MPT International 2/2019 (May)

G 25074 MPT Metallurgical Plant and Technology International, No. 2, May 2019

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Metallurgical Plant and Technology

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ISSN 0935-7254

June May 2016 2019

Nucor Steel Gallatin upgrades hot strip plant with Danieli Quality Strip Production (page 20)

Primetals Technologies modernizes Angang Iron & Steel’s continuous slab caster (page 28)

Polytec laser surface velocity measurement ‘in more than one dimension’ (page 40)

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Alex Manford Chief Editor, MPT International

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QSP is designed to work with thicker slabs (up to 130 mm) than other thin slab technologies. This makes it possible to increase production levels up to 3 million t/year with only one casting strand, and produce the highest range of grades using the controlled metallurgical technology. In short, Danieli has supplied the most productive caster ever installed. The first slab is due in September 2020, and the first rolled coil in November of that year. Product quality will also be significantly increased.

According to Paolo Losso, president of Danieli corporation, the plant operates on a “totally different level to serve a highly demanding market.” Other key factors of the benchmark plant include its Industry 4.0 features – e.g., mechatronic technologies and a new meltshop that is “the most modern one in the USA,” according to Danieli.

It will be worth keeping an eye on the anticipated benefits at Nucor Steel Gallatin. Not least because such optimized processes can better protect operators during periods of market uncertainty, as evidenced in ArcelorMittal’s recent announcement (p. 7). The company, which produces about 6% of the world’s steel, is temporarily reducing its annualized European primary steelmaking production by 3 million t.

ArcelorMittal attributes its decision to weakening demand and rising imports, coupled with insufficient European Union (EU) trade protection. While the EU faces a deteriorating trade environment and, of course, doubts over Brexit, steel demand in the USA should continue its growth (as seen in 2017-18) but at a slower rate with the waning effect of fiscal stimulus and a monetary policy normalization, reports the World Steel Association (worldsteel, pp. 18-19).

The advancements at Nucor Steel Gallatin, such as the plant’s aspiration to achieve zero downtime through predictive operations, should bear testament to how technological innovations and effective production planning can help steelmakers remain strong in these uncertain times.

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A major project featured in MPT International’s first issue of 2019 is being completed for Nucor Steel Gallatin (pp. 20-26). Danieli has been contracted to revamp the hot strip plant in Ghent, Kentucky, USA, with its Quality Strip Production (QSP®) technology. Danieli’s team worked together with Nucor for more than a year to find the best solution. It is the first time a classical compact thin slab casting and rolling facility has been fully reconfigured into an ultra-modern plant.

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››› Premier steel technology events line-up in Europe, the USA and Russia AISTech, METEC 2019 and three exhibitions in Russia – Tube Russia, Metallurgy and Litmash – are all calendar highlights for the steel industry. They promise the latest technical innovations, plus key discussions about productivity and the environment

COVER STORY:

METEC 2019: measuring technologies for metal pipes, strips and plates Exhibitors at METEC in Düsseldorf, Germany (June 25 to 29), include Sikora. The German manufacturer and supplier will demonstrate its advanced measuring technology for the metals, hose and tube, wire and cable, optical fibre and plastics industries

Nucor Steel Gallatin has selected Danieli as its technology supplier for the complete equipment and automation system, from raw material to hot rolled coil, at its rolling plant located in Ghent, Kentucky, USA. The plant has a nameplate capacity of 1.6 million short t/year (approximately 1.4 million t/year) of hot rolled coils. The first cast slab is scheduled for September 2020 and the first rolled coil for November that same year. The project is due for completion in February 2021.

(See full story page 20)

Nucor Steel Gallatin to upgrade its hot strip plant with Danieli Quality Strip Production (QSP®)

Contact: www.danieli.com Email: info@danieli.com

Nucor has contracted Danieli to upgrade its hot strip plant in Ghent, Kentucky, USA. The revamp is the first time that a classical compact thin slab casting and rolling facility has been fully reconfigured into an ultra-modern Quality Strip Production (QSP®) plant

Nucor Steel Tuscaloosa selects Primetals Technologies for plate mill upgrades

Reduced handling with a new reel hole fixation robot from Tebulo

The upgrades to Nucor’s plate mill in Alabama, USA, will include a new Power Coiler and Level 1 automation system upgrade. The supplied equipment will enable Nucor to produce heavier line pipe gauges. Completion is scheduled for 2020

After a successful feasibility study, Tebulo Industrial Robotics from Warmenhuizen, North Holland, has engineered a new reel hole fixation robot for the steel industry. The new technology can improve the cold coiling of steels with certain material thicknesses

Primetals modernizes Angang Iron & Steel’s continuous slab caster with soft reduction technology

Radical Lead Time Reduction (RLTR) method could halve the construction times of large-scale plants

Segregation during the casting process can create undesirable material properties. DynaGap Soft Reduction from Primetals Technologies has proven integral in helping Angang Iron & Steel Group, China, enhance its product quality, productivity and flexibility

When building large-scale plants, traditional forward planning methods can negatively impact both time and costs. Instead, maexpartners of Germany has devised a unique RLTR method which, according to the company, can shorten construction times by 40-50%

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Laser surface velocity measurement ‘in more than one dimension’ for planetary mills Precise knowledge of all variables is required to control a process and, ultimately, increase profitability.

With this in mind, Polytec Laser Surface Velocimeters (LSV) are used to measure length and velocity in a wide variety of industries

SMS group GmbH Messe Düsseldorf Nuova Carpenteria Micro Epsilon Zumbach Pfeifer AIC

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Rheinbraun ABB Saar Metallwerke Stein Redecam Group Combilift Velco

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International industry news Technical innovations Cartoon In the next issue Imprint

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Vesuvius Rübsamen Polytec FIMI Primetals TMT

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USA

Egypt thyssenkrupp wins major order for fertilizer complex in Egypt. thyssenkrupp’s plant engineering business has won a major order from the Egyptian chemical and fertilizer manufacturer NCIC (El Nasr Company for Intermediate Chemicals). The order for the engineering, procurement and construction (EPC) of a new fertilizer complex was signed in Cairo on March 17, 2019. thyssenkrupp is realizing the project in a consortium with Petrojet, an Egyptian provider of integrated services for oil and gas, the petrochemical industries and more.

The order value for thyssenkrupp is in the mid-three-digit million euro range.

Canada Can-Eng Furnaces to deliver thin walled casting heat treating system. Can-Eng Furnaces International Limited of Ontario, Canada, a provider of state-of-the-art thermal processing systems for ferrous and non-ferrous metals, has been chosen to design and commission a high-capacity, heattreatment system for a Tier 1 Global Automotive Manufacturing Company. The new system provides T-6 and T-7 processing capabilities for lightweight aluminium High Pressure Die Casting (HPDC) automotive components. Features of the system include Can-Eng’s Lean Manufacturing robotically integrated part handling system, individual part processing features that deliver predictable metallurgical and part dimensional properties, Precision Air Quenching (PAQTM) Technology, a level 2 automation system for the managing of individual component parameter traceability, system diagnostics and CQI-9 reporting. The system is scheduled for commissioning in Q1, 2020, and will support a next model generation Luxury SUV being released in 2021.

SSAB reports strong earnings improvement in Americas and special steels. SSAB’s operating profit for the first quarter of 2019 was SEK 1,674 million (approximately USD 175 million) compared with the first quarter of 2018, attributable to SSAB Americas and SSAB Special Steels. Operating profit was also up compared to the fourth quarter of 2018, when there were several planned maintenance outages. SSAB Americas’ operating profit rose to SEK 956 million (approximately USD 99.8 million) for the first quarter. This improvement was driven primarily by significantly higher realized prices compared with the first quarter of 2018. Demand remained strong in most segments.

TMW completes ‘one-stop’ heavy gauge, high strength processing centre. The Material Works, Ltd. (TMW) has completed commissioning of its advanced, heavy gauge slitter and is now running full production with coils up to 5/16" (8 mm) thick. This is TMW’s second slitter from Red Bud Industries, USA, and the latest step in an extensive cycle of investment in new equipment and upgrades at the processing centre for slitting, eco pickled surface (EPS) pickling, stretcher levelling and cut-to-length processing of heavy gauge and high strength flat rolled metals. The new heavy gauge slitter can process material up to 100 K tensile strength at its full thickness and width of 0.315" x 75" (8 x 1,905 mm). It accepts coils up to 55,000 lbs., produces to a width tolerance of +/0.005" and features an integrated packaging line. The slitter is located right next to TMW’s environmentally friendly EPS pickling line.

China Inteco and Erzhong carry out the first heat with China’s largest ESR plant. In November, last year, Inteco began installing a highly complex metallurgical 150 t electroslag remelting (ESR) plant at Erzhong, China, and at the end of March the first heat was

carried out by Inteco’s team of experts on site, together with the customer, according to the agreed schedule. The plant has two melting stations in which ingots with a diameter of up to 2,100 mm are remelted using electrode exchange technology.

Dongfeng Forging orders 5,000 t eccentric forging press from SMS group. Dongfeng Forging Co., Ltd., part of the commercial vehicle manufacturer Dongfeng Motor Group, has placed an order with SMS group for the supply of an MP 5000 eccentric forging press with a forging force of 5,000 t for its plant in Shiyan, Hubei Province, China. Founded in 1969, Dongfeng Forging operates a total of 26 forging lines at this site including, among others, a 12,000 t wedge press supplied

by SMS group. Dongfeng Forging intends to use the new forging press to manufacture light-truck crankshafts with a maximum finished part weight of 21.5 kg. The new eccentric press will forge parts precisely, highly efficiently and fully automatically with a nominal forging force of 50 MN. In addition to the press, the scope of supply includes process development services, sequence-controlled loading and unloading belt conveyors, an electrically operated automatic walking beam for parts handling and an integrated die spraying system. Also, SMS group will supply a line control system for connecting other equipment units as, for example, the heating system.

Chengde Jianlong orders Danieli Automation Q3-Intelligence for intelligent plant. Chinese special steel long product manufacturer Chengde Jianlong Special Steel has contracted Danieli Automation to supply its Q3-Intelligence advanced Business Analytics solution suite for the metals industry. Q3-Intelligence will give Chengde Jianlong the ability to measure all the performance figures of the technological processes through a comprehensive key performance indicator (KPI) library, based on specific Danieli process know-how. The analysis covers 13 individual plant processes including steelmaking, casting and rolling.

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‹‹‹ Two 20-high, copper cold-finishing mills ordered from Danieli.

Ningbo Powerway Alloy Material Co of China has chosen Danieli Fröhling foil-rolling technology for its thirdphase expansion project. To be installed in Ningbo, Zhejiang Province, eastern China, the new 20-high cold finishing mills for Ningbo Powerway Alloy Material Co. will competitively roll a wide product mix of copper alloys, from soft pure copper up to hard phosphor bronze.

India Andritz to supply new tension-levelling line and new degreasing line to Hindalco Industries Ltd. Andritz, the international technology group, has received an order from Hindalco Industries Ltd., India, to supply a new tension levelling line with an annual capacity of 100,000 t and a new degreasing line with an annual capacity of 150,000 t.

Start-up is scheduled for spring 2021.

The new lines are designed to produce high-quality aluminium from series 3000, 5000 and 6000. The Andritz scope of supply comprises the complete lines, together with the mechanical and electrical equipment and also start-up of the plant. Hindalco, of the Aditya Birla Group, is the world’s largest aluminium rolling company and one of Asia’s biggest producers of primary aluminium.

Tata chooses CMI’s technology for its new cold rolling complex.

The steel producer and global steel giant, Tata Steel has awarded CMI Industry Metals a contract for three state of the art processing lines: two Continuous Galvanizing Lines (CGL) and one Continuous Annealing Line (CAL). All three high-end lines are to be supplied to the client’s site at Kalinganagar in the Jajpur district of Orissa, India. They will enable Tata Steel to produce skin panels for car outer bodies, helping it retain leadership among domestic suppliers to high-quality segments like the automotive and white goods sectors.

As such, all three lines are central parts of the Phase Two expansion of the client’s steel plant, and are to increase the annual galvanized steel production by 1 million t.

South Korea Primetals optimizes pickling line-tandem cold mill for Hyundai Steel in just a few weeks.

Primetals Technologies optimized the drive and automation equipment of the pickling line-tandem cold mill (PLTCM) No. 1 at the Dangjin plant of Hyundai Steel, a Korean steel producer. After a refurbishment phase at the end of 2018, all the agreed proofs of performance for the production of more than 20 different product groups were completed by January, in a period of just four weeks. The production capacity of the PLTCM was substantially increased at the same time, which now enables it to supply cold-rolled strip to an additional strip galvanizing line at the plant in Suncheon, South Jeolla Province, South Korea. The refurbishment was preceded by a detailed analysis of the weak points of the entire plant and the development of a targeted refurbishment concept. This increased the production potential of the existing lines and minimized the investments needed for new equipment.

Denmark Tibnor’s acquisition of Sanistål’s steel distribution business completed. SSAB’s subsidiary Tibnor has now completed the acquisition of the steel distribution business of Sanistål A/S, Denmark’s second largest steel distributor. The acquisition was announced in November 2018 and supports SSAB’s strategic target to strengthen its Nordic home market position. The acquired distribution business had sales of around SEK 1.9 billion (approximately USD 19.8 million) in 2018. A cornerstone of SSAB’s strategy is leadership in the Nordic home market. Here, Tibnor plays an important role as steel distribution channels today account for more than half of the total Nordic steel market.

>>

World crude steel production was 155 million t in March 2019 for the 64 countries reporting to the World Steel Association (worldsteel), a 4.9% increase compared to March 2018. World crude steel production was 444.1 million t in the first three months of 2019, up by 4.5% compared with the same period in 2018.

ArcelorMittal is to temporarily reduce its annualized European primary steelmaking production by 3 million t. A combination of weakening demand, rising imports coupled with insufficient European Union trade protection, high energy costs and rising carbon costs are cited as reasons behind the decision.

RHI Magnesita announces 5% global price increase for its portfolio. This increase has been applied to the refractory products supplier’s whole product spectrum, worldwide, including basic (magnesia and dolomite based) and nonbasic products, varying in a range of 3% to 20%. The company has already started to inform customers.

ABB has launched new digital AbilityTM Data Analytics Platform for iron, steel and other metals manufacturers. The software suite provides data-integration, monitoring, data analytics and optimization in one single platform for faster, more data-driven decision making.

Tata Steel has unveiled its ‘most sustainable yet’ storage facility in IJmuiden, the Netherlands. The official opening of the new, ultra-modern storage facility for steel coils was on May 8, 2019. Air-curtains to prevent heat loss, automated loading bays and energy-recovering cranes are among the new 10,000 m² facility’s innovations.

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Finland BE Group becomes SSAB Laser® Certified Partner in Finland and the Baltics. SSAB has appointed BE Group, which serves customers in the engineering and construction sectors, as an SSAB Laser® Certified Partner. BE Group is a long-standing partner of SSAB in trading hot-rolled plate, strip and tubular products. SSAB Laser has been especially developed for laser cutting and cold forming. The product improves general productivity, output and end-product quality. SSAB Laser also has guaranteed flatness, both before and after laser cutting. The SSAB Laser distribution network now consists of 22 dedicated partners in 13 countries across Europe. Customers in Finland and the Baltics should benefit from better steel availability and faster deliveries.

Portugal Megasa Group chooses SMS Group reheating technology. SMS group has been chosen by Megasa Group for the supply of a new walking beam furnace to be installed in the existing bar mill of SN Seixal Siderurgia Nacional S.A. in Aldeia de Paio Pires, Portugal.

The new furnace, rated at 160 t/hour cold charged and 210 t/hour hot charged, will include the latest technological packages developed by SMS group. Start-up is scheduled for the end of summer 2020.

Russia MMK selects Paul Wurth for modernization of its No. 2 blast furnace. MMK (Magnitogorsk of the Chelyabinsk region, Russia) will conduct the complete overhaul in 2020. After fundamental renewal and modernization, the blast furnace will appear as a structure without a lintel ring. Paul Wurth will help MMK define the profile of the modernized furnace by considering the raw materials base and process conditions of the customer.

Detail engineering will be provided for the high-heat loaded bosh and belly areas, cooling elements and primary cooling system. Paul Wurth will also

supply horizontally arranged copper cooling plates, highly conductive graphite refractory bricks and ramming mass. A complete set of equipment in compartment (EIC) for the dedicated pump house with heat exchangers and the related cooling circuit will be part of the deliverables.

Spain SMS group upgrades walking beam furnace at Sidenor Basauri, Spain. Sidenor Basauri from Spain has enlisted SMS group to supply a stage two upgrade of its walking beam furnace. This will increase the furnace’s bloom reheating capacity for Special Bar Quality (SBQ) steel production from 85 t/hour to 130 t/hour. Supplied

by SMS group in 2016, the furnace was originally designed with the provision for a future capacity increase. In the design phase, the SMS engineers had already taken into consideration all civil and mechanical modifications required for the future capacity boost in order to guarantee a short plant shut down and a fast restart. The second start-up after the upgrade is scheduled for the second half of 2020.

ArcelorMittal to temporarily reduce annualized European primary steelmaking production by three million t. ArcelorMittal has announced its intention to temporarily idle production at its steelmaking facilities in Kraków, Poland, and reduce production in Asturias, Spain. In addition, the planned increase of shipments at ArcelorMittal Italia to a 6 million t annual run-rate will be slowed down following a decision to optimize cost and quality over volume in this environment. Together, these actions will result in a temporary annualized production reduction of around 3 million t. The decision is due to a combination of weakening demand, rising imports coupled with insufficient EU trade protection, high energy costs and rising carbon costs.

Sweden Ovako publishes additional climate declarations. Ovako of Sweden, a developer of high-tech steel

solutions for the bearing, transport and manufacturing industries, has previously published climate declarations for its production flows at Hofors, Smedjebacken and Boxholm (all Sweden). Now, it has published another for its production facility in Imatra, Finland. The climate declarations compare Ovako’s carbon footprint per kg of finished steel product with the global average, from raw material until the finished product leaves its production facilities. Ovako’s products have an 80% lower carbon footprint than average for hot-rolled steel products. The declarations are available on the website of The International Environmental Product Declaration (EPD) System.

Turkey Diler Demir Çelik orders vacuum degassing station. A new vacuum degassing station will be installed in the meltshop of Diler Demir Çelik, located in Dilovasi, Turkey. It will be designed with a movable tank with fixed and lifetable cover. Suction capacity of about 180,000 m3 will be ensured by a six-module, mechanical dry pump and Danieli Automation process control.

The innovative Q-AFS technological package will provide automatic control of slag foaming during the pumpdown period, which results in increased availability and productivity of the vacuum degasser. This order follows the recent caster modernization at that site.

Ukraine Continuous caster and secondary metallurgy facilities by Primetals receive FACs from MMKI. In late March, Ukraine’s second largest metallurgical enterprise, Ilyich Iron and Steel Works of Mariupol (MMKI), issued the Final Acceptance Certificates (FACs) for a two-strand continuous slab caster, a twin ladle furnace with an alloying station, and the associated dedusting system, all supplied

by Primetals Technologies. The twostrand caster CC4 is designed to produce 2.5 million t/year of slabs. This increases MMKI's annual production capacity to around 4 million t, as well as expanding its product portfolio to

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‹‹‹ include, for example, HC, UHC and ULC steels. A Level 3 heat-pacing solution coordinates the steel production with the casting operation.

United Kingdom

10TH INTERNATIONAL METALLURGICAL TRADE FAIR WITH CONGRESSES

Liberty invests GBP 35 million in project to create smarter, greener and cleaner steel. Liberty will play a key role in a landmark new GBP 35 million research network. It is the first time UK steel producers and representatives from the manufacturing sector have lined up behind a co-ordinated research programme. The network, called SUSTAIN, is supported by the Engineering and Physical Sciences Research Council with the largest ever investment by a UK research council in steel research. Led by Swansea University, Wales, partnered with the universities of Sheffield and Warwick, England, SUSTAIN is projected to double UK steel manufacturers’ gross value added (GVA) by 2030, boost jobs in the industry to 35,000 and increase productivity by 15%.

Inteco successfully installs another ESR plant for Breitenfeld Edelstahl AG. After erection of the 30 t electroslag remelting (ESR) plant began on schedule in January 2019, the first successfully remelted ingot was presented approximately ten weeks later. In May 2018, a contract was signed for the engineering and supply of a state-of-the-art ESR plant, located in Upper Styria, Austria, that will further increase the ESR capacities of quality and premium steels.

In addition to the existing two ESR plants and the Vacuum Arc Remelting (VAR) furnace, this plant will be the fourth remelting plant in the ultra-modern special steel plant to meet Breitenfeld’s high requirements.

Hitachi metals grants FAC to SMS Group for largest four-column open-die forging press. Hitachi Metals of Yasugi, Japan, has granted SMS group the final acceptance certificate (FAC) following the successful commissioning of its 90/108 MN open-die forging press. This is the largest four-column open-die forging press in push-down design that SMS group has built in the last 25 years. The plant operates with a forging force of up to 90 MN and an upsetting force of 108 MN. It quickly and precisely forges flat and round bars from ingots at a maximum starting material weight of 30 t. Two rail-bound manipulators position the forgings with millimetre precision and move them fully in sync with the press stroke. The new open-die forging press will process temperature-sensitive materials such as titanium alloys, tool steels, high-speed steels and nickel-based alloys.

Primetals to supply Quantum EAR and ladle furnace and ladle furnace to Wuzhou Yongda. Primetals Technologies has received an order from Chinese steelmaker Wuzhou Yongda Special Steel Co., Ltd. to supply a Quantum electric arc furnace (EAF) and a ladle furnace for a greenfield project in Wuzhou city in China’s Guangxi Zhuang Autonomous Region. This marks the tenth EAF

Metals EFFICIENT PROCESS SOLUTIONS

Key technology – metallurgy METEC, with the area of forging technology, is the leading global event for the production and processing of raw iron, steel and non-ferrous metals.

Theory meets practice Supporting events, such as the 4th European Steel Technology and Application Days (ESTAD), are discussion forums for new steel technologies and applications at the highest level worldwide.

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www.messe-duesseldorf.de

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››› Quantum furnace for China. The furnace is designed to handle scrap steel of very varied composition and quality. The electrical energy requirement of the EAF is extremely low because the scrap is preheated. This reduces both the operating costs and the CO2 emissions. The new furnaces are scheduled to be commissioned in early 2020.

Kemppi acquires Italian Trafiet Group to strengthen its position in welding aftermarkets. Kemppi has acquired a 100% of the shares of the Italian welding torch manufacturer Trafimet Group S.P.A. The contract was signed in Italy on March 1. The acquisition brings in a company with a strong position, especially in the welding torch and consumable aftermarkets. In addition to the torches, the Trafimet product range includes welding accessories such as welder’s safety products. Both companies will continue as separate businesses after the acquisition.

STAP tap hole emergency opening at Acciaierie Bertoli Safau.

Acciaierie Bertoli Safau, a leading European manufacturer of steel used in specialized engineering applications, has awarded MORE the order for the STAP multi-axis equipment which automatically opens the tap hole in the event of clogging by an oxygen lance in the EAF. The STAP device is not used regularly in each cycle, but only when required. Nevertheless, it can prevent long delays that can accumulate in several melt shops due to the time required for operators to repair the occurrence of the non-spontaneous opening. The primary features of the equipment are: highly versatile movement with four independent axes, highly precise remote control and an arm length of up to 6 m. The new equipment is scheduled to be in operation by the third quarter of 2019.

SMS group supplies high-performance compact cold mill. Marcegaglia Ravenna S.p.A. has contracted SMS group for the complete supply of a two-stand reversing cold mill of CCM® (Compact Cold Mill) design. Marcegaglia’s headquarters is located in Gazoldo degli Ippoliti, Mantua province, North Italy. The new CCM will be implemented at the Ravenna facility

where Marcegaglia produces cold rolled carbon steel sheets and strips for industrial applications. The mill processes a comprehensive material mix, including high carbon and duplex steels, chromemanganese alloyed steels and silicon steels. The annual capacity is about 550,000 t. Depending on the product mix, it rolls strips with widths of between 750 and 1,570 mm and entry thicknesses ranging between 0.60 and 5.00 mm. The minimal achievable final thickness is 0.23 mm.

NLMK DanSteel expands its niche plate line. NLMK Group, a global steel company, has begun hot testing of its accelerated cooling system at NLMK DanSteel's hot-rolling plate mill in Denmark. The new equipment will fundamentally change the company's product mix and increase the share of niche plate, including for offshore wind power generation and pressure vessels. The new accelerated cooling system is in-line with the hot-rolling mill. After rolling to the final thickness, the plate is fed into the cooling system and cooled rapidly with water under controlled conditions. Thermomechanical rolling allows the production of plates with improved weldability while improving the strength and toughness. The new cooling system will boost the production of niche premium plate from the current 0.1 million t to 0.35 million t.

Nucor Group’s-‘most environmentally-friendly’-reheating furnace.

Nucor Steel Marion, Inc. of Marion, Ohio, USA, granted SMS group the Final Acceptance Certificate (FAC) of the supplied walking beam furnace shortly after successful commissioning. Nucor now operates its most energy-efficient furnace with the lowest emission values achieved within the Group. Its nitrogen oxide (NOx) content is close to 25 parts/million. The furnace is designed according to innovative pre-fabrication methods and features proprietary SMS ZEROFlame burners. It has the capability to deliver 120 short t/ hour of hot billets at 2,255 °F (1,235 °C) with less than 1.04 million British thermal units/t. Scale loss saving has also been remarkable, with a measurement of less than 0.5% in weight, compared with the 0.75% guaranteed. This represents a very solid performance

and significant cost savings for the process.

CMI obtains final acceptance for Foshan Chengde’s pickling section. Privately owned Foshan Chengde New Material Co., Ltd. has awarded CMI the final acceptance certificate (FAC) for the pickling process section of its new cold annealing and pickling line (CAPL) that has been erected at the customer’s site at the Tieshan Port (Seaside) Industrial Park. Based in Guangdong Province, China, Foshan Chengde produces a large variety of stainless steel strips and pipes. The state-of-theart chemical treatment equipment, provided by CMI Industry Metals, is one of the centrepieces of the client’s new CAPL. It will help Foshan in its endeavour to achieve the highest-quality end products and improve its competitive position, both in the domestic market and overseas. The new CAPL has a capacity of 500,000 t/year and is processing austenitic stainless steel grades, such as 200 and 300 series austenitic nickel-chromium (Ni-Cr) stainless steel.

Construction starts on Liberty’s GBP £ 10 million Global Technology Centre. Liberty Engineering Group, part of global GFG Alliance, is constructing a new GBP £ 10 million (approximately USD $ 13 million) Global Technology Centre in Leamington Spa, Warwickshire, UK. The state-of-the art 50,000 sq. ft. centre will become the UK hub for Liberty’s R&D and engineering expertise. It will house more than 100 highly-skilled technical professionals, including 40 new engineering posts to be created by the investment. The flagship centre will support Liberty’s plans to grow its market share in the automotive and other sectors by providing solutions ranging from design and prototyping to volume manufacturing. The centre will also house Liberty’s Vehicle Technologies, 920Engineering (920E) and Shiftec businesses, renowned internationally for their advanced lightweight braking and control systems. thyssenkrupp to establish an Additive Manufacturing TechCenter Hub in Singapore. thyssenkrupp will establish an Additive Manufacturing TechCenter Hub in Singapore, this

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‹‹‹ year. The announcement, made at Hannover Messe 2019 in Hannover, Germany (April 1 to 5), illustrates the company’s initiative to bring its engineering and innovation capabilities to customers in Asia Pacific. Supported by the Singapore Economic Development Board (EDB), it will serve as the regional hub for the company’s Mülheim TechCenter and aims to unlock the potential of additive manufacturing, also known as 3D printing, for customers in Singapore and across Asia Pacific. thyssenkrupp first launched a dedicated TechCenter for additive manufacturing in Mülheim an der Ruhr, Germany, in 2017, capable of delivering the full spectrum of the additive manufacturing value chain.

JSW Steel plans to ramp up production capacity at its Vijayanagar, Karnataka, India, plant. JSW Steel has an ongoing project to raise production at the plant from 12 t/year to 13 t/year, which will be completed

by March 2020. Seshagiri Rao, joint managing director at JSW Steel, said the company already has the requisite permission to enhance output at Vijayanagar up to 16 t/year. Depending on iron ore availability, production will be raised to 18 t/year. On the cost front, he said steel companies typically spend Rs. 5,000 to 6,000 crore for setting up 1 t/year of steel production capacity, but JSW Steel has managed it at Rs. 3,500 crore. The cost of brownfield expansion at Vijayanagar will be much lower, at about Rs. 3,000 crore, he said.

Construction continues on the new voestalpine special steel plant in Kapfenberg. One year after the ground-breaking ceremony for the world’s most advanced special steel plant, construction work for voestalpine’s EUR 350 million project in Kapfenberg, Styria, Austria, is on schedule.

After completion of the construction site and associated infrastructure, Group company voestalpine Böhler Edelstahl has now awarded the contract for construction of the plant’s hall.

Austrian companies Unger Stahlbau Ges.m.b.H, based in Burgenland, and Haslinger Stahlbau GmbH from Carinthia (both Austria), will form a consortium to erect the steel construction covering an area of three hectares. The industrial equipment permit for the new plant was issued in March 2019.

Improved productivity and energy savings for Gerdau Midlothian EAF. Installed on electric arc furnace (EAF) “B” at the Midlothian plant in Texas, USA, and started up in January 2019, the new Danieli Q-MELT suite is helping Gerdau to perform at high levels. The Q-MELT suite is an EAF automatic system designed to enhance melting process flexibility for any type of raw material charge mix. It consists of MeltModel, Q-REG and Lindarc technological packages and improves EAF performances significantly by lowering energy consumption, power-on time and electrode consumption. The improved productivity and energy savings led to a quick acceptance.

Harsco signs seven-year growth contract with Egyptian Steel. The Metals & Minerals division of Harsco Corporation, a diversified industrial company providing a range of onsite services and engineered products to the global steel, energy and railway sectors, has further expanded an existing agreement with Egyptian Steel, the manufacturer of rebar and wire rods in the Middle East and North Africa. Under the terms of this expanded agreement, Harsco will provide scrap and slag management, material handling and metal recovery services at Egyptian Steel’s Beni Suef plant. Harsco has provided similar services to Egyptian Steel’s Al Ain Al Sokhna site since late 2017.

Meros off-gas cleaning systems supplied by Primetals started-up at Kardemir, Turkey. In December 2018, a Meros off-gas cleaning plant supplied by Primetals Technologies was started up at sinter plant No. 3 of Turkish steel producer Karabük Demir Celik Sanayi ve Ticaret A.S. (Kardemir), followed by the Meros plants supplied for Kardemir's sinter plants No. 1 in early February and No. 2 in early March.

Each Meros plant is able to treat 400,000 Nm³/h of sinter off-gas, reducing sulfur oxide (Sox) by more than 90% as well as delivering extremely low dust emissions. All the three Meros plants are using sodium bicarbonate as a desulphurization agent. The projects were realized within a very short time span. For example, only ten and

half months were required from the technical specification of the Meros plant installed at sinter plant No. 3 until start-up. With the new Meros plants, air quality in the valley of Karabük is improved considerably.

Tata Steel’s sales director is appointed president of Europe’s leading steel for packaging association. Tata Steel’s sales director packaging, Tony Waite, has been appointed president of the Association of European Producers of Steel (APEAL), succeeding Stéphane Tondo of ArcelorMittal. Tony’s nomination is in line

with the biennial rotating presidency of APEAL. The association’s achievements under Mr. Tondo’s presidency include consolidated sustainability leadership of steel for packaging with a recycling rate of 79.5%. Mr. Waite will oversee implementation of the European Union’s Circular Economy Package, levering good practices in collection, sorting and recycling of steel packaging across all member states. He joined Tata Steel in 1999 and is looking forward to his 20th year in the company and the industry.

Schmolz + Bickenbach AG announces changes to the Board of Directors. At the annual general meeting of Schmolz + Bickenbach on April 30, 2019, Jens Alder, Alexey Moskov and Adrian Widmer are proposed as new members of the board of directors.

All three have many years of international management experience. >>

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holders' Committee and Supervisory Board of Voith GmbH & Co. As a production engineer with a doctorate, at Siemens he was responsible for, among other things, the Industry Sector and most recently for the Medical Technology Division of Siemens Healthineers.

He also acted as chief technology officer (CTO) of Siemens AG and, in this capacity, advanced the company's digital transformation.

Patton appoints new leadership in EMEA. Patton, manufacturer of SmartNodeTM voice-over-IP (VoIP) products, has appointed two new business leaders, Marjan Torkar and Michael Schwidder, to expand its business operations and drive revenue growth throughout Europe, the Middle East and Africa (EMEA). Marjan Torkar is former Mobik CEO and Dialogic vice president. He is responsible for Patton’s European business unit with the mission to grow revenue and deliver strong EBITDA performance.

Michael Schwidder, with over 20 years of channel experience in Europe, is responsible for executing Patton’s chan-

ABB names Peter Voser as interim CEO, Ulrich Spiesshofer steps down. The board of directors of ABB, Zurich, Switzerland, and its CEO Ulrich Spiesshofer have mutually agreed for him to step down from his role, which he has held since 2013. The chairman of the board, Peter Voser, will become interim CEO in addition to his current role with immediate effect. An official search to find a new CEO has been initiated.

Nucor chief digital officer (CDO) and executive vice president (EVP) announces retirement. R. Joseph Stratman, CDO and EVP of Nucor Corporation, USA, has announced that he plans to retire on June 8, 2019 after more than 29 years of service with the company. Mr. Stratman began his career with Nucor in 1989 as controller of Nucor building systems, Indiana.

He then served as controller of Nucor-Yamato Steel Company, general manager of Nucor Steel-Nebraska and general manager of Nucor-Yamato. He was promoted to vice president (VP) of Nucor in 1999 and to EVP of Beam and Plate Products in 2007. Mr. Stratman later served as EVP of Business Development, EVP of Raw Materials and most recently as CDO and EVP. Effective as of May 19, 2019, Mary Emily Slate will be promoted to EVP and will assume responsibilities for the Tubular Products Group, logistics and certain joint ventures.

Top UK steel executive to join Liberty as it expands in continental Europe. Industrials group Liberty, part of the global GFG Alliance, has recruited Jon Ferriman, one of the UK’s most senior steel executives, as Integration Director to help lead its expansion in continental Europe. Liberty has made a binding conditional offer to acquire seven steel producing sites from ArcelorMittal in six European countries, including two major integrated works in the Czech Republic and Ro-

mania. For Mr. Ferriman, this will be the latest step in a distinguished 36year career; most recently as hub director of Tata Steel UK where he headed the company’s entire Strip Products UK business and its UK research and development activities.

Tata Steel makes key appointment to support business growth.

Tata Steel of Mumbai, India, has announced a key appointment as the company looks to maximize on an upturn in its oil and gas activity. Peter Bradshaw joins Tata Steel as technical sales manager – energy and power with nine years of experience in technical

sales and the oil and gas industry. His focus will be on Tata Steel’s offshore line pipe products, including the benefits of Tata’s successful high frequency induction (HFI) pipe. While Mr. Bradshaw’s remit will be to support the global oil and gas industry, a growing return to optimism in the North Sea has seen an increase in business for Tata Steel. The company has supplied more than 1 million t of pipeline for oil and gas projects in the North Sea over 24 years, including in excess of 500,000 m of reel installed pipe and more than USD $ 321 million (GBP £ 250 million) invested in subcontracts for North Sea projects.

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New member of the Supervisory Board of thyssenkrupp AG. Prof.

Siegfried Russwurm has been appointed to the supervisory board of thyssenkrupp. Prof. Russwurm is a former member of the managing board of Siemens and chairman of the Share-

nel-centric, two-tier distribution strategy to achieve revenue targets in Europe as director of channel management. The two new leaders at Patton will expand operations and drive revenue growth in EMEA with innovative unified communications (UC), Cloud and Internet of Things (IoT) solutions.

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Mr. Alder, a Swiss citizen, is executive chairman of Alpiq Holding Ltd. in Lausanne, Switzerland; Mr. Moskov, a Cypriot citizen, is the owner and executive chairman of Witel AG in Zurich, Switzerland; and Mr. Widmer, a Swiss citizen, is Group chief financial officer (CFO) of Sika AG, a global specialty chemicals company based in Baar, Switzerland.

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››› the wire, cable and wire processing industries. › 5 – 6 June 2019 Essen, Germany Organizers: untitled exhibitions www.automation-essen.com All about automation. Under the banner of ‘In Focus’, this year’s event promises well-informed discussions about the requirements for automation solutions within the context of Industry 4.0. These include systems, components, software and engineering for industrial automation and communications. Tried and tested products are as important at this event as advice on practicable digital transformation solutions, along with necessary steps for the targeted implementation of Industry 4.0 in the future. › 17 – 21 June 2019 Salzburg, Austria Organizers: MINES ParisTech CEMEF www.icasp5-csscr5.org ICASP-5 and CSSCR-5. The 5th International Conference on Advances in Solidification Processes (ICASP-5) and the 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR-5). The scope of these events covers all aspects of solidification related researches and applications.

It is an opportunity for solidification experts, from both academic research area and engineering applications, to share their knowledge and new scientific achievements, and to discuss the common challenges and potential pathways for future developments. › 18 – 20 June 2019 Düsseldorf, Germany Organizers: Messe Düsseldorf GmbH www.messe-duesseldorf.de wire Russia Moscow. wire Russia attracts exhibitors and suppliers of wires and cables to discuss the latest technologies, specialty products, innovative machines, and concerns relating to wire and cable manufacturing as a unique communication platform. Experts from around the world use the trade fair as an information centre for the latest developments and trends in

› 19 July 2019 (one day) Hamburg, Germany Organizers: Meorga GmbH www.meorga.de MEORGA MSR-Spezialmesse Nord.

This exhibition for products related to process control, instrumentation, control and control technology will take place in Hamburg, Germany. Attendees can inform themselves of the latest industry trends and innovations, exchange ideas with colleagues and make new contacts. In addition, experienced professionals will be present to answer questions from visitors. › 24 – 28 June 2019 Düsseldorf, Germany Organizers: Steel Institute VDEh www.METEC-ESTAD2019.com ESTAD 2019. The European Steel Technology and Application Days (ESTAD) takes place for the fourth time this year. The long-lasting alliance between the METEC international trade fair for metallurgy and this accompanying conference makes it a quintessential meeting point for the world’s leading steel experts. › 25 – 29 June 2019 Düsseldorf, Germany Organizers: Messe Düsseldorf www.METEC.com METEC 2019. The tenth international metallurgical trade fair will be staged together with the trade fairs GIFA, THERMPROCESS and NEWCAST. Its exhibits will include machinery and equipment for iron, steel or non-ferrous metal production, plus equipment for metallurgical plants, rolling mills or steel mills. › 13 – 15 August 2019 Toronto, Canada Organizers: AIST (The Association for Iron and Steel Technology) www.aist.org/conferenceexpositions/steelsim The 8th International STEELSIM Conference. The important role of modeling and simulation of metallurgical processes has achieved worldwide acknowledgment, especially in opti-

mizing technological processes, reducing production costs and increasing steel quality. STEELSIM2019 is an excellent venue for producers, academia, researchers and engineers from around the globe to discuss recent developments and exchange information on issues related to the modelling and simulation of metallurgical processes. › 18 – 20 September 2019 Bangkok, Thailand Organizers: Messe Düsseldorf Asia www.wire-southeastasia.com Tube Southeast Asia 2019, wire Southeast Asia 2019. Returning to Bangkok in 2019, wire Southeast Asia, from the organizers of Germany’s wire Düsseldorf, marks its 13th edition as the region’s most authoritative trade event for the wire and cable industries. › 30 September – 2 October Vienna, Austria Organizers: ASMET (The Austrian Society f. Metallurgy a. Materials) www.stainlesssteel2019.org ESSC & Duplex Conference. After the successful Graz 2015 and Bergamo 2017, once again, the 11th European Stainless Steel Conference Science & Market and the 8th European Duplex Stainless Steel Conference & Exhibition will be jointly organized, as a single event, by ASMET. The conference focuses on all aspects of development, production technology (hot and cold rolling, heat treatment and more) and the corrosion of stainless steels and duplex stainless steels. It attracts delegates from both academic and industrial backgrounds. › 12 – 15 November Moscow, Russia Organizers: Expo-Park Exhibition www.metal-expo.ru/en METAL-EXPO 2019. Despite the use of synthetic materials and the most up-to-date digital technologies, products of the steel industry, mechanical engineering and metalworking remain highly significant across all the industry segments. MetalExpo presents the most interesting solutions through its conferences, seminars, and roundtables. This year’s largest exhibit showcases Russian equipment made with the latest innovative technologies.

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AISTech: The Iron & Steel Technology Conference and Exhibition AISTech 2019, steel’s premier technology event, is being held at the David L. Lawrence Convention Center in Pittsburgh, Pennsylvania, USA (May 6 to 9).

As in previous years, AISTech features technologies from all over the world that help steel producers compete more effectively in today’s global market. It remains a ‘can’t miss’ event for anyone involved at any level of today’s steel marketplace, providing perspective on the technology and engineering expertise necessary to power a sustainable steel industry.

More than 8,000 people are expected to attend AISTech 2019. With more than 500 exhibiting companies, the event promises many opportunities to meet face-to-face with key individuals from around the world that are involved in the production and processing of iron and steel.

In addition, more than 550 technical presentations will be delivered. Attendees can reflect on a constantly changing industry, gain a command of cutting-edge steel-related technologies, and discover new ways to improve productivity.

Contact: www.aist.org

Contact: www.messe-duesseldorf.de

Contact: www.messe-duesseldorf.de

Photo: Messe Düsseldorf

AISTech, METEC 2019 and three exhibitions in Russia – Tube Russia, Metallurgy and Litmash – are all upcoming calendar highlights for the steel industry. They promise the latest technical innovations, essential opportunities for networking, plus key discussions about productivity and the environment.

Tube Russia, Metallurgy and Litmash The three exhibitions Tube Russia, Metallurgy and Litmash will be held together in Moscow, between May 14 to 17, 2019. The trade fair trio is organized by Messe Düsseldorf GmbH, its Russian subsidiary Messe Düsseldorf Moscow and the Russian partners Metal Expo. This year is expected to bring another strong appearance across each of the three events with 250 exhibitors from 20 countries. The trade visitors will primarily come from Russia, the neighbouring Commonwealth of Independent (CIS) states and other European nations.

Meanwhile, wire Russia – which was still held concurrently with the three other trade fairs in Moscow in 2017 – will now be staged as a separate event in Moscow one month later (from June 18 to 20, 2019). This is due to the growing volume of exhibitors from the segment of wire and cable, machinery manufacturers, and the limited number of exhibition spaces available in Moscow during the month of May.

The International Metallurgy Trade Fair (METEC) From June 24 to 28, the VDEh Steel Institute will be organizing the 4th European Steel Technology and Application Days (ESTAD) in Düsseldorf, Germany. Europe's leading conference

for the steel industry will accompany the International Metallurgy Trade Fair (METEC), the world's leading trade fair for metallurgical technology.

This year, METEC takes place for the 10th time. The 4th ESTAD is organized by the Steel Institute VDEh in cooperation with its partners, the Austrian Society for Metallurgy and Materials, Jernkontoret of Sweden and the Associazione Italiana di Metallurgia of Italy.

The conference will focus on all technical topics related to steel, its production and applications, as well as environmental and energy aspects. This gives participants the opportunity to obtain comprehensive first-hand information. The programme for 2019 is divided into five thematic areas: • ironmaking, • steelmaking, • rolling and forging, • steel materials and their application, • additive manufacturing, • surface technologies, • environmental and energy aspects.

The long-lasting alliance between the METEC international trade fair for metallurgy and this accompanying conference makes it a quintessential meeting point for the world’s leading steel experts. Visiting the 4th ESTAD 2019 should again be a must for steel producers, suppliers and users.

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Sikora, a manufacturer and global supplier of advanced measuring technology for the metals, hose and tube, wire and cable, optical fibre and plastics industries, is exhibiting at METEC in Dusseldorf, Germany (from June 25 to 29).

The company will present a broad portfolio of innovative systems for the non-destructive quality control and process optimization of steel tubes, strips and plates at its booth 3A58.

They include the Radar Scan 6000, a system for non-contact inline measurement of the diameter and ovality of metal tubes and rods. The system is based on progressive, high-resolution radar technology and records measuring values over 360° of the circumference of the product, to micron accuracy.

The measurement is carried out by radar transceivers simultaneously from

several directions and is insensitive to heat, dust and steam. Typical measuring ranges of 300 to 2,500 mm are covered. The Radar Scan 6000 requires no coupling media and continuously delivers precise measuring values which offer high reliability and availability for the user. Due to its slim design, the system can be easily integrated into the production process for hot, as well as cold, measurement.

The technology measures regardless of the surface roughness in typical tube applications. Measuring values are displayed clearly, graphically as

well as numerically, on the display of the processor system, EcoControl 6000. Furthermore, extensive trend and statistical functions, as well as comprehensive data logging, are available. The Radar Scan 6000 is designed to contribute to the highest product quality, process optimization and cost savings during tube manufacturing.

Another highlight at the Sikora booth is the Planowave 6000 M, a non-contact measuring system that is used for the non-destructive thickness

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Non-contact temperature measurement in metal production

measurement of slabs, strips and plates.

The system offers a precise thickness measurement independent of the material, temperature and surface of the product. An external calibration on the material is not needed. The measurement of the product is also based on radar technology. Transceivers above and below the material continuously send and receive frequency modulated millimeter waves. The thickness – typically centreline thickness – of the product is precisely determined from

the runtime difference. By using a traversing set of transceivers, the cross-section profile of the product can be determined optionally.

The Planowave M is designed for a typical measuring range of up to 500 mm. The system is used directly in the production line, or at the end of the line, for final quality control. This system also combines with the display and control system EcoControl 6000 for the visualization of the measuring values, the display of trends and statistics as well as for data logging.

Furthermore, Sikora presents its Laser Series 6000 gauge heads which measure the diameter of tubes, wire rods and bars with a higher precision and repeatability, plus a wide range of interfaces. Three high-end models complement Sikora’s product portfolio and cover product diameters from 0.2 to 78 mm. These are capable of up to 5,000 measurements per second, all with extremely high single value precision that enables optimum line control and reliable statistical data. Once again, the measuring values are clearly visualized and operations are performed intuitively via the EcoControl display.

According to Sikora, all of its measuring systems are designed to assure the highest quality and an efficient process during production.

Contact: www.sikora.net

Infrared pyrometer for non-contact temperature measurements from -50°C to 2200°C  Temperature measurement from a safe distance even of moving, difficult-to-access and very hot objects  Ideal for high-speed measurements  Temperature resistance of sensors up to 250°C

Thermal imaging cameras for industrial temperature monitoring from -20°C to 2000°C  Compact IR cameras for metal production and processing  Protection housing for harsh environments  Process documentation with thermal videos and images

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Growth in steel demand remains positive In 2018, global steel demand increased by 2.1% (after adjusting for China’s clampdown on induction-furnace based steel and subsequent furnace closures), growing slightly slower than in 2017. In 2019 and 2020 growth is still expected, but in a less favourable economic environment. China’s de-

Contact: www.worldsteel.org Email: info@worldsteel.org

celeration, a slowing global economy, and uncertainty surrounding trade policies and the political situation in many regions suggest a possible moderation in business confidence and investment.

Chinese steel demand remains robust owing to government stimuli Chinese steel demand continues to decelerate as the combined effect of economic rebalancing and trade tension is leading to slowing investment and sluggish manufacturing performance.

Mild government stimulus cushioned the economic slowdown in 2018. In 2019, the government is likely to heighten the level of stimulus, which is expected to boost steel demand.

In 2020, a minor contraction in Chinese steel demand is forecasted as the stimulus effects are expected to subside.

Steel demand in the developed world reacts to a weaker trade environment Steel demand in the developed economies grew by 1.8% in 2018 following a resilient 3.1% growth in 2017. worldsteel expects demand to further decelerate to 0.3% in 2019 and 0.7% in 2020, reflecting a deteriorating trade environment.

In 2017-18, steel demand in the US benefitted from the strong growth of the economy driven by government-led fiscal stimulus, leading to high confidence and a robust job market. In 2019, the US growth pattern is expected to slow with the waning effect of fiscal stimulus and a monetary policy normalization. Therefore, both construction and manufacturing

growth is expected to moderate. Investment in oil and gas exploration is expected to decelerate as well, while a boost in infrastructure spending is not expected.

The European Union (EU) economies also face the deteriorating trade environment and uncertainty over Brexit. A slower growth in demand for steel in the major EU economies (especially in the more export dependent countries) is anticipated in 2019. Steel demand growth is expected to improve in 2020, dependent on a reduction in trade tensions.

Japan recorded a growth in steel demand in 2018, supported by a favourable investment environment and continued construction activities, as well as a boost in consumer spending prior to the consumption tax increase.

In 2019 and 2020, steel demand is likely to contract slightly due to a moderation of construction activities and decelerating exports, despite the support provided by public projects.

Steel demand in Korea has been contracting since 2017 due to reduced demand from two major steel-using sectors: shipbuilding and automotive.

Steel demand is expected to continue declining in 2019 due to toughened real estate market measures and a deteriorating export environment.

A mild recovery is predicted in 2020.

Developing economies present a positive, but mixed, picture Steel demand in the emerging economies, excluding China, is expected to grow by 2.9% and 4.6% in 2019 and 2020 respectively.

ASIA. Having overcome the shocks of demonetization and the Goods & Ser-

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The World Steel Association (worldsteel), one of the world’s largest industry associations with a membership representing around 85% of global steel production, has released its latest Short Range Outlook (SRO). The SRO includes forward-looking statements based on current judgements of what the future holds, subject to risks and uncertainties that could cause actual results to differ going forward.

Commenting on the outlook, Mr. Al Remeithi, Chairman of the worldsteel Economics Committee, said: “In 2019 and 2020, global steel demand is expected to continue to grow, but growth rates will moderate in tandem with a slowing global economy. Uncertainty over the trade environment and volatility in the financial markets have not yet subsided and could pose downside risks to this forecast.”

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The World Steel Association (worldsteel) released its latest Short Range Outlook (SRO) in April. According to the report, global steel demand is forecast to reach 1,735 million t in 2019, an increase of 1.3% over 2018. Demand is then projected to grow by 1% to reach 1,752 million t in 2020.

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Latin America. A broad recovery in steel demand across Latin America is expected to continue despite internal and external uncertainty. Recovery in Brazil is in its third year with the construction sector set to mildly improve in 2019. On the other hand, steel demand growth in Mexico is expected to be moderate, influenced by weak mining investment, fiscal budget constraints, policy uncertainties and a slowing US economy.

The political situation in Venezuela and its impact on the region is unclear.

As pent-up demand and government stimulus measures subsided, the automotive industry saw a sharp slowdown in growth in 2018 in many countries, particularly in the EU, Turkey and China. The largest decline was observed in Turkey (-9.0%) and in the UK (-5.5%).

As a result, global auto production growth decelerated to 2.2% in 2018 from 4.9% in 2017. In 2019, global auto production will continue to decelerate to 1% growth with stabilization expected in 2020. However, in Latin America, especially in Brazil, auto production will buck the trend and continue to show a steady rebound.

The momentum of construction activities is also expected to moderate somewhat in the developed economies, but thanks to the rebound in the developing economies, global growth will be maintained at a 3% level in 2019-20. However, in China, Turkey, South Korea and Argentina, construction activities are expected to continue to contract in 2019.

With weakening investment and a worsening trade environment, the global machinery sector is expected to show a steady deceleration that will last until 2020. This will be more pronounced in major production hubs such as Germany, Japan and China.

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Commonwealth of Independent States (CIS) and Turkey. Despite improved oil prices, growth in steel demand in Russia will continue but is expected to be constrained by structural issues. The growth outlook for Ukraine is stable and improving, supported by domestic consumption.

The Turkish economy is still reacting to the currency crisis of August 2018 which led to a contraction in steel demand. This is expected to continue into 2019, with some stabilization in 2020.

Automotive and construction

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Middle East and North Africa (MENA). Economic diversification efforts in the Gulf Cooperation Council (GCC) continue in reaction to a low oil price environment but fiscal consolidation is still suppressing construction activities. Steel demand is expected to continue to contract in 2019, with a minor recovery anticipated in 2020.

Iran’s steel demand will also contract in 2019 as the reinstatement of US sanctions causes a recession in the economy.

The situation in North Africa looks brighter, with Egypt recovering strongly

after the structural reforms of 2017. Investment in energy and a recovery in the real estate market are expected to drive Egyptian steel demand. Other North African economies are also expected to show resilient growth in steel demand, backed by strong investment activities.

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vices Tax (GST) implementation, the Indian economy is now expected to achieve faster growth starting in the second half of 2019, after the election.

While the fiscal deficit might weigh on public investment to an extent, the wide range of continuing infrastructure projects is likely to support growth in steel demand above 7% in both 2019 and 2020.

Steel demand in developing Asia excluding China is expected to grow by 6.5% and 6.4% in 2019 and 2020 respectively, making it the fastest growing region in the global steel industry.

In the Association of Southeast Asian Nations (ASEAN) region, infrastructure development supports demand for steel.

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In order to extend the range of steel grades and increase production capacity, Nucor has contracted Danieli to upgrade its hot strip plant in Ghent, Kentucky, USA. The revamp is the first time that a classical compact thin slab casting and rolling facility has been fully reconfigured into an ultra-modern Quality Strip Production (QSP®) plant.

Located in Ghent, Kentucky, USA, the thin slab rolling plant operated by Nucor Steel Gallatin (formerly known as the Gallatin Steel Company) has a nameplate capacity of 1.6 million short t/year (approximately 1.4 million

Contact: www.danieli.com Email: m.bulfone@danieli.it; info@danieli.com

t/year) of hot rolled coils with a thickness range from 1.4 to 12.7 mm, widths of up to 1,625 mm and a maximum coil weight of 35 short t (approximately 31.75 t).

The facility includes a 185 t twin shell direct current electric arc furnace (DC EAF), a single ladle metallurgy furnace (LMF), a vertical caster producing slabs of 65 mm thick by 1,625 mm wide, a 206 m tunnel furnace, a sixstand close-coupled rolling mill, traditional laminar cooling and one down coiler. The current capabilities of the steel plant are mostly structural steel, micro-alloyed grades and thin line pipe grades.

Like similar compact plants, Gallatin was originally designed for doubling the annual capacity by means of

a second steel meltshop and second vertical casting strand, with a tunnel furnace connected by a swivel ferry system to the six-stand tandem hot strip mill. The original expansion plan called for the new equipment to be a copy of the existing installation of a caster and tunnel furnace.

Nucor Steel, which became the owner of the Gallatin Steel Company in October 2014, has recently approved an investment to advance the technological capabilities and competitiveness of the Nucor Steel Gallatin sheet mill. Danieli was selected as the technology supplier for the complete equipment and automation system, from raw material to hot rolled coil. The first cast slab is scheduled for September 2020 and the first rolled coil for No-

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Expanded production of AHSS grades In the spirit of full partnership, the Nucor and Danieli team of specialists agreed to re-engineer the facility by changing the original concept into an advanced Quality Strip Production (QSP®) plant with improved thermomechanical rolling capabilities. This would expand production of advanced high-strength steel (AHSS) grades, heavy gauge American Petroleum Institute (API) line pipe steel grades and a number of other added-value grades.

“For more than 20 years, my work has been dedicated to thin slab casting and rolling and I personally visited the Nucor Steel Gallatin Plant the first time back in 2002,” said Christian Bilgen, Executive Vice President (EVP) Rolling Technologies of Danieli.

“Looking at the new plant concept, I am very proud that the Nucor and Danieli teams together will convert

the existing concept into a new generation of thin slab casting and rolling plants. The possible product portfolio will be significantly widened, including thick API line pipe steels, and the product quality will be considerably increased.” The revamped plant will include a high-performance DC EAF and Twin LMF with provision for vacuum degassing in the future.

Being equipped with state-of-the-art technology, the new meltshop will make use of the most recent process management tools. One of these will be the new Q-Melt® technological package. The automatic EAF technology is designed to enhance the competitiveness and performance of the EAF and is a key function for optimizing the transformation costs.

“The new meltshop will be the most modern one in the USA where plant operations are surrounded by the latest steelmaking technologies,” said Paulo da Costa, meltshop technical sales manager at Danieli.

“Industry 4.0 is a key aspect in the process control, either by applying

adaptive process control for the 188 short t (approximately 170 t) DC EAF – where Q-Melt will dynamically alter the EAF profiles for the best practice – or by using mechatronic technologies that make it possible to conduct the majority of the operations remotely from the main pulpits.

“Safety and productivity are the pillars that will guarantee the success of this project,” Mr. da Costa added.

Scope to double production capacity in the meltshop If there is scope to double the meltshop’s production by installing a new production unit, then the design vision will change for the casting and rolling plant. After the upgrade, the complete production will be delivered by a single-strand vertical curved caster with a total capacity of up to 3 million short t/year (around 2.7 million t/ year).

The new caster represents the fifth generation of Danieli high-production slab casting machines. The slab will be delivered to the rolling mill by a new >>

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tunnel furnace via a swivel-type ferry system. The new layout will allow for the installation of the new caster and first portion of the tunnel furnace and swivel system, without affecting the mill’s production. Furthermore, two new roughing stands will be added to further expand the rolling capabilities.

The independent high-speed roughing, intermediate transfer bar cooling and separated finishing rolling introduces the ability to perform a thermomechanical rolling process, as is typical for conventional HSMs. This will lead to a complete replacement of the existing tunnel furnace, widening of the finishing mill (FM) equipment, new run-out table with advanced combined intensive and lami-

Danieli QSP® plant performances OMK Vyksa, located in Russia’s Nizhny Novgorod region, is the country’s largest domestic manufacturer of steel welded pipes and railway wheels. The facility is a Danieli single-strand QSP® plant with a plant layout similar to one planned for Nucor Gallatin.

It starts with a casting machine producing 90 mm slabs, a 200 m tunnel furnace, two powerful high-reduction stands, a transfer bar area with intermediate transfer bar cooling and TBF that is followed by six finishing stands.

Due to this flexible plant layout, OMK is able to cover a wide range of products from thin gauges of 1.0 mm up to 12.7 mm of API grades for special applications in an overall width range from 800 to 1,800 mm.

In 2015, the product mix consisted of more than 50 percent API grades (up to API X80) and in general of products with an excellent surface quality (98.6%

prime rated coils). Today OMK operates the mill constantly above the rated capacity of 1.2 t/year and will achieve a new production record this year close to 1.3 t/year.

The installation of a new intensive cooling unit in the run-out table (ROT) cooling section will help OMK to increase the mechanical properties of the produced steel grades (strength and impact toughness) and opens up the possibility to decrease high-cost alloying elements such as manganese, silicon and niobium.

OMK is now one of the world’s powerful thin slab plants for pipe grade most production. In 2017, 99% of the products were used for pipe applications, with approximately 50% falling under API or similar specification. Furthermore, OMK is using those pipe grades in its own pipe shops to produce final products for the oil and gas pipe market.

nar cooling and two new downcoilers with coil handling.

The vertical-curved caster will be equipped with a complete suite of advanced technological packages, including Danieli’s latest design of multimode electromagnetic brake (MM®-EMB) to ensure the control of fluid dynamics within the mould, enabling high throughput of quality thin slabs. The tunnel furnace and heated transfer table, installed between the roughing stands and finishing stands, will be supplied

by Danieli Centro Combustion.

The six-stand FM will be retained but it will be widened and upgraded with new interstand guides, loopers and a new bending and shifting system. This will allow Nucor Steel Gallatin to roll strips as wide as 1,870 mm (73.5") To further enhance the performance of the FM, the first three rolling stands

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will be reinforced to withstand higher rolling forces.

Two new powerful roughing stands and a vertical edger will be installed ahead of the FM. With its total draft of 100 mm, the powerful edger allows the full recrystallization of the slab edges and makes it possible to expand the capacity of the plant when producing narrow products.

The complete process control, from melting to finished hot-rolled coils, will be developed by Danieli Automation. The challenge is to optimize the operation between the existing and the new meltshop, while controlling the quality of the caster and QSP. As part of the implementation strategy, the new automation system will shadow and parallel the current automation systems to allow a seamless switchover. The automation system will be designed for integrating the Industry 4.0 concept.

Designed to be modern in the next 30 years “At Danieli Automation, we are very well aware that we are going to create a reliable plant,” said Antonello Mordeglia, president, Danieli Automation.

The plant, explained Mr. Mordeglia, is: “Targeting zero down-time because it will be based on the predictive concept, designed today to be modern in the next 30 years.

“We will predict maintenance, events, orders management and much more. Energy and utilities will be continuously adjusted to run at the lowest possible operational expenditure (OpEx) without compromising the output material quality and delivery time.”

The project will be implemented over a sequence of three carefully planned mill shutdowns after 9, 15 and 23 months. The strategy will take maximum advantage of the annual maintenance outages already planned by the plant.

Matteo Bulfone, Vice President of Danieli, flat product hot rolling mills, added: “We will make the plant able to cast and roll wider products, yet we will retain the six existing rolling stands.

“The layout is conceived in such a way that large parts of the new equipment can be installed and tested offline. But, at the same time, we shall plan the shutdowns for the equipment installed in-line with hourly precision.”

During the last shutdown, the complete roughing mill (RM) group – previously preassembled off-line – will be moved in line via a lift-shift system.

The foundations of the mills will be

prepared under the existing tunnel furnace without interfering with the production.

A new benchmark for casting and rolling plants Given the nature of this project – to convert a traditional compact strip production (CSP) mill into a QSP plant, together with a high-performance meltshop – the Nucor and Danieli teams are determined to establish a new benchmark casting and rolling plant throughout the world.

"This project is going to strengthen further the partnership between Nucor and Danieli in the flat-products segment. The Danieli QSP technology will allow Nucor Steel Gallatin to vault the mill into a totally different level to serve a highly demanding market,” said Paolo Losso, President of Danieli Corporation.

The first thin slab plant in the world to exceed 3 t/year On the subject of productivity, Tangshan Iron & Steel in China was the first thin slab plant in the world to exceed 3 t/year after adopting the thin slab casting and rolling process in 2005.

In 1997 Essar Steel Algoma in Canada became the first thin slab casting and rolling plant in the world to produce peritectic steel grades, as well as HSLA grades like DSPC 700 with a yield strength exceeding 700 MPa, which are used, for example, in the automotive sector. Customers to whom Essar Steel Algoma regularly supplies these grades include all of the major North Ameri-

can OEMs, primary suppliers to the auto industry, major service centers in the Midwest, as well as Tier 1 manufacturers (among whom are the largest car manufacturers in North America).

Looking into the market of electrical applications, like the laminations for the cores of transformers and the stators and rotors of motors, Benxi Iron & Steel (China) is a pioneer in the production of silicon steel using its thin slab casting technology to produce electrical steel with a Si content of up to 3.2% with more than 4.0 m/min casting speed. >>

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Different plant configurations for HRC production The Danieli Wean United QSP is a technology for thin slab casting and rolling plants designed according to the specific needs of the product mix and production capacity.

Soon after the first pioneering applications of thin slab casting and rolling technologies in the late 1980s, Danieli recognized the necessity to develop its own design concept to overcome the limitations of “first generation” plants in terms of quality and productivity.

The two main areas in which Danieli introduced its innovative and comprehensive approach are the thin slab caster design and the configuration of the rolling mill.

Since its first pioneering applications in 1985, the vertical curved caster design has been adopted with application of the patented dynamic soft reduction process. This design allows both superior slab quality and the maximum flexibility in selecting the slab thickness, according to both productivity and quality requested by the mill.

Compared with other rolling mill configurations, where all rolling stands are arranged together and operate as a tandem FM, Danieli identified several mill-stand arrangements with separate roughing stands and finishing stands in order to apply advanced rolling practices typically adopted in conventional HSM, such as thermomechanical rolling. The number of

stands is selected according to targeted slab thickness and final coil gauge.

The QSP layout is recommended for very demanding customers who want to produce the top range of commercial steel grades. QSP is designed to work with thicker slabs (up to 130 mm) than other thin slab technologies. This makes it possible to increase production levels up to 3 million t/year with only one casting strand, and to produce the highest range of grades using the controlled metallurgical technology with ‘two-step rolling’, thermomechanical rolling in particular, due to the special layout features installed in this plant configuration.

The thicker slabs and the superior temperature control of the QSP layout mean that eight rolling stands can be installed (two RMs and six FMs) to produce a complete range of products, including a light gauge strip down to a thickness of 1.2 mm in coil-to-coil rolling mode. The investment required to implement the QSP configuration is fully repaid by the possibility of mass producing products with high added value. This means that the plant is very profitable even with only one casting strand, without the need for future expansion.

The QSP layout provides several advantages that lead to superior strip quality: • Vertical edger attached to the RM for accurate strip width control.

• Separated RM and FM to increase the overall flexibility of the plant

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and the steel grade production range.

Transfer bar furnace (TBF) to homogenize transfer bar temperature, with consistent benefits in terms of rolling stability in the FM. Possibility of installing an intermediate cooling system before the TBF when API grades are produced.

Three high-pressure descalers positioned to ensure a superior quality strip surface.

Drum crop shear at FM entry for safe and stable threading during thin and ultra-thin gauge rolling.

Further examples To better understand the QSP technology, it is worth examining other projects not strictly related to Nucor Gallatin. An alternative QSP layout is recognized by the marked being a perfect compromise between investment cost and production capability. This QSP layout is shorter, due to the fact that there is no TBF. This makes the layout very compact with the RM and the FM coupled to work in tandem.

The configuration has most of the advantages of the QSP – e.g. three descaling points, a vertical edger at the RM, a crop shear before the FM, intermediate cooling and advanced run out table cooling system – in a shorter layout.

The product mix can cover most market requirements. The absence of ‘two-step rolling’ (thus a long intermediate table and related TBF) only creates a limitation in special grades to be

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New generation layout for thin-slab casting and rolling Danieli, together with its customers, has progressively developed a new generation thin-slab casting and rolling layout. This marks a new phase in the evolution of the QSP process under the acronym of DUE®, which stands for Danieli Universal Endless.

What makes the DUE concept different is the ability to adopt ‘universal’ rolling modes resulting in the fact that

now, within a single plant, it is possible to perform endless and coil-to-coil rolling. This new approach can be seen as the natural evolution of the original Danieli concepts that marked the progress of the thin-slab route, namely the application of the vertical-curved design thin-slab caster, and the separation of the rolling stands into high-reduction units and finishing units.

The market recognizes significant extra margins for advanced highstrength products compared to mass production of soft grades with lower revenues. At the same time, thin and ultra-thin gauge products are generating significant profits. The DUE technology ensures the success for the complete steel grade portfolio.

Danieli Universal Endless constitutes a universal tool able to reach all the production requirements of the flat products market by applying the process that is best suited to each steel grade and product. Endless and coilto-coil process modes, thermo-mechanical rolling and multi-phase grades, ultrathin and thick products all are now possible in a single produc-

tion line. The ability to provide the mill with a thicker slab (110 mm), compared to the traditional thin-slab approach, is reflected in the remarkable increment in the reduction ratio from slab to strip, which in turn allows the production of ultra-thin gauges down to 0.8 mm and wall-thickness strips up to 25 mm, in widths from 900 mm up to about 2,000 mm.

Slab-width change during casting is an incorporated function of the technology, thus further increasing plant flexibility. Thanks to the combination of slab thickness (110 mm) and casting speed (over 6 m/min), production rates up to 3 t/year are possible on a single casting strand, making the capital expenditure (CapEx) investment per t extremely attractive.

The DUE layout configuration, together with an effective combination of thermal and electrical energy (gasfired tunnel furnace and induction heating), optimizes energy consumption, making DUE a truly ‘green’ plant while also reducing OpEx by about 1520% compared to the current bench>> mark of thin-slab-based plants.

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produced with true thermo-mechanical processes, such as thicker pipeline grades API X70-X80 for Arctic applications. The nominal slab thickness in this configuration is usually 70 mm (with the possibility to reach 85 mm).

The compact layout and the tandem rolling of RM and FM make the plant suitable for semi-endless rolling technology to produce ultra-light gauges below 1.0 mm on seven stands (two RMs plus five FMs), with the addition of special machines such as a highspeed shear, threading device and high-speed coilers equipped with four wrapper rolls.

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The first Danieli Universal Endless plant is installed in the Caofeidian Industrial Area, Tangshan City, Hebei Province, China. Operated by Shougang Jingtang United Iron & Steel Co. Ltd. (SGJT), the DUE plant will be designed for the production of 2,100,000 t/year of high-value-added hot rolled coils, for a wide mix of steel grades and strip dimensions from 0.80 to 12.7 mm thick and from 900 to 1,600 mm wide.

The DUE unique vertical-curved caster features a 5.5 m main radius, designed to operate with a single slab thickness of 110 mm after dynamic soft reduction (130 mm at mould exit), with a casting speed in excess of 6 m/ min, depending on the steel grade.

Such an unprecedented combination of slab thickness and speed makes it possible to easily reach the mass flow conditions required by the full endless production mode, necessary for effective production of ultra-thin gauge.

The tunnel furnace, which is developed in-house by Danieli Centro Combustion, is approximately 80 m long and provides a fundamental buffer function that increases plant flexibility. It allows the work roll change to be

performed as a background task, without affecting the operation of caster and meltshop, ‘switching’ from endless to coil-to-coil operating mode during roll changes, which in any case does not reduce plant productivity.

The DUE hot rolling mill features a well-known and already successfully proven configuration with separation of the mill stands into high reduction units and finishing units, in order to perform the dual step rolling. The transfer bar area includes: • a drum crop shear for cutting head and tail ends, achieving most stable rolling conditions in coil-to-coil production mode and for automated emergency strategies in endless rolling; • an induction heating system designed and manufactured in-house

by Danieli Automation, for consistent production of thin and ultra-thin gauges in endless mode, which can be retracted off-line when not in use (i.e., during coil-tocoil production mode); • a dedicated high-pressure descaling unit at the FM entry (in addition to the one at the high reduction stand

entry), to eliminate imprinting scale phenomena on the final strip; • an intensive cooling system, incorporated into the descaler box at FM entry, used when producing TMR and/or API grades in order to guarantee the correct bar temperature profile and to achieve proper control of grain growth, which are essential features of the thermo-mechanical rolling process.

The mill stands, designed to guarantee superb geometrical and mechanical properties of the final product, are equipped with all the state-of-the-art features for exceptional strip crown and profile control, bearing in mind that these control functions also have to be operational under-load conditions as required by the endless rolling process. The line is completed with the laminar cooling system, consisting of a combination of power and normal units for outstanding strip cooling strategies, followed by the coiling area, made up of a high-speed shear for cutting coils to length when working in endless mode, pinch rolls and downcoilers.

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The upgrades to Nucor’s plate mill in Alabama, USA, will include a new Power Coiler and Level 1 automation system upgrade. The supplied equipment will enable Nucor to produce heaver line pipe gauges. Project completion is scheduled for the first quarter of 2020.

Nucor Steel Tuscaloosa, Inc. has selected Primetals Technologies to upgrade its plate mill in the city of Tuscaloosa, western Alabama, USA. The upgrade, scheduled for completion in the first quarter of 2020, includes a new downcoiler of the Power Coiler type with a four wrapper roll design. It will enable the facility to produce heavier line pipe gauges for the energy industry.

The downcoiler is capable of handling 1.25" thick low-carbon-grade steel and 1" in. thick pipe grades, at up to 102" wide. The scope of supply also includes runout tables, a new coil handling area, inspection line with shear, hydraulics, banders, markers and an upgrade to the Level 1 automation system.

North America’s largest recycler

Picture: Primetals Technologies

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Nucor Steel Tuscaloosa, Inc. is one of three plate mills operated by Nucor Corporation which produce plate for manufacturers of barges, bridges, heavy equipment, tanks, ships, wind towers and other items. The capacity of the plate mills is estimated at approximately 2,825,000 t/year.

Contact: www.primetals.com Email: rainer.schulze@primetals.com

Nucor and its affiliates are manufacturers of steel products, with operating facilities primarily in the USA and Canada. The products it produces include: carbon and alloy steel – in bars, beams, sheet and plate – as well as hollow structural section tubing, electrical conduits, steel piling, steel joists and joist girders, steel decking, fabricated concrete reinforcing steel, cold

finished steel, steel fasteners, metal building systems, steel grating, wire and wire mesh.

Nucor, through The David J. Joseph Company, also brokers ferrous and nonferrous metals, pig iron and hot briquetted iron (HBI)/direct reduced iron (DRI).

It also supplies ferro-alloys and processes ferrous and nonferrous scrap. It is also North America's largest recycler.

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Since steel does not solidify at a fixed temperature, but over a temperature interval, slabs in the casting process have a ‘mushy region’ at the centre where the steel is neither entirely liquid nor solid.

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In December 2018, Primetals Technologies received the Final Acceptance Certificate (FAC) for the modernized two-strand continuous slab caster CCM1 in steel works no. 3 of Angang Iron & Steel Group Co. in Anshan, China. The caster was started-up in late October 2018 and processed more than 1,700 heats equalling approximately 348,000 t within less than two months.

The objectives of the project were to improve the product quality and productivity, and also to increase the flexibility of the processing of different steel grades and casting formats.

The casting plant is equipped with modern equipment and technology packages, including DynaGap Soft Reduction to improve the interior quality of the slabs. In order to minimize shutdown times, the project planning attached particular importance to a quick implementation: the casting machine was revamped within just 30 days.

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If conditions aren’t right during the casting process, segregation can occur in slabs, creating undesirable material properties. A trusted solution from Primetals Technologies, DynaGap Soft Reduction, has proven integral in helping Angang Iron & Steel Group of China enhance its product quality, productivity and flexibility.

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near the point of solidification. This method is called soft reduction. With DynaGap Soft Reduction, the technology calculates the ideal roll-gap set points with online process models that take into account the temperature field in the strand and employing a steel-grade dependent gap practice.

Even in varying casting conditions, the pressure is always applied just at the right point by hydraulically adjustable SMART segments in the casting strand.

Each roll controlled by its own hydraulic cylinder If conditions aren’t exactly right, segregation occurs in this centre part of the slab. Because of thermal contraction near the point of final solidification, there is a flow of residual melt toward the centre. Since that residual melt often contains high levels of carbon, sulfur, and other kinds of impurities, the centre segregates from the rest of the material and creates undesirable material properties in the resulting product.

One way to minimize centre segregation is to compensate the thermal contraction by intentional thickness reduction

Automating changes in the roll gap with hydraulically adjustable SMART segments was a giant leap forward in terms of efficiency and product quality in continuous casting. But quite naturally, segment-level control of the roll gap allows only one gap setting across all the rolls contained in a segment. Consequently, it hits the point of solidification only by some measure of approximation. For sensitive steel grades, this might not be enough.

That is why Primetals Technologies has developed the Single Roll DynaGap (SRD) segment. Each individual roll is controlled by its own dedicated hydraulic cylinders. With high-quality data from the DynaPhase and Dynacs 3D sec- >>

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www.zumbach.com • sales@zumbach.ch

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››› ondary cooling models, the SRD segment can hit the exact point in the strand where dynamic soft reduction has to be applied for maximum centre quality. The segment is interchangeable with DynaGap SMART segments, as well as with other segment designs, and can thus easily be integrated into existing setups. SRD segments have already been deployed in production at the Ternium integrated steel works in Santa Cruz, Brazil. In light of the strong results, the company recently decided to equip an additional strand with the technology.

Directly from the mechatronics lab Since its first application in 1997, DynaGap has been continually refined to evolve the precision in soft reduction from the segment to individual rolls.

The offering today includes DynaGap 3D and Single-Roll DynaGap. In 1995, Rautaruukki of Finland – today known as SSAB Raahe – a manufacturer and supplier of metal-based components and systems for the construction and engineering industries, decided to begin replacing its three

vertical casters with a new one featuring a straight mold and liquid core bending and straightening.

The desire was not so much for higher-quality slabs, although this was a factor, rather, the plant’s just-in-time production schedules demanded that the casters produce slabs of up to eight different thicknesses. This required manual adjustment of the roll gap several times a day. Each one of these changes meant up to two hours of standstill and onerous labour for the crew.

At the same time, the answer to Rautaruukki’s problems was being developed in a university mechatronics laboratory in Linz, Austria.

Until then, hydraulic adjustment in the roll gap had only been possible using servo hydraulics technology that is far too costly, and way too prone to malfunctioning in dusty environments, to be employed in regular continuous casting plants.

Researchers and engineers in Linz, working with continuous casting experts from Primetals Technologies (still at the time known as VAI), realized that a simpler setup involving

more robust on/off valves could do the job just as well, and prove to be a lot more durable in the environment of a casting facility. Combining this hardware with position sensors would: • Dramatically reduce the need for manual labour and downtimes when adjusting the roll gap.

• Thickness could be changed remotely at the push of a button.

• By adding advanced automation and process models, the dynamically adjustable roll segments would significantly increase internal slab quality.

When Rautaruukki engineers learned of the technology in the run-up to a continuous casting conference in Linz, they were immediately convinced.

Work started in 1996 and was concluded successfully when the caster was started up on December 15, 1997, right on schedule. Performance and availability were excellent from the start, as the machine cast slabs first in three, then four different thicknesses per day, drastically cutting the amount

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‹‹‹ of manual labour required for the rollgap changes. Careful inspection of numerous slabs by the Rautaruukki quality department showed internal quality to be excellent.

Following the success in Finland, installations of DynaGap at other sites followed with ILVA, voestalpine Stahl, Bethlehem Steel, POSCO, and Outokumpu were among the early adopters.

Today, DynaGap Soft Reduction operates in close to 300 casting strands around the world.

One of China’s leading steel producers Angang Iron & Steel Group Co. is located in Anshan in the Liaoning Province in China. It has an annual production of approximately 35.8 million metric t (as of 2017) and is one of China's leading steel producers.

Steel works no. 3 in Anshan employs a conversion route through a basic oxygen converter, ladle furnace and RH plant. It has an annual capacity of five million metric tons and supplies two casting plants. Continuous slab caster CCM2 has already been modernized

by Primetals Technologies and has been back in successful operation since July 2015.

The two-strand continuous slab caster CCM1 in steel works no. 3 has a production capacity of 2.5 million t/year.

Its machine radius is 9 m and metallurgical length 36 m. The caster produces slabs with a thickness of 230 mm in widths ranging from 990 to 1,550 mm.

The maximum casting speed is 2.1 m/ min. The plant casts ultra-low carbon to high carbon steels, peritectic, deep drawn and high-strength low-alloy (HSLA) steels, as well as micro-alloyed, low-alloyed and silicon steels.

Improved interior quality of the slabs The modernization project included equipping continuous slab caster CCM1 with a new tundish car and a new tundish with LevCon mold level control, which uses optimal control theory while being robust enough to operate in the difficult conditions of a steel work. The straight cassette-type Smart Mold is equipped with the Mold Expert breakout detection system, DynaWidth for automatic width adjustment, and the DynaFlex mold oscillator. Bender and Smart Segments, as

well as I-Star rollers, are used in the strand-guiding system.

The Dynacs secondary cooling system dynamically calculates and controls the temperature profile along the entire strand. This enables the working points of the strand cooling, and thus the final strand solidification, to be determined precisely as a function of the casting speed, slab format and steel grade.

DynaGap Soft Reduction is used to improve the interior quality of the slabs. The roll gap is dynamically adjusted during the final solidification in accordance with the operating points calculated by Dynacs, a level 2 secondary cooling model. This minimizes

segregation in the centre of the strand.

The secondary cooling uses DynaJet spray cooling with a centre/margin setting.

In addition, Primetals Technologies handled the basic engineering of the tundish, the ladle shroud, the dummy bar system, the supporting structure and the maintenance stands; as well as the detailed engineering for the shroud manipulator, the tundish car, mold and mold oscillator, the segments of the strand-guiding system, the secondary cooling and the dummy bar.

The automation system and the consulting services for the construction and commissioning were also part of the order.

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For cold coiled steels with certain material thicknesses, the inner flap regularly drops down when it comes off the mandrel. Sometimes, there is even a risk of collapse.

After a successful feasibility study, Tebulo Industrial Robotics from Warmenhuizen, The Netherlands, has engineered a new reel hole fixation robot for the steel industry.

For cold coiled steel coils with material thicknesses ranging from 0.13 to 0.5 mm, the inner flap regularly drops down when it comes off the mandrel.

Even during handling, there is a considerable risk that the entire coil will collapse. This is due to insufficient internal stiffness of the coils.

If this happens, a flap that drops down must be welded or glued manually by the operator in a relatively unsafe manner. A coil weighing 30 t has to be removed because it can no longer be placed back on a mandrel.

Backed by a successful feasibility study, this was a sufficient reason for Tebulo Industrial Robotics, to engineer a new reel hole fixation robot for the steel industry.

Fewer interruptions with ‘state-of-the-art’ robotics Founded in the Netherlands in 1974 and headquartered in Warmenhuizen, North Holland, since 2015, Tebulo specializes in robotics manufacturing, sales and support in order to, according to the company’s mission statement: “Bring a lagging metals industry back up to a front-running position through the use of state-of-the-art robotics.”

Contrary to traditional methods, the company’s robotized solution now coils the material directly onto the mandrel so the production process may continue without unnecessary interruptions. Consequently, the 8 to 10 mm thick steel sleeves – which were traditionally pushed over the mandrel

Contact: tebulo.com Email: info@tebulo.com

before the material could be coiled up – are no longer necessary.

This makes a substantial difference in man hours and handling costs. The sleeves no longer need to be transported from one location to another. Moreover, sleeves are no longer dropped and/or deformed. There is also no longer a need to reserve storage space in a warehouse or at the mandrel.

Converting a standard robot into a new tool “In developing the head for the reel hole fixation robot, we were intensely focused on reducing storage, handling, as well as material costs. It was also essential that the payback time was less than 1.5 years,” said Hans Spaans, chief technical officer (CTO) of Tebulo Industrial Robotics.

Based on the above requirements, Tebulo Industrial Robotics took a standard ABB robot and converted it into a new tool, with welding functionality completely tailored to this purpose.

The welding tool is designed for sheet metal with a thickness ranging from 0.13 to 0.5 mm. The average welding depth varies from 2 to 3 mm (approximately 10 wraps). The number of spot welds and the welding depth together provide reinforcement of the reel hole.

Similarly to the procedure with the sleeves, as described above, the last 10 to 15 m of material cannot be used the newly-developed robotized solution, and should therefore be disposed of as scrap.

Twin spot welder integrated into the robot head “In this case, traditional spot welding was not an option since there was no possibility to reach the back of the material. That's why we opted for twin spot welding,” explained Mr. Spaans.

The twin spot welder, integrated in the new robot head, consists of a welding tool with four welding tips (two on one side and two on the other) in conjunction with an 'intelligently' working pressure mechanism.

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Because the chosen welding method requires a great amount of power, the robot head has 40 mm thick copper hollow water-cooled cables running from the transformer to the welding tips. The transformer is powered by a control unit located in the background. As soon as the desired welding program is entered on this unit, a low voltage and a high current runs from the transformer to the individual welding tips to generate a medium high frequency welding current for the electrical welding process.

Welding is done with a pulsation frequency of between 1,000 and 4,000 Hz. At the part undergoing plastic deformation, temperatures may increase from 1,200 to 1,400 °C whereas the cooling water temperature in the 20 litre capacity unit reaches 60 °C. The water in this closed loop circuit cools the welding transformer, the head cables as well as the two welding tips. So, it is essential that the recycled water is constantly cooled in the heat exchanger during the welding process.

A compact robot design for flap detection Another important design requirement was the size of the robot head. The robot head must always be able to enter the reel hole without getting stuck anywhere, even when a particular flap is hanging loose.

Mr. Spaans explains, “In this case, the coil of steel always has a 420 mm reel hole diameter. So, in the design phase, it was decided to maintain a minimum free passage of 340 mm for the robot head. In the available space, the head must be able to scan and weld a 360° area without any complications. >>

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Next, the robot head starts out by firmly pressing the flap outwards, against the inside of the coil to create a nice, round hole. Especially for this purpose, the robot head comes equipped with a pneumatically driven cylinder with a 160 mm stroke length which pushes out two pressure blocks. The four welding tips then move alternately. Based on the transition resistance caused by several layers of material, welding requires a pressure of approximately 450 kg. This is achieved with two pneu-

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— Millmate Thickness Gauging systems Gapless gauging for aluminium strip

The Box Gauge measures aluminium strip thickness with a gapless sensor – excitation and receiver in one single unit. The compact and robust design, together with insensitivity to alloy variations and harsh rolling mill environments, enables accurate measurements in any position, even interstand in a tandem mill. Thus the MTG Box Gauge is ideal for use with all types of AGC, for control of thickness as well as for reducing thickness errors. abb.com/thicknessgauging

matically driven cylinders, each with a 30 mm stroke length. During the application of the first welds, the coil is still half situated on the reel, ensuring the flap cannot drop inside. Upon completion of the welding, the coil is completely removed from the reel so that the production process may continue.

Additionally, the robot can access the coil of steel from the other side to fully strengthen the inside, 20 to 30 s after it has been completely removed from the reel. In this way, with the help of the aforementioned welding tool, the coil's own material is utilized to create a sleeve inside of the reel hole.

Mr. Spaans explains further: “Particularly, the detection of the beginning of the flap and the calculation of where the first spot weld must be placed is a precision job. If the first weld is placed incorrectly, then the inner wrap pulls apart during hoisting which must be avoided at all cost.”

The selection of the correct welding parameters is initiated depending on the processed material thickness. During welding, it is then measured whether the current flows through or not. If the current does not flow properly (e.g. because the copper points are not properly pressed ) this is immediately detected by a sensor which sends a feedback signal to the PLC. The correct pressure, clean pressing material, good components and a properly functioning electronic feedback system are all essential for a good weld.

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welding pattern, communicating the data with the line control.

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“The scan data are communicated to a programmable logic controller (PLC).

Having made a successful scan, the entire robot head retracts and the robot takes up its starting position. Next, the PLC calculates where the robot head should start applying the first welds.”

He adds: “We opted for a 180° rotation range because of the large number of continuously rotating (power) cables, water and pneumatic hoses. The robot head is therefore equipped with a double set of welding tips at 180° relative to each other, achieving in all cases a 360° range.”

The PLC then determines the exact location to start welding as well as the

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

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The production line, with the currently running robotized welding installation, has a capacity of approximately 400 coils per week. The steel coil stays on the reel for an average of 20 to 30 s during the first stage of the welding process. As soon as the coil has come

off the reel, it is no longer time critical at all. This leaves the robot with about 15 min to perform the remaining activities. In other words, flap detection as well as producing the first welds in particular should be carried out as quickly as possible.

“The biggest challenge in the development of the robot head was to find

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an optimal balance between transformer, power supply, cable diameter and reel hole size,” says Mr. Spaans.

“For example, 450 kg of pressure had to be applied in an extremely small diameter reel hole, while the robot head had to be as compact and light as possible.

After all, the robot also had to be able to handle the head over a larger distance. From a safety point of view, we opted for pneumatics instead of hydraulics for the welding tool’s drive technology, since the risk of potential oil leakage was undesirable.”

The reel hole fixation robot can also be used for aluminium coils, said Mr. Spaans: “Since there are so many different types of aluminium, the correct parameter set must first be determined for each type.”

Finally, it is worth mentioning that the robot needs a floor space of approximately 3 x 3 m, within which it can operate the so-called ‘safe move'. As soon as the robot detects interference with the imposed restrictions, it is fully-automatically limited by a built-in safety controller which closely monitors all of its movements. “Safety first,” adds Mr. Spaans.

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When building large-scale plants, traditional forward planning methods have been found to negatively impact both time and costs. Instead, maexpartners, a business management consultancy in Germany, has devised a unique RLTR method which, according to the company, can shorten construction times by 40-50%.

The market situation in steel mill construction is still highly demanding.

Given the tough competition worldwide, profitability and cost efficiency are becoming increasingly important.

A decisive factor in this context are the lead times for large-scale construction projects: the shorter the time-to-market, the earlier steel producers will be able to recoup their investment.

In response to these challenges, maexpartners, a management consultancy company based in Düsseldorf, Germany, has developed a new method that can reduce lead times significant-

Contact: maex-partners.com Email: thorsten.helmich@ maex-partners.com

ly in plant engineering and construction. A maexpartners client, ‘one of the world’s largest suppliers of turnkey solutions, specifically in steel mill construction’, has already applied the method successfully.

The solution, ‘Radical Lead Time Reduction’ (RLTR), involves a unique approach to dramatically reducing the construction time of plants, as well as the costs.

Thorsten Helmich, partner at maexpartners GmbH, said: "Given the usual average lead times of at least two to three years for large-scale plant construction, and project volumes of generally well over EUR 100 million, this naturally has significant effects.”

According to Mr. Helmich, the efficiency calculation vastly improves because construction is much faster and the potential start-up is therefore moved forward.

Traditional rolling forward planning when building plants maexpartners’ client (whose identity is withheld by a non-disclosure agreement) builds entire production plants and also supplies infrastructure, logistics and attendant facilities on request.

The supplier either manufactures key components itself or with the support of contractual partners. Additional subcontractors are also frequently brought in.

Coordination of these three groups, and the complexity of the interfaces, can lead to an instable implementation process. This often results in reworking and delays on large, sophisticated and costly components.

Like many of its competitors, the steel mill builder has, in the past, practiced traditional rolling forward planning when building plants. This starts with engineering followed by procure-

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PROJECT MANAGEMENT ment, component manufacture, logistics and including assembly and the construction of the plant. Although there are certain activities that can be carried out simultaneously, every single phase must be completed in order to ‘kick-off’ the next.

Therefore, in keeping with the push principle, a completed phase therefore triggers the next step. This can sometimes result in considerable overlapping and, not infrequently, an unclear handing-off of the individual activities. In other words, actual construction does not start until all of the parts are available.

Just two weeks for the set-up phases of large-scale projects The RLTR method developed by maexpartners is based on a planning structure that is fundamentally different and targets the holistic optimization of processes at all stages of large-scale plant construction. This concept, explained Helmich, combines with an indepth understanding of the client’s situation and its previous courses of action when building plants. The sequence of

the individual phases and activities in this process is actually reversed. Project planning starts by looking at the completed installation and works backwards, beginning with the built object and analyzing everything from logis-

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In this respect, these modules set the pace for planning. Every single construction stage calls for the completion of the previous step. It basically 'pulls' the results of previous work as an essential foundation for further work, as

“Radical Lead Time Reduction (RLTR) is the game changer in large-scale plant construction and, in this respect, will change the ground rules in the industry.”

tics to manufacture and procurement, all the way back to engineering.

In this process, the construction site has to be modularized and broken down into numerous smaller construction stages; maexpartners refers to these modules as ‘construction units’ or ‘installation kits’. These elements make it possible to plan precisely when a component has to be at the right place and what it has to look like, as well as which resources and documents are needed for its installation.

well as all necessary information. This pull system differentiates the process fundamentally from the classic approach.

"During the planning stage, we are already defining precisely when the installations are to take place, which parts need to be ready in time for it, and how they have to be designed," explained Mr. Helmich explains.

In this way, the construction site 'pulls' the required previous work results along the entire building process.

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Modularization of the individual construction sites also seeks to achieve a high degree of simultaneity and synchronization of the individual steps.

Certain work processes, therefore, no longer take place one after another but often overlap with others. This is a concept familiar from concurrent engineering (or simultaneous engineering) whereby the different stages of designing and developing products run simultaneously rather than consecutively. But RLTR is fundamentally different in its pull principle. For effective 'pull', it is imperative that all work packages be defined accurately. This includes keeping a record of all the necessary materials, drawings, technical data and other relevant information. maexpartners uses templates for this level of detailed planning. These templates for predefined sequences and schedules are developed and based on years of experience, and can also be customized. This alone is what makes it possible to shorten set-up phases of large-scale projects to just two weeks.

In the past, these have often taken up to three months.

The master schedule is the most important management tool Once all of these installation kits have been fully recorded, they are imported into the master schedule. This is the single most important planning, controlling and management tool used in the project's implementation. It contains the data for starting and completing a work package, the duration of the individual measures and the workflow map.

As an all-inclusive and integrated management tool, the master schedule can be linked seamlessly to specific IT solutions, including: • Insite LMS (or Logistics, Material, Site Management) construction software which optimizes project management with a focus on endto-end information; • Primavera project management software, specifically designed to help manage complex projects. It, in turn, has an interface to the SAP (systems, applications, products) system.

The aim of the master schedule is to link the individual installation kits as

planning sequences with all previous activities from engineering, as well as from procurement, manufacture and logistics, and to specify definite interfaces. This optimizes production flow.

For example, an objective could be to split up work sequences that take too much time into smaller packages. As a result, this can guarantee even higher parallelism.

“Even more effective than this, however, is that we create a real flow between the individual measures,” said Mr. Helmich. “That, by far, best leverages the improvement in efficiency.”

Shorter lead times and reduced costs The above benefits were reported by maexpartners’ client through its implementation of the RLTR method. After just two weeks, all planning for the large-scale plant construction project was solidly drafted and the lead time could be reduced by 39%. The project implementation was also stabilized as a result of the structured RLTR planning.

“When it comes to organizing thousands of work steps and millions of parts, having reliable and efficient project processes is understandably elementary,” said Mr. Helmich.

This, in turn, entails a considerable reduction in non-conformance costs; the costs that result in deviations between preliminary costing; and the final calculation due to errors in development, planning, procurement and implementation. For the large-scale project of maexpartners’ client, the steelworks contractor, these expenses were reduced by 31%.

Reduction of the total plant construction time is usually even greater through the use of the RTLR method.

The more complex the project, the greater its impact, according to maexpartners.

While it has been found that smaller subprojects can be implemented much faster, maexpartners reports that the effect is still most evident on large-scale construction projects. Because implementation assumes vast industrial experience and the relevant know-how, such professional support is found to yield considerable benefits.

“We have verifiably already managed to cut the lead time almost in half while using the same capacitive framework,” said Mr. Helmich. He added: “RLTR is thus the game changer in large-scale plant construction and, in this respect, will change the ground rules in the industry.”

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Precise knowledge of all variables is required to control a process and, ultimately, increase profitability. With this in mind, Polytec Laser Surface Velocimeters (LSV) are used to measure length and velocity in a wide variety of industries – not only in a planetary mill, but also on different planets.

Laser precision metrology has long been established in the manufacturing of foils, textiles and building materials, and particularly in the metal-processing industry. For these applications, Laser Surface Velocimeters (LSVs) enable high-precision process control in continuous casting, the rolling of hot and cold flat steel, and the production of tubes and rods.

However, LSVs are faced with a particular challenge in the process control of a planetary mill, since velocity measurement in more than one dimension is required.

Designed for use in any process environment Polytec Laser Surface Velocimeters, see Figure 1, overcome this challenge and others as a result of their extensive interface concept, the process-oriented accessory range and their unique optical configuration. The optical measuring systems have been specially developed for use in harsh environments.

They work without wear and tear and are maintenance-free in 24 h continuous operation. Polytec LSVs are equipped with all the Ethernet, encoder or field bus interfaces required for integration in process control systems.

Irrespective of the terminal device (PC, tablet or smartphone), the integrated web interface of ProSpeed, the latest sensor generation, enables easy start-

Contact: www.polytec.com Email: info@polytec.de

up and operation, either by cable or wirelessly. Tailor-made accessory solutions mean that the LSV can be used in any process environment. The thermo protective housing not only protects the measuring instrument against the ingress of dust and liquids, but also enables operation at ambient temperatures of up to 200 °C. Air purge units with air flow amplification reduce the compressed air consumption and provide a clear view of the measured material under the most adverse ambient conditions such as vapour, mist and dust. Deflection systems direct the laser beams of the LSV up or down, thereby enabling installation in confined spaces such as C-frames of thickness gauges in rolling mills.

The models with short stand-off distances also have an extremely large depth of field, owing to the special optical configuration of the LSV. This means that the position of the measurement surface can vary within a range of 120 mm without the LSV losing the measurement signal, even with a stand-off distance of 30 cm.

Process control in a planetary mill Several rollers (e.g., four) are arranged at an angle around the red-hot rolling product in a planetary mill. These rollers revolve around the steel rod during the rolling process and thereby generate a rotational movement in addition to the forward movement.

This causes the rolled steel to tumble at the outlet of the rolling mill, since it is no longer guided there. The tumble is undesirable, as it makes the transfer to the following process steps more difficult. The rotational movement of the rolled steel must be measured independently of the forward movement to prevent this behavior.

Traditional contact- based measurement procedures for velocity measurement (e.g., measuring wheels) are not suitable for this application. Apart from the inherent weaknesses of all contact-based measurement procedures – such as slippage, mechanical wear and therefore inaccuracy – the velocity component transverse to the measurement direction is the main

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‹‹‹ About Polytec

factor that prevents the use of measuring wheels.

The tried-and-tested non-contact metrology from Polytec, see Figure 2, is used here instead. Due to the high temperatures arising from the red-hot steel, the sensors are provided with a thermoprotective housing, which permits operation at ambient temperatures of up to 200 °C, without additional protective measures. Measurement of the rotational velocity by the first

LSV, Figure 3, enables the rolling process to be regulated in such a way that there is no rotational movement and no wobbling of the rolled steel rod on transfer to the next process step. Only an LSV that works according to the ‘heterodyne process’ (to generate new frequencies by mixing two or more signals) can be used to control the rotational velocity with a target value of 0.

Only by using this measurement procedure the sensor is able to measure the

As a laser technology pioneer, Polytec has offered optical metrology solutions for research and industry since 1967. The high-tech company is based in Waldbronn near Karlsruhe, Germany, and after trading as a distributor in its early years, made a name for itself as a developer of inhouse, laser-based measuring instruments in the 1970s. It is currently a global market leader in the field of non-contact vibration measuring technology with laser vibrometers.

Systems for length and velocity measurement, surface characterization, analytics and process automation also form part of the wide range of in-house developments. The distribution of image processing components and optical systems is another of Polytec's core areas of expertise.

standstill (0 velocity). To achieve this, the frequency of one of the two laser beams is shifted by an offset frequen- >>

+353 47 80500

combilift.com

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››› cy which causes the fringe pattern to move over the surface of the measured material with a known velocity, even at standstill. Apart from standstill detection, this means that the direction of movement of the measured material can also be determined.

The second LSV is arranged at an angle of 90° relative to the first and measures the forward motion and length of the steel rod. The length information is required for precise cut-off control.

The advantages of the special highprecision optical configuration of the LSV, and the meticulously designed accessories, become apparent here once again. If both LSVs are aligned exactly perpendicular to the respective measurement direction, by means of the finely adjustable Polytec mounting platform, all the influences of the other velocity component in the transverse direction are eliminated. As a result, the rotational velocity

is determined without being influenced by the forward speed and vice versa.

Technology box: laser Doppler velocimetry Velocimeters work according to the so-called Differential Doppler Technique. Two laser beams, each incident to the optical axis at an angle w, are superimposed on the surface of the sample. There, they generate an interference pattern of light and dark fringes, as shown in Figure 5. The fringe spacing Δs is a system constant that depends on the laser wavelength l and the angle between the laser beams 2w. The following applies: Δs = l/(2 sin w).

Technologies for electric steel plants

If a surface moves through the fringe pattern, the intensity of the light that it scatters back is modulated. As a result, a photodetector in the sensor head generates an active current (AC) signal, whose frequency fD is directly proportional to the velocity component of the surface in the measurement direction vp. The following applies: fD = vp/Δs = (2vp/l) sin w (where fD is the Doppler frequency, vp the velocity component in the measurement direction and Δs the fringe spacing in the measurement volume). The value l/sin w makes up the material measure for the velocity and length measurement.

It is measured precisely for every sensor head and is printed on the identification label.

Forming of foaming slag Injection installations for fine carbon with 1 – 4 conveying lines Injection technique Installations for injection of filter dust, additives etc. into furnaces or ladles Pneumatic addition of lime Injection of coarse lime via the furnace roof for the protection of the hot spots Refractory repair systems Slinger machines, gunning machines and gunning manipulators for the quick and effective repair of EAF and ladles etc.

Gunning manipulators for RH-degassers

www.velco.de

VELCO - Gesellschaft für Förder-, Spritz- und Silo-Anlagen mbH Haberstraße 40 · D-42551 Velbert · Germany Tel. +49 2051 2087-0 · Fax +49 2051 208720 · E-Mail: info@velco.de

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EXPERTISE

EXCELLENCE AT THE CORE OF YOUR PROCESS For more than a century, Vesuvius’ global community has continuously expanded what’s possible in metal flow engineering. We invest in continuous data capture, robotics and artificial intelligence technologies to support our customers in their journey towards Industry 4.0. Also we keep pushing the boundaries of our hi-tech refractory products.

At Vesuvius, we invest today in breakthrough technologies you will need tomorrow.

Visit us at AISTech 2019 - 6-9 May, Pittsburgh, PA, Booth 645 & METEC 2019 - 25-29 June, Dusseldorf, Germany, Hall 5/D19 www.vesuvius.com

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ufactured parts. The bending cell automatically sets up the press brake tools and the robot grippers. More than 80 m of tools are held within the bending cell. Four stations with flexible configurations handle the material supply. When completed, the parts are placed on a conveyor belt or stacked on pallets.

Contact: www.lvdgroup.com

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AUTOMATION Two custom bending cells, each comprised of a press brake by LVD Group of Belgium and Fanuc robots, have automated the production of complex formed parts for Kuipers CNC-Blechtechnik of Meppen, Germany. The parts could not otherwise have been manufactured using a standard modular solution.

The press brake features LVD’s Easy-Form® Laser adaptive bending system which provides angle measurement and correction in real time to ensure high-quality bent parts.

Today, Kuipers, a 100-year-old sheet metal subcontractor that serves a wide range of industries, uses the bending cells to more easily handle complex interlaced parts with a high number of bends. In contrast to standardized automation solutions, the LVD bending cells also offer the flexibility to program parts tailored to Kuipers’ requirements.

After the success of its first custom bending cell, Kuipers decided to order a second cell that is designed from the ground up and equipped with two movable Fanuc robots.

The first robot feeds the parts from the material supply and pre-centres the blanks. The second robot handles the parts during the bending process and stores and stacks the man-

for the physical space and research positions. The current focus is on international recruitment to create a research team of approximately 30 people.

The IARAI will be helmed by two renowned experts in machine learning and data science. Dr. Sepp Hochreiter is an artificial intelligence pioneer and inventor of the long short-term memory (LSTM) neural network framework from Johannes Kepler University in Linz, Austria. He will be joined by Dr. David Kreil, a leader in data science, from Boku University in Vienna.

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ADVANCED RESEARCH HERE Technologies, headquartered in Amsterdam, the Netherlands, provides mapping and location platform services. The company has announced the establishment of the new international Institute for Advanced Research in Artificial Intelligence (IARAI) that is to be located in Vienna, Austria.

The IARAI will be the world’s first global machine-learning research institute to use industrial-scale geolocation data. As an independent institution, the IARAI will conduct research in machine learning that will deepen the location intelligence needed to build an autonomous world. That includes heightened location awareness for autonomous vehicles; more accurate, self-healing maps; better traffic prediction models; and an optimized fleet management and city infrastructure.

Going forward, HERE will cooperate closely with the institute by providing its unique datasets and expertise. This groundbreaking initiative will give HERE greater access to emerging technological capabilities in the company’s core fields of interest, developed based on its data.

AI algorithms can extract complex patterns from vast numbers of data points and, in doing so, are able to self-correct and learn patterns. By applying these algorithms to location data, the IARAI is poised to tackle the most pressing, location-based problems both in industry and society. Over a five-year period, HERE will provide the institute with more than EUR 25 million in critical financial assistance to support the IARAI’s development. That includes funding

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INFORMATION TECHNOLOGY B&R, headquartered in Eggelsberg, Austria, and part of ABB Group, has grown into a leader in industrial automation. The company’s solutions combine state-ofthe-art technology with advanced engineering to provide customers in virtually every industry with complete solutions for machine and factory automation, motion control, human machine interfaces (HMI) and integrated safety technology.

B&R has added new functions to its mapp Motion software package, making it possible to represent the actual structure of a complex machine and achieve ‘intuitive’ and uniform access to all areas of motion control technology – e.g., single axis, computer numerical control (CNC) machines and robotics applications. The various subsystems of a machine can now simply be linked together. The movements of robots can be easily synchronized, with gantry systems or tool tables and no additional programming.

A ‘frame hierarchy’ function can be used to represent the actual structure of a machine. Coordinate systems are positioned at key points, such as the tool mounting flange.

Each coordinate system can be assigned a name that identifies it within the application. The solution is designed to ensure clearly organized, easily readable code – even in complex applications.

Meanwhile, the ‘programmed moving frame’ function couples a coordinate system to an axis and defines an additional degree of freedom. This allows optimized movements and better utilization of robot dynamics. The function incorporates the movement of the gantry system into

the path calculations of the robot. The programmer doesn't need to coordinate the movements of the gantry system and robot manually. The same applies in cases where robots or CNC machines are combined with moving workpiece tables.

Only one controller is necessary for the machine, robot and other moving components. The robot and additional components act as one unit. Coordinated path planning allows optimal utilization of the dynamic limits of the individual components. It also guarantees that all specified process parameters are adhered to, such as the relative speed between tool and workpiece.

Contact: www.br-automation.com

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MEASURING EQUIPMENT Buehler ITW Test and Measurement of Lake Bluff, Illinois, USA, a leading manufacturer of equipment, consumables and accessories for metallography and materials analysis, joined the exhibitors at Control 2019 exhibition in Stuttgart, Germany. The company showcased its new, robust and automated universal hardness tester, the Wilson® UH4000, that is capable of handling high sample volumes and can therefore contribute significantly towards increased productivity and reduced costs.

Designed for a fast testing cycle, Wilson UH4000 universal hardness testers feature a rugged cast steel frame to provide outstanding durability, specifically in harsh environments.

They enable accurate hardness measurements to Rockwell, Vickers, Knoop and Brinell standards even in the toughest conditions. The integrated DiaMet® software is optimized for these measurements to make the system easy to operate with testing that is simple, repeatable and automatic.

A new eight-position turret can hold the desired combinations of indenters and objectives, and contributes significantly towards speeding up testing cycles in batch testing.

The operator can test to a variety of assessment methods without the need for a manual indenter or objective changes. A sturdy cover protects the highly accurate measurement system and turret assembly against external influences and collisions, e.g. with test pieces. The large T-slot stage offers a clamping surface of 300 mm by 400 mm and high weight capacity, thus enabling the testing of heavy and big parts.

Wilson UH4000 hardness testers are flexible and suited to a variety of tasks in quality control and process-related quality assurance, both in laboratories and directly on the shop floor. They can be used for:

• large or small components in the automotive sector and in metal production; • for hardness measurements on large, flat or cylindrical castings or forgings, steels, heat treated materials, cemented carbides, ceramics, plastics and composite materials.

The range also includes the UH4250 and UH4750 models for which the hardness scales range from 0.5 to 250 kilogram-force (kgf) and from 3 to 750 kgf, respectively.

Contact: www.buehler-met.de

MEASURING TECHNOLOGY NDC Technologies, a leading global provider of precision measurement and control solutions, will exhibit its latest gauging technologies at this year’s METEC trade fair in Düsseldorf (June 25 to 29) at Hall 3, Stand E26. They include technologies for accurately measuring the length and speed of moving products and the coatings applied to metal surfaces.

The new Beta LaserMike LaserSpeed® Pro non-contact gauge measures the length and speed of any moving surface with +/-0.03% accuracy (the highest in the industry) and is equipped with expansive capabilities in Ethernet connectivity, communication and control consistent with Industry 4.0.

Engineered for a wide range of metal coating processes, the IG710e and SR710e Near Infrared gauges effectively measure a variety of coatings on metal coils in real-time.

The IG710e provides highly accurate, versatile and reliable

coating weight and coating thickness measurements, while the SR710e delivers the highest precision and performance for measuring thin, high-value coatings.

Contact: www.ndc.com/metals

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ANALYTICAL SOFTWARE Altair, a global technology company that provides solutions in product development, high-performance computing and data intelligence, has announced a speedup of its Altair OptiStruct™ structural analysis solver by up to 10 times. This was achieved with the NVIDIA graphics processing unit (GPU).

Altair OptiStruct is an industry-proven, modern structural analysis solver, and a market-leading solution for structural design and optimization.

OptiStruct helps designers and engineers rapidly develop innovative, lightweight, and structurally efficient designs based on finite-element and multi-body dynamics technology, and through advanced analysis and optimization algorithms.

The GPU runs on accelerated system architecture with no compromise in accuracy, according to Altair. This speed boost has the potential to significantly impact industries including automotive, aerospace, industrial equipment, and electronics that frequently need to run large, high-fidelity simulations.

“This breakthrough represents a significant opportunity for our customers to increase productivity and improve return on investment (ROI) with a high level of accuracy, much faster than was previously possible,” said Uwe Schramm, Altair’s chief technology officer (CTO) for solvers and optimization. “By running our solvers on NVIDIA GPUs, we achieved formidable results that will give users a big advantage.”

The test suite included a variety of industry models and multiple solution types such as statics, frequency response, buckling, and optimization. Support for GPU acceleration began with OptiStruct’s direct solver and with the large-scale noise, vibration and harshness (NVH) Automated Multi-level Sub-structuring Eigen Solver (AMSES), a standard feature of OptiStruct. AMSES drastically cuts the time required to compute eigenvalues for analysis in NVH simulations, and it can rapidly calculate thousands of modes with millions of degrees of freedom. The same impressive levels of acceleration were achieved with both solvers.

Most recently, the OptiStruct development team has extended GPU support by porting OptiStruct’s preconditioned conjugate gradient (PCG) iterative solver on the same NVIDIA GPU-accelerated system. This has resulted in some of the highest performance boosts seen. For some models – such as compact, block-like, solid structures – the PCG solver can be faster than the direct solver, especially when GPUs are in play. The upcoming OptiStruct 2019 release will include support for multiple GPUs. The OptiStruct speedup on GPU-accelerated systems enables scaling for large models, particularly NVH models,

which may run poorly or not run at all on CPU-based systems. The greater memory capacity of GPUs, including the ability to use multiple GPUs, means they can handle much larger and more complex models.

Contact: altairhyperworks.com

s m a r t ro b ot i c s

platforms for plant

digitalization

towards steel industry 4.0

iSMARTSTEEL Meet us at:

AISTech 6-9 May | #1937 MADE IN STEEL 14-16 May | #M17

METEC 25-29 June | #5G21 FUTURE STEEL FORUM 25-26 September | #20

sales@bmgroup.com | www.bmgroup.com

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SPECIAL EQUIPMENT Patton Electronics of Gaithersburg, Maryland, USA, a longstanding manufacturer of hardened industrial network equipment, has unveiled its new and ruggedized industrial-grade analogue SN4140E Voice-overInternet Protocol (VoIP) gateway series.

Described as ‘a new frontier’ by Patton, the first-in-class solution is designed to deliver VoIP telephony in outdoor or environmentally exposed environments where heating and cooling cannot be controlled.

The solution offers flexible combinations of up to eight analogue interfaces: plain old telephone service (POTS); Foreign Exchange Subscriber (FXS) which delivers the analogue line to the subscriber; and the Foreign Exchange Office (FXO) port that receives the analogue line.

Patton’s industrial VoIP gateway facilitates IP-based voice delivery for such applications as industrial automation, military communications, railways, public transportation, and public and private outdoor phones. This includes emergency phones in parking lots, along roadways and railways and within underground tunnels. The unit can be vehicle-mounted and is suitable for military applications. Eu-

ropean military organizations have already purchased the SN4140E for operational testing.

The gateway also provides interconnection and conversion between modern IP-based Voice networks. It does so with Session Initiation Protocol (SIP) – used to manage voice, video and messaging applications –and traditional analogue phones with analogue private branch exchange (PBX) and public switched telephone network (PSTN) lines.

Housed in a hardened metal enclosure, the SN4140E device can withstand shocks (IEC 60068-2-27), vibrations (IEC 60068-2-6), extreme temperatures (from -40 up to +70 °C), condensation and frost, and up to 85% humidity (an optional conformal coating offers protection up to 100%).

In addition, DIN-rail mounting and shelf mounting are supported. Twelve to 48 voltage direct current (VDC) terminal block power input is standard, while an active current (AC)to-DC adapter with a screw-down plug fastener is also supplied. Protection against power spikes and surges is also built-in according to MIL STD 1275 standards.

Contact: www.patton.com

Dear MPT reader, This is my last cartoon for MPT. As a metallurgist, I served the steel industry and plant engineering companies since 1963. At first in the field of cold rolling and, afterwards, as Editor-in-Chief of Stahl und Eisen and MPT International.

For the last 20 years, I have continued as a cartoonist for MPT. But, as I’m coming to the age of 80, I think that it is now time to hang up my pen!

Best wishes for you and our industries, Utz Peter Greis

New ideas can run amok

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COIL PROCESSING SOLUTIONS

LIGHT-ALLOY PROCESSING EQUIPMENT Strong know-how, decades of experience gained from taking on customers’ problems and a customised range of solutions designed to step up the productivity and therefore the business of the customer.

This is FIMIGroup: a designing and manufacturing group of companies with high added value both on the strictly technical level and on that of the flexibility and versatility of its solutions.

FIMIGroup via dell’Industria, 15 23897 Viganò (Lc) - Italy Tel. +39 039 92141 Fax. +39 039 927 2090 info@fimigroup.it

» » » » » » » » »

TTL - Tension Levelling Lines LTSG - Degreasing & Pre-Treatment LV

- Coating Lines

LFP - Slab Milling Lines TL

- Tension Leveller

CRB - Trimming Shears OLT - Oilers GFF - Embossers PSA - Stitching Machine

FIMIGroup will exhibit at next Aluminium China, held in Shanghai New Int’l Expo Centre 10 - 12 July 2019 Join us at Hall W1 - Stand 1J10

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IMPRINT IMPRINT

MPT International is published by

Circulation: 6,600 copies

Torsten Paßmann (Deputy Editor) Phone +49 (0) 22 03 / 35 84-120

Maenken Kommunikation GmbH, Cologne/Germany.

Unit price:

Internet: www.mpt-international.com

see cover, plus forwarding expenses

Publishing House:

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(responsible for editorial, advertising,

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Danieli supplies new CC8 caster at voestalpine Stahl in Linz, Austria The new CC8 caster produces slabs with a nominal thickness of 225 mm and widths ranging from 740 mm up to 1,820 mm. The product mix includes electrical steels with a silicon content greater than 2.0%, ULC, LC, structural steels (including micro-alloyed), press hardening grades, HC, and special steel grades (TRIP, 9% nickel).

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GIFA, METEC, THERMPROCESS and NEWCAST 2019: the hotspot for international foundry and metallurgy technology In June 2019, Düsseldorf, Germany, turns into the hotspot for international foundry and metallurgy technology.

Around 2,000 international exhibitors will take part in the world’s leading trade fairs GIFA, METEC, THERMPROCESS and NEWCAST from June 25 to 29. The trade fair quartet covers the entire range of foundry technology, casting products, metallurgy and thermal processing technology in an extensive depth and scope.

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PIONEERS AT HEART

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Metallurgical Plant and Technology International, No. 2, May 2019

THE Tapping Technology Plea

TMT – Tapping Measuring Technology GmbH P.O.Box 101355 - D-57013 Siegen • Hagener Straße 103 - D-57072 Siegen Phone +49 271 4014-0 • Fax +49 271 4014-210 • E-Mail: contact@tmt.com Managing Directors: Stefan Buch • Claude Bodeving • Registration No. HR B 5741

www.tmt.com

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TMT – Tapping Measuring Technology Sàrl P.O.Box 2233 - L-1022 Luxembourg • 32, rue d`Alsace - L-1122 Luxembourg Phone +352 261920-0 • Fax +352 261920-2779 • E-Mail: contact@tmt.com Managing Directors: Stefan Buch • Claude Bodeving • Registration No. B 91897

A joint company of DANGO & DIENENTHAL and PAUL WURTH

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