnmhenderson.com

Heavy-duty plastic chains 32 pages, English, German In this brochure, igus®, specialist in high-performance polymers, presents examples of the wide range of applications for its metal-free heavy-duty polymer chains, e.g. in power plants, steel mills, offshore, coal handling, etc. The brochure also provides an overview of available accessories. Contact: www.igus.de

Additive manufacturing series production 4 pages, English A brochure outlining the concept for additive manufacturing series production devised by SMS group in cooperation with 3D printing specialists Additive Industries. From metal powder of highest purity produced in the powder atomization plant, the integrated metal AM process, MetalFAB1, makes products for high-end industrial applications. Contact: www.sms-group.com; www.additiveindustries.com

Rapid cooling and tempering Leaflet, English As an alternative to classic isothermal or spheroidizing annealing, Deutsche Edelstahlwerke and its customers developed the RC+T process (rapid cooling and tempering). This process saves time-consuming process steps and simultaneously optimizes the steel properties. Contact: www.dew-stahl.com

2TQFWEVU CPF CEEGUUQTKGU HQT ƂTG ƂIJVKPI 32 pages, English A product guide for fire fighting equipment offered by Safe Fleet Emergency & Industrial for oil and gas operations. The guide includes a wide range of nozzles for specific applications such as master stream, hand lines, hydrants, etc., as well as monitors, fittings, appliances and wrenches. Contact: www.safefleet.net

MPT International 4 / 2018

IN THE NEXT ISSUE…

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Steelmaking Stainless steel strip production with advanced process control at Fuxin Special Steel, China Fuxin Special Steel Co. Ltd is now one of the biggest flat stainless steel producers in China. The completely new stainless steel plant comprises modern facilities as an EAF, two ladle furnaces, one AOD converter and one VOD treatment station as well as slab casters for flexible formats. The steel plant is designed for an annual production of 0.72 million t with the option to extend the capacity at a later stage.

Environmental protection Thermally reductive conditioning of converter slags Unlike granulated blast furnace slag, converter slag shows no appreciable binding behaviour after normal finish grinding. That is why the resulting slags have not been used in cement so far, but in road construction. A significant portion also has to be deposited. Against the backdrop of the preservation of resources, research on an innovative process for converter slag reconditioning is under way.

Heat treatment New cooling technology for heavy plate mills and heat treatment lines With the MultiFlex Quench®, a new technology for cooling plates in heat treatment lines has been successfully established in the market. Flexible cooling strategies can be used to produce common standard materials as well as special or newly developed materials with high quality requirements.

This preview may be subject to change.

Metallurgical Plant and Technology

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© 2018 jbd Gesellschaft für Medien und Kommunikation mbH, Düsseldorf This journal and all articles and illustrations contained in it are protected by copyright. With the exception of statutory allowable cases, utilization without the consent of the publishers is a punishable offence. This is particularly applicable to reproductions, translations, microfilming and storing and processing in electronic systems. Upon acceptance for publication, the author agrees to grant, transfer and assign to the publisher all exclusive rights to publish the work during the lifetime of the copyright. In particular, the publisher will have full authority and power to reproduce the work for commercial purposes in copies of any form (microfilm, photocopy, CD-ROM, or other means) and/or to store the work in electronic or other databases. Printed by: Kraft Premium GmbH Industriestr. 5–9, 76275 Ettlingen, Germany Printed on paper bleached totally chlorine-free (TCF) using heavy metal-free printing ink.

MPT International 4 / 2018

GSM 200 to capacity and GFM 100 to capacity

performance for high productivity GLAMA Maschinenbau GmbH

Headquarters: HornstraĂ&#x;e 19 D-45964 Gladbeck / Germany Fon: +49 (0) 2043 9738 0 Fax: +49 (0) 2043 9738 50 email: info@glama.de

GIR-P 1 t capacity

glama.de

GFM 150 t capacity