MPT International 1/2019 (Feb)

Metallurgical Plant and Technology G 25074

1

ISSN 0935-7254

February June 2016 2019

ISRA Parsytec’s 3D surface inspection system enables 100% detection (page 44)

World’s first reverse cold mill upgraded to a Hyper UC-mill

by Primetals (page 23)

Energiron reduction process could decrease CO2 emissions by more than 50% (page 36)

BAR AND WIRE ROD PLANTS

Cooling bed with HSD®

Combined Bar and Wire Rod Mill

Wire rod on LCC®

INGENIOUS SOLUTIONS TO FUEL YOUR SUCCESS Here’s how you benefit from SMS group bar and

Our success formula gives you exactly what you

wire rod mills: Cost-effective manufacturing of all

want: top quality combined with high productivity

dimensions and material grades … plus

and cost-effectiveness. Let’s add value along the

perfect meshing between machines, technology,

entire value chain, together.

electrical systems, and automation processes.

Leading partner in the world of metals

SMS group GmbH Ohlerkirchweg 66 41069 Mönchengladbach, Germany Phone: +49 2161 350-1724 Fax: +49 2161 350-1753 barandwirerodmills@sms-group.com

SMS group S.p.A. Via Udine, 103 33017 Tarcento (Udine), Italy Phone: +39 0432799111 Fax: +39 0432792058 www.sms-group.com

www.sms-group.com

‹‹‹

EDITORIAL

3

Compelling operational and cost advantages are crucial for greener steelmaking Intelligent manufacturing, greener processes and environmental production are among the themes that are expected to draw more than 70,000 visitors to the world’s second largest casting metallurgy event in Shanghai, China, next month (Metal + Metallurgy China, March 13 to 16, p. 13).

While China makes significant strides towards the green transformation of its metallurgy and foundry sectors – not least through its ‘Three Year Plan’ to tackle air pollution by 2020 – significant efforts have also been undertaken by Tata Steel, and Danieli in collaboration with Tenova HYL, in this field.

The first MPT of 2019 features not one, but two, major innovations that not only tackle the issue of carbon dioxide (CO2) emissions in steelmaking head-on, but which integrally rethink the traditional blast furnace (BF) route in steelmaking.

At its HIsarna plant in IJMuiden, the Netherlands, Tata Steel has gradually evolved a completely new technology (pp. 40-43) for producing iron in a reactor where iron ore is injected at the top. This could enable future steel production with at least 20% lower CO2 emissions by reducing the number of energy-intensive steps normally required in conventional BF processes. The system is undoubtedly revolutionary – Tata Steel believes its impact may be likened to the introduction of continuous casting in the 20th Century.

Then there is the Energiron direct reduction (DR) process (pp. 36-39) that, according to Danieli and Tenova HYL, could more than halve the levels of carbon emissions typically produced by conventional blast furnace–basic oxygen furnace (BF-BOF) mills. Tenova HYL has already taken an order from Sinosteel of China to supply its Energiron technology for a new direct reduction micro-module in South America (p. 6). Going forward, additional advantages may be achieved by feeding Energiron plants with hydrogen (H2).

For operators, Energiron and HIsarna each tick two a crucial boxes. Firstly, they facilitate stable blast furnace operations. Secondly, the solutions are sustainable for the long-term. As Hans Fischer, Chief Executive Officer and Chief Technical Officer of Tata Steel’s European operations, commented on the subject of CO2 efficiency in steelmaking: “The steelmaking industry has a collective responsibility to set bold targets, raise the bar and find opportunities to collaborate in order to drive progress on this front.”

As long as innovators continue to drive forward solutions which are ‘sustainable across the board’ – providing the compelling capital (CapEX) and operational expenditure (OpEX) benefits so crucial for operators – steelmaking can support a greener future for us all.

Tata Steel and Danieli/Tenova HYL have signposted the way towards a green future, says Alex Manford, Chief Editor of MPT International

Alex Manford Chief Editor, MPT International MPT International 1 / 2019

4

››› CONTENTS

International industry news 14 German Design Award 2019 given to 3D spray head for forging plants SMS group has received one of the world’s most prestigious design awards for its small machine component made through additive manufacturing. The recognition should open up new ways of thinking about the design and functional layout of components.

COVER STORY:

Events

The Slab Master by ISRA Vision AG, of

13 Metal + Metallurgy China 2019

unveils new dedicated die casting fair

based on laser triangulation to inspect the

The world’s second largest casting metallurgical event, Metal + Metallurgy China 2019, takes place in Shanghai, China, between March 13-16. The exhibition’s main themes focus on intelligent manufacturing, greener processes and environmental protection.

Darmstadt, Germany, uses 3D technology surface of steels. This process employs a precise laser along with high definition cameras to measure elevations on the material’s surface. The laser light source projects a beam of light onto the steel’s surface, and the cameras then measure the reflected light. The result is three-dimensional surface inspection. (See full story page 44)

Rolling mill technology

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

17 New automatic roll mark detector improves cold rolling mill performance The innovation from SR-Instruments and ArcelorMittal can help cold rolling mills achieve significant cost savings. The solution, an on-line installation into the exits of cold rolling mills, automatically inspects every coil for roll marks – even those which are non-visible.

23 First reverse cold mill worldwide upgraded to a Hyper UC-mill by Primetals Started up at Masteel in China, the Hyper Universal Crown (UC)-mill from Primetals Technologies employs smaller diameter work rolls for reduced rolling loads.

Masteel can now produce harder and thinner materials with improved product quality.

Steelmaking – Ironmaking

Digitalization

24 thyssenkrupp introduces a new oxygen technology for the blast furnace process

28 The steel industry and plant engineering: from digitalization to a digital eco-system

thyssenkrupp has developed an innovative blast furnace oxygen injection technology, the Sequence Impulse Process (SIP) which uses Induced Shock Waves.

The world’s first plant of this type has been under construction in Germany, to be commissioned in 2019.

MPT International 1 / 2019

Digitalization has been much discussed in the steel industry and plant engineering sector for years. Katja Windt, CDO of SMS group, examines the digital transformations taking place in numerous processes, e.g. increased automation along production chains.

Environmental protection

Quality assurance

36 New Energiron reduction process can sustainably decrease CO2 emissions in steelmaking

44 3D surface inspection for highest quality in metal production ISRA Parsytec has developed a new system that enables 100% 3D surface inspection and measurement from the first production step. The system is helping operators spot defects in steels earlier for substantial cost savings.

Compared with the traditional blast furnace–basic oxygen furnace (BF–BOF) route, more than 50% of carbon dioxide (CO2) emissions can be saved with Energiron direct reduction. The process can produce high grade steel in an economical and sustainable way.

40 Tata Steel's new HIsarna technology exceeds expectations in sustainable

steel production Tata Steel has developed a potential substitute for the blast furnace process for future steel production with at least 20% lower CO2 emissions. The company believes its impact may be compared to the introduction of continuous casting in the 20th Century.

Columns 6

International industry news

48 Technical innovations 52 Cartoon 53 Literature service 54 In the next issue 54 Imprint

Advertiser’s index SMS group GmbH 2 Zumbach 9 Micro Epsilon 15 ABB 21

Combilift 29 AIST Association 33 Keller HCW 34 R+W 47

IMS 49 Primetals 55 Kocks 56

MPT International 1 / 2019

6

››› INTERNATIONAL INDUSTRY NEWS

The Americas Bolivia Tenova HYL will supply a direct reduction injection (DRI) micro-module to Sinosteel. Tenova HYL, part of Tenova group specializing in direct reduction (DR) technologies, has been chosen by China’s Sinosteel Equipment and Engineering as its technology provider for a DR micromodule. Tenova HYL’s DR technology will be used for the first stage of the project for Empresa Siderúrgica del Mutún (ESM), a state-owned mining company, at Puerto Suárez in the municipality of Santa Cruz Department, Bolivia, South America. It will include: a 250,000 t/ year DRI facility; a 650,000 t/year concentration plant; a 400,000 t/year pelletizing facility; and a steel plant with a continuous caster, rolling mill and a total capacity of 190,000 t/year of long products. This cost-effective micromodule will use the state of the art Energiron Zero-Reformer (ZR) process which is capable of supplying the melt shop with high quality DRI with metallization levels of 94% and an adjustable high carbon content in the range of 3-4%.

Brazil Stahlwerk Thüringen to upgrade with new CCS® universal mill.

Stahlwerk Thüringen GmbH, part of Brazilian Grupo CSN, has awarded SMS group the order to supply a new CCS® (Compact Cartridge Stand) universal stand U1 for its section mill in Unterwellenborn, Germany. The new CCS stand is to replace the existing U1 stand in operation since 2002 as breakdown stand for the three-stand CCS tandem group. This upgrade has become necessary as a result of the continuously growing range of sections produced, especially to include increasingly heavier and larger section sizes. The new stand will be designed for a nominal rolling force of 6,000 kilonewton (kN) horizontal and 4,000 kN vertical (maximal 9,400 kN and 6,800 kN respectively). It will come with stronger roll guides and optimized roll cooling.

MPT International 1 / 2019

USA Nucor-Yamato Steel selects SMS group for upgrade of the no. 2 rolling mill. Nucor-Yamato Steel Company (NYS) has selected SMS group for the replacement and upgrade of rolling equipment at their heavy section mill in Blytheville, Arkansas, USA. NYS is comprised of two rolling facilities commonly referred to as Mill 1 and Mill 2, capable of producing an annual capacity of 2.4 million t of finished product. SMS group will upgrade Mill 2, which produces large wide flange and H-pile sections. The core of the upgrade is the substitution of the UR-E and UF stands with a modern tandem-reversing mill type CCS 1500.

Nucor to build new state-of-theart plate mill. Nucor Corporation has announced plans to build a stateof-the-art plate mill in the Midwest, USA. Nucor's Board of Directors has approved an investment of 1.35 billion US$ to build the mill, which is expected to be fully operational in 2022 and will be capable of producing 1.2 million t/year of steel plate products. The project is expected to create approximately 400 full-time jobs.

California Steel awards two upgrade projects to Primetals Technologies. To expand its product mix and improve utilization, California Steel Industries (CSI) has contracted with Primetals Technologies for two electrical and automation projects for its 86" hot strip mill and no. 2 continuous galvanizing line in Fontana, California, USA. The continuous galvanizing line upgrade is scheduled for a mid-2020 completion, and the 86" hot strip mill project is expected to be complete by mid-2022.

Fives commissioned to add new continuous hot dip galvanizing line. Fives, the global industrial engineering group, was awarded a contract

by Steel Dynamics, Inc (SDI), one of the largest steel producers in the USA. The Columbus Flat Roll Division of SDI is investing 140 million US$ to add a new continuous hot dip galvanizing line (CGL no. 3) into its existing plant in Columbus, Mississippi, USA and diversify its product portfolio. Currently,

the Columbus Division serves the needs of the automotive, agriculture, appliance, building and construction, energy, heating, ventilation and air conditioning (HVAC), lighting and machinery industries. Fives’ project includes design, supply and commissioning of the complete CGL no. 3 that will be capable of producing 400,000 t/ year.

Asia China CMI obtains final acceptance for the pickling process section at Foshan Chengde. Privately owned Foshan Chengde New Material Co., Ltd. has awarded CMI the final acceptance 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 is a global technological process enterprise producing a large variety of stainless steel strips and pipes. The state-ofthe-art chemical treatment equipment is among the centrepieces of the client’s new CAPL, helping Foshan to achieve the highest-quality end products and improve its competitive position, both in the domestic market and overseas.

Shandong Laiwu orders four Braun high-performance abrasive cut-off machines. Braun Maschinenfabrik GmbH of Austria, the manufacturer of cutting and grinding machines, and its Chinese subsidiary, Braun Machine Technologies (Beijing) Co., Ltd. have received the largest order in the company’s 170 years’ history. Shandong Laiwu Iron & Steel Co., Ltd., part of Shandong Iron and Steel Group, Ltd. (SISG), has awarded the contract for the high-performance abrasive cutting facilities with associated equipment for its newly built bar mill in Laiwu, Shandong province. The scope of supply comprises four traverse abrasive cut-off machines, type TS 16 F (suitable for the utilization of cutting wheels up to 1,650 mm diameter), all associated peripheral material transport and han-

‹‹‹

INTERNATIONAL INDUSTRY NEWS dling equipment, as well as the complete electrics and automation system.

Braun will also carry-out the supervision of the erection work, commissioning of the equipment and training of the customer’s personnel. SISG’s new bar mill in Laiwu is designed for an annual capacity of 800,000 t and will produce bars with diameters of 50 up to 130 mm. Commissioning is scheduled for the first quarter of 2019.

inforcing rings, shafts, parts for turbine blades, and supercritical components for gas turbines made of high temperature, corrosion-resistant special steel and superalloys. The new press allows Sichuan Liuhe Forging to continue to offer a consistently high level of product quality for its customers in the aerospace industry and to operators of large-scale steam turbines.

Shougang Jingtang orders continuous pickling line from Primetals. Shougang Jingtang United Iron & Steel Co., Ltd. (part of the Shougang Group) of China has placed an order for a continuous pickling line (CPL) with Primetals Technologies.

The line can process around 1.5 million t/year of hot rolled strip. It is designed to produce ultra-high strength steel (UHSS) grades for high added value products used in automotive, bus and truck production and all heavy industrial applications.

The CPL from Primetals can pickle hot rolled strip with thicknesses ranging from 0.8 to 6.0 mm (7.0 mm in the future) and widths from 750 to 1,650 mm, and handle coils weighing up to 33,6 t. The strip speed upon entry is 650 m/min, the pickling itself runs at 320 m/min, and speeds of up to 400 m/ min are reached in the exit section.

Primetals is responsible for engineering, manufacturing and all core equipment for the line which is part of the second phase of a new production plant in Caofeidian, Hebei Province.

Startup is planned for late 2019.

India

Sichuan Liuhe Forging orders high-speed open-die forging press from SMS group. Sichuan Liuhe Forging Co., Ltd. of Jiangyou in the province of Sichuan, China, has placed an order with SMS group to supply a high-speed, 50/55 meganewton (MN) open-die forging press. The press is of the two-column, push-down design and features a table shifter and die shifting unit. The open-die forging press operates with a press force of up to 50 MN and a maximum upsetting force of 55 MN. The press is suited for forging high-quality products with finished dimensions within the close tolerance range of ± 1 mm. Sichuan Liuhe Forging is a specialist manufacturer of forged semi-finished products, re-

Tata Steel chooses CMI’s technology for its new cold rolling complex in Odisha. Tata Steel has awarded CMI Industry Metals a contract for three state of the art processing lines: two continuous galvanizing lines (CGL) & 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 the eastern Indian state of Odisha. The three processing lines will allow Tata Steel to produce skin panels for car outer bodies, helping it retain leadership among domestic suppliers to highquality segments like the automotive and white goods sectors. All three lines are central parts of the phase two expansion of the client’s steel plant, to increase its annual galvanized steel production by 1 million t.

South Korea Hyundai Steel commissions new horizontal roller straightener from SMS group. Korean Hyundai Steel has awarded SMS group the Final Acceptance Certificate after successful commissioning of a new straightening machine for the medium section mill at its Incheon site, South Korea. The new horizontal roller straightener replaces an existing straightener installed in 1995. With the new horizontal roller straightener from SMS group, Hyundai Steel is able to roll larger sheet piles and beams up to a web height of 450 mm. In addition to extending the product range, the straightener helps to improve the tolerances and quality of the sections. This straightener type impresses also with reduced maintenance and lower media consumption while maintaining a high level of process reliability.

7

News in brief Danieli has struck a new partnership with GFG Alliance for the design and construction of a new high-tech rail and section mill at the Whyalla Steelworks. The new 750,000 t/year structural and rail heavy section mill will be an environmentally friendly facility that will increase the Steelworks production capacity, reduce waste and enable GFG’s Liberty Primary Steel to lift product capability and improve its competitive advantage.

Nucor Corporation has announced record consolidated net earnings of 2.36 billion US$, or 7.42 US$ per diluted share, for 2018 compared to 1.32 billion US$, or 4.10 US$ per diluted share, for 2017. The new earnings record of 7.42 US$ per diluted share in 2018 is a 24% increase, compared to Nucor’s previous record earnings of 5.98 US$ per diluted share in 2008.

OMK contracts Danieli for a new pipe complex. The hot mill will feature innovative Danieli Fine Quality Train (FQT) technology to be installed at Vyksa Steel Works, Russia. OMK’s new seamless pipe complex will produce 500,000 t/year of OCTG seamless pipes (casing and tubing), linepipe and industrial pipes from 2” 7/8 to 10” 3/4. The plant consists of a hot rolling line based on innovative FQT and a finishing centre featuring heat treatment, quality assurance and finishing lines.

ArcelorMittal has forecast a slight expansion of global steel demand in 2019. The company said it expected world steel demand to grow by between 0.5 and 1 % this year after an increase of 2.8 % in 2018. Last year, driven by a healthy market, ArcelorMittal achieved its highest earnings in a decade. >> MPT International 1 / 2019

8

››› INTERNATIONAL INDUSTRY NEWS

United Arabian Emirates Emirate Steel orders automatic temperature and sampling manipulator from More. Emirate Steel, UAE, with a capacity of 3.5 million t/ year has awarded More S.r.l. with an order for the CATFIS 2.1 automatic temperature and sampling manipulator for its SMP3 electric arc furnace (EAF). The technology operates through the EAF slag door and it was developed with four axis and four degrees of freedom. As a sturdy piece of equipment, the CATFIS 2.1 can operate in very constrained and confined areas and is designed to be easily reconfigured if changes on the plant take place. Its main features include: an anti-collision system; minimum maintenance operations; a compact design; easy equipment installation and displacement. The installation is scheduled for the first quarter of 2019.

Europe The Netherlands Tata Steel steelmaking plant recognized as a ‘factory of the future’. The World Economic Forum (WEF) has inducted Tata Steel’s steelmaking plant at Ijmuiden, the Netherlands into its prestigious community of ‘Manufacturing Lighthouses’ – state-of-the-art production facilities which successfully adopt and integrate the cutting-edge technologies of the future and drive financial and operational impact. This makes Tata Steel part of a network of just 16 key factories to create the world’s leading learning platform for production. Tata Steel’s site at IJmuiden has been lauded for its pioneering use of advanced analytics to optimize the way raw materials are used, increase the yield at every step of the steelmaking process and further improve logistics between the different processes and the quality of the product for customers.

Companies World record ultra-thin hot rolled strip with a thickness of 0.6 mm supplied by Primetals. In October 2018, an Arvedi ESP (Endless MPT International 1 / 2019

Strip Production) line installed in a plant belonging to the steel producer Rizhao Steel Group Co., Ltd. of Rizhao, China, produced ultra-thin hot strip with a thickness of just 0.6 mm for the very first time. Hot strip as thin as this had never before been achieved anywhere in the world. This thin strip can cover more than 80% of regular commercial cold-rolled thicknesses. The line was supplied by Primetals Technologies. This widens Rizhao's range of products, especially for cold strip substitutes. After the line entered service in April, success was achieved just six months later.

MMK ships record volume of galvanized steel in 2018. Magnitogorsk Iron and Steel Works (MMK) shipped 1,269 million t of galvanized steel in 2018, the highest figure in the company's history. This result is 11.9% higher than the previous record of 1,134 million t of galvanized steel set by the company in 2017. Over the past 15 years MMK has been consistently increasing the production of galvanized steel. In 2002 and 2008, the company commissioned two high-performance continuous hot-dip galvanizing lines at its metal-coating shop.

In 2012, MMK commissioned the second stage of a cold-rolling unit at sheet-rolling shop 11, comprising a continuous hot-dip galvanizing line as well as a combined continuous annealing and hot-dip galvanizing aggregate.

In July 2017, MMK put into operation the no. 3 unit for continuous hot-dip galvanizing with a capacity of 360,000 t/year. Development of coated metal production is in line with MMK’s goal to increase output of high value-added advanced processed products.

Quality Tracking System for steel coils project comes to a successful conclusion. After three successful years of development and deployment, the Quality Tracking System for steel coils project governed by the European Steel Association (EUROFER) closed on January 23. The project has contributed to the further digitalization of the sector and helped support the ambition to achieve the ‘zero defect vision’ for users of flat steel products. The system was developed by a consortium of the members, with EUROFER acting as the governance body, to help increase

the overall resource efficiency of the steel supply chain. Unique ‘1D’ bar codes are printed automatically along coils at regular intervals – typically every metre – to detect isolated quality issues (imperfections). Standardized quality data, when synchronized with the bar code, provides the position of a flaw and allows steel users to avoid that part of the coil during their processes, and reject a section of steel on the blanking or stamping line. The Quality Tracking System has been submitted to the European standards body, CEN, with publication of the European standard expected at some point in 2019.

Nucor Corporation announces record consolidated net earnings.

Nucor Corporation, USA, has announced record consolidated net earnings of 2.36 billion US$ for 2018 compared to 1.32 billion US$ for 2017.

The new figure is a 24% increase over the company's previous record earnings reported in 2008. Consolidated net earnings of 646.8 million US$, reported in Q4 2018, represents the strongest fourth quarter performance in Nucor’s history. Key factors, according to the company, include shipping a record amount of steel and, over the past decade, investing more than 9 billion US$ to increase the Company's peak earnings power and build on product diversity.

Nucor Corporation announces plans for a state-of-the-art plate mill. Nucor Corporation has announced plans to build a new plate mill in the Midwest, USA. Nucor's Board of Directors has approved an investment of 1.35 billion US$ to build the mill which is expected to be fully operational in 2022. It will be capable of producing 1.2 million t/year of steel plate products. The project is expected to create approximately 400 full-time jobs and is part of the company’s drive to continue delivering sustainable, profitable growth and superior returns for shareholders. The new plate mill will produce cut-to-length, coiled, heat-treated, and discrete plate ranging from 60 to 160 inches wide, and in gauges from 3/16 of an inch to 14 inches in thickness; enabling Nucor to supply plate products that the Company does not currently offer. Nucor cur-

‹‹‹

INTERNATIONAL INDUSTRY NEWS rently operates plate mills in North Carolina, Alabama and Texas, USA. Eddyfi Technologies acquires NDT robotics leader Inuktun. Eddyfi Technologies, a world leader in advanced non-destructive testing (NDT), has acquired Inuktun, a well-known developer and manufacturer of remotely operated crawlers and camera systems. For 30 years, Inuktun of Nanaimo, British Columbia, Canada, has offered robotic systems that bridge the gap between NDT inspectors to go safely beyond physical inspection limitations. This strategic acquisition is the sixth by Eddyfi in 32 months, and is anticipated to benefit the company’s technology portfolio through the combination of Inuktun robots with Eddyfi’s sensors and instruments. Customers can select from a range of crawlers, cameras and controllers to create their own off-the-shelf, yet customized, solutions.

SSAB’s operating profits rise by 21 million US$. SSAB’s operating profit for the fourth quarter of 2018

was 1,117 million US$. Despite significantly higher maintenance costs, this was comparable to Q4 2017. The improvement is mainly attributed to SSAB Americas. Operating profit was down quarter on quarter, primarily due to planned maintenance outages.

SSAB Special Steels saw continued strong demand in most segments. During the quarter, it took the decision to prolong a planned maintenance outage in Oxelösund, Sweden, and increase preventive maintenance efforts given the disruptions that occurred earlier in the year. This impacted shipments and costs negatively during the quarter, but creates better conditions for more stable production going forward. The operating result was 77 (692) million US$ for Q4.

Inteco proves its strong position in China’s remelting market. Inteco has reported an ‘exceptional fast and smooth’ first heat with the 8 t electroslag remelting (ESR) furnace. Nantian Tool Steel in Huangshi, Hubei province, China, awarded Inteco with the design and supply of an 8 t and a

9

16 t ESR furnace back in 2017. The plant of the latest technical generation is especially dedicated to the high-quality, repeatable and most economical ESR production in static mould, single electrode operation. Following the first ingot produced in the 8 t furnace, the hot commissioning of the 16 t furnace will follow shortly and is expected to be just as successful.

NSSMC overhaul its rolling facility for the production of wheels.

Nippon Steel & Sumitomo Metal Corporation (NSSMC) has decided to completely overhaul its rolling facility for the production of wheels at the Osaka Steel Works of its Railway, Automotive & Machinery Parts Unit. It is among the company’s major initiatives to globalize and strengthen the manufacturing capabilities of its domestic mother mills. NSSMC is Japan’s only manufacturer of railway wheels and sells to customers in Japan and abroad. The wheel mill is the most important facility, contributing to hot processing and forming. NSSMC will combine a state-ofthe-art wheel mill with unique rotary >>

Offering The Most Suitable Dimensional Measuring Solutions Regardless of Shape, Size, Speed or Temperature, We Measure It All !

Static, Oscillating, Rotating, Full Profile Capture, We Do It All !

25 – 29 June, 2019 Düsseldorf, Germany Booth # 5F22

MPT International 1 / 2019

www.zumbach.com • sales@zumbach.ch

10

››› INTERNATIONAL INDUSTRY NEWS

forging technology to enhance its manufacturing base for the stable supply of higher-grade, higher-value-added wheels worldwide. The company will also enhance its capability to respond to the latest refinement of European Standards.

Danieli and Yildiz Lar startup a new cold tandem mill in Turkey.

Described as ‘impressive’ by Danieli, the startup was at Yildiz Lar’s new complex in Izmit (sometimes called Kocaeli), Turkey. Initial quality and productivity results were twice the contractual values, and the PAC was signed after two weeks. Four weeks later, productivity was three times the expected rate. The new five-stand tandem mill is made up of six-high stands featuring Danieli Optimized Shaped Roll Technology (OSRT), controlled by a Danieli Automation process control system.

An automatic eccentricity compensation algorithm ensures precise and simple control of strip thickness for a tolerance of ± 0.6%, head/tail off-gauge length lower than 4 m, and strip flatness of less than 5IU. Production includes coils in a final strip thickness of 0.20 mm and widths up to 1,550 mm in a product mix including DP600, DP1000, IF and HSLA. NLMK Group to boost second-largest Lipetsk furnace capacity by 8%. NLMK Group has embarked on a large-scale reconstruction of blast furnace no. 6 (BF-6) at its site in Lipetsk, Russia. The project will enable an 8% increase in BF capacity to 3.4 million t/year of pig iron, significantly improving its environmental performance and extending its interrepair cycle by 50% to 25 years. Investment in the upgrade will exceed 34 billion RUB. Currently, work is underway to install new blast air heaters and dedusting systems, assemble main units and steel structures. These works will be completed before the shutdown of the blast furnace, scheduled for May 2019. During the 130-day stoppage, the furnace will be dismantled and rebuilt from prefabricated modules.

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 MPT International 1 / 2019

TMW’s second slitter from Red Bud Industries, the latest in an extensive cycle of new equipment and upgrades. The processing centre’s capabilities include slitting, EPS pickling, stretcher leveling and cut-to-length processing of heavy gauge and high strength flat rolled metals.

SSAB Europe will carry out repairs and maintenance at one of the two blast furnaces at its Raahe site in Finland. This means the operations at blast furnace no. 2 will be stopped for around eight weeks and the total cost is estimated to be around SEK 200 million (around 21.5 million US$) in the first quarter of 2019.

AOD converter modernized by Primetals starts up at Outokumpu, Finland. The no. 1 Argon Oxygen Decarburization (AOD) converter was started up at the Tornio, Finland, works of Outokumpu Stainless Oy in December 2018. Primetals Technologies was responsible for the planning, manufacturing and supply of the new equipment. This covered the trunnion ring, tilting drive, the rotary joint and the pipework. The patented Vaicon Drive Damper system, developed by Primetals, was installed on the tilting drive.

It reduces vibrations produced by the blowing processes, and thus the mechanical loads acting on the entire system from the converter down to the

foundations. This reduces wear and maintenance costs while lengthening the service life of the plant. Outokumpu’s works in Tornio, Lapland, is an integrated production complex with a cold rolling capacity of 1.2 million t per annum.

Tata Steel restarts blast furnace no. 5 at Port Talbot, UK. Tata Steel’s plant in Port Talbot, Wales, UK, has completed a major life extension project of one of its two blast furnaces. The restart of blast furnace no. 5 cost 'tens of millions' of pounds (GBP) according to Tata Steel, and is a critical part of the company’s long-term strategy to strengthen its UK operations and underpin improvements throughout its UK supply chain. Once the heart of the furnace – which is normally more than 1,200 °C – had cooled, last year, engineers replaced part of the heat resistant interior and vital structural parts. The waste gas and dust extraction system was also replaced. The final part of the process involved the hot blast main being opened to inject air at 1,100 °C, thereby bringing the furnace back to life.

Personalities Rhodes Interform expands service offering with three new appointments. Rhodes Interform, of Wakefield, West Yorkshire, UK, the

Rhodes Interform has added Nigel Hartley, Service Engineer (third from left) and Paul Lowden, Senior Service Engineer (third from right), to its team

‹‹‹

INTERNATIONAL INDUSTRY NEWS Group Rhodes business specializing in bespoke composite and metal forming machinery, has expanded its team with the appointment of three new service engineers to enhance its services to customers.

The new starters include Gary Lymm, Nigel Hartley and Paul Lowden who are all highly experienced in either mechanical, hydraulic or electrical engineering, servicing and repair. They will each play a key role in expanding service agreements with customers, including reducing plant downtime and maximizing operational efficiency through planned maintenance schedules. Their appointments are a response to growing demand over the past 12 months for Rhodes Interform’s repair and maintenance services from the metal press industries, including aerospace, automotive, white goods and general sheet metal fabrication.

Elena Lobodina to head NLMK Trading. NLMK Group, the global steel company, has announced the appointment of Elena Lobodina as general director (CEO) of NLMK Trading.

Elena’s key challenges will include the

Giulio Bozzini

ini’s financial and operational experience spans 30 years for important multinational companies. Since 1994, he has worked in Saipem, a worldwide leader in drilling services, as well as in EPC/EPCI pipelines and complex projects in the oil and gas market, listed in the Italian stock Exchange, where he held several leadership positions, most recently as chief financial and strategy officer. From 2012 to 2016, he covered the role of executive vice president planning and control in Eni, Italian multinational oil and gas company. After graduating in Business Administration at Bocconi University in Milan, Italy, Mr. Bozzini started his professional career in 1988 in the KPMG Audit Department.

Former RHI Magnesita CEO passes away after long illness. RHI Magnesita of Austria has announced the passing of its former CEO, Franz Struzl. He passed away on January 28 at the age of 76, led the company from September 2011 to June 2016. Mr. Struzl is remembered for this strategic views

Elena Lobodina

development of NLMK Group’s customer service across global markets and the introduction of best practices in sales business processes.

NLMK Trading manages NLMK Group’s export deliveries. The company’s sales policy is focused on working with end consumers.

Giulio Bozzini is appointed as the new Tenova CFO. Giulio Bozzini has become the new Tenova chief financial officer (CFO), reporting directly to Andrea Lovato, Tenova CEO. Mr. Bozz-

Franz Struzl

11

and his modern approaches, and participated as a key stakeholder in the merger of RHI and Magnesita. Mr. Struzl completed his studies at the Vienna University of Economics and Business in 1965. After more than 40 years at Alpine Steel Group (later voestalpine AG), he became Chairman of voestalpine AG in 2001. He held this position until 2004 and soon afterwards became CEO of voestalpine, Brazil (Villares Metals), remaining there until 2010. In 2011, he joined RHI AG as CEO and was responsible for the increase in profitability. A severe illness led to his retirement in 2016. Mr. Struzl leaves behind his wife Doris and four children.

Nippon Steel & Sumitomo Metal Corporation announce change in chairman and president. At its meeting of the board of directors held on January 10, 2019, Nippon Steel & Sumitomo Metal Corporation announced two new appointments for the position of chairman and president. Kosei Shindo (currently representative director and president) will be appointed as representative director and chairman. Eiji Hashimoto (currently representative director and executive vice president) will become representative director and president.

Both appointments will become effective as of April 1, 2019.

Cleveland-Cliffs makes two new appointments to its Board of Directors. Cleveland-Cliffs of Cleveland, Ohio, USA, an iron ore mining company and pioneer in developing the beneficiation and pelletizing process, has appointed M. Ann Harlan and Janet L. Miller to its Board of Directors.

Ms. Harlan was formerly vice president, general counsel and secretary at the JM Smucker Company, a fortune 500 food manufacturing and marketing company. Ms. Harlan will join the Audit Committee of Cleveland-Cliffs’ Board. Ms. Miller is an executive officer with University Hospitals, a nationally ranked health care system headquartered in Cleveland, Ohio, with annual revenues in excess of 4 billion US$. With the addition of Ms. Harlan and Ms. Miller, the ClevelandCliffs’ Board of Directors is now comprised of 11 members, of which ten are independent directors. >> MPT International 1 / 2019

12

››› INTERNATIONAL INDUSTRY NEWS

Ametek Land names Manfred Hayk as new global infrared product manager. Ametek Land, a leader in temperature measurement and combustion emissions, is pleased

Manfred Hayk

to appoint Manfred Hayk as the company’s new global infrared (IR) product manager, based in Germany. Mr. Hayk has over 15 years’ experience in infrared temperature measurement and more than 20 years in optical metrologies, including laser technologies and further high-end metrologies. Previously, he was the company’s sales channel manager for Europe, the Middle East, Africa and Russia. Mr. Hayk will lead Ametek Land’s Global IR product team which focuses on developing intelligent infrared technologies for superior application solutions to serve Ametek Land’s new and existing markets. He will also develop new ways to help customers control and improve their processes, and develop an outstanding family of new intelligent thermal imaging solutions for different industrial applications.

Poppe + Potthoff appoints new chief executive of mobility to its management team. Poppe + Potthoff of Werther, Germany, is a group of companies developing and producing customized steel tubes, common rail subsystems, high-pressure injection lines, precision components, drive shafts and couplings, as well as special machines and test stands.

Dr.-Ing. Bengt-Henning Maas has been appointed as chief executive of mobility to lead the product segments tubular components (customer-specific precision steel tubes, common rails and high-pressure lines as well as specialized mechanical engineering) and precision components. The Doctor of Physics came to Poppe + Potthoff from steel research in 2014 and has been driving the topic of Industry 4.0, among others.

› 06 – 08 May 2019 Pittsburgh, USA Organizers: Association for Iron & Steel Technology www.aist.org/conference expositions/aistech

› 14 – 16 May 2019 Milan, Italy Organizers: siderweb www.madeinsteel.it

Events › 20 – 23 March 2019 Tokyo, Japan Organizers: The Iron and Steel Institute of Japan www.isij.or.jp Iron and Steel Institute of Japan.

The ISIJ Meeting, one of the most important events of its kind, is held every year in spring for three days. More than 1,500 participants, over 600 papers for regular presentations and about 80 papers for discussions with features both from Japan and abroad.

› 23 – 25 April 2018 Moscow, Russia Organizers: ITE Group www.miningworld.ru MiningWorld Russia 2019. MiningWorld Russia offers an effective business platform for producers and suppliers. The event attracts specialists of Russian mining companies, mineral processing enterprises and trading companies, which are interested in purchasing of machines and equipment for mining, processing and transportation of minerals.

MPT International 1 / 2019

AISTech 2019. The steel industry’s premier technology event features ideas from all over the world to help steel producers compete more effectively in today’s global market. It remains unmissable for anyone involved, at any level, in today’s steel marketplace with the technologies and engineering expertise necessary to power a sustainable steel industry.

› 13 – 16 May 2019 Atlanta, Georgia, USA Organizers: The Wire Association International (WAI), Inc. https://interwire19.com Interwire 2019. This years event has a ‘Next Generation’ theme, and a new conference format featuring speakers from the industry's most influential companies. Interwire includes WAI's 89th Annual Convention, its 3rd Global Continuous Casting Forum and the International Fastener Manufacturing Exposition (IFME).

Made in Steel 2019. Southern Europe’s biggest conference and exhibition dedicated to the steel industry. Besides a showcase, it is a culture hub which, through conventions, forums and round tables, hopes to further competitive collaboration and the exchange of information, two vital ingredients for business growth.

› 24 – 28 June 2019 Düsseldorf, Germany Organizers: Steel Institute VDEh www.METEC-ESTAD2019.com ESTAD 2019. The European Steel Technology and Application Days (ESTAD) 2019 will take place for the fourth time. The long lasting alliance between the METEC – international trade fair for metallurgy and this accompanying conference makes this event to be the quintessential meeting point of the world’s leading steel experts.

‹‹‹

EVENTS

Metal + Metallurgy China 2019 unveils new dedicated die casting fair Now the world’s second largest casting metallurgical event, Metal + Metallurgy China 2019 takes place in Shanghai, China, between March 13 to 16. This year’s event will be held under the theme of ‘intelligent manufacturing, green and environmental protection’.

Asia’s number one metallurgy and casting exhibition, Metal + Metallurgy China 2019, will take place between March 13 to 16 at the Shanghai New International Expo Centre. The largescale event comprises the 17th China International Foundry Expo, the 13th China International Die Casting Industry Exhibition, the 19th China International Metallurgical Industry Expo, the 15th China International Refractories and Industrial Ceramic Exhibition and the 17th China International Industrial Furnace Exhibition.

Metal + Metallurgy China 2019’s organizers say it is now the second largest exhibition of its kind in the world. This year’s event will upscale with new outdoor pavilions and a dedicated fair for die casting applications, bringing the total exhibition area to 100,000 m2.

In addition to the various exhibitions that are held under the ‘Metal + Metallurgy China 2019’ banner, several further events will run parallel with the show. They include: the China International Steel Summit; the Second Meeting of the 8th Council of China Foundry Association; the 15th Annual Congress of China Foundry Association; and the Innovation Award for China Foundry.

The theme of this year’s event, ‘Intelligent Manufacturing, Green and Environmental Protection’, pushes the continued development of green standards for China’s enterprises – e.g. accelerating the elimination of ‘backward’ production capacities and resolving overcapacity issues.

Hannover Milano Fairs Shanghai Ltd Contact: www.mm-china.com

Growth of die casting and higher value products Die casting is the most widely used metal casting method in foundry processes, a trend which is expected to increase dramatically in China with the country’s continuing promotion of ‘Made in China 2025’.

Directly inspired by Germany’s advancements within Industry 4.0, Made in China 2025 seeks to upgrade the country’s manufacturing capabilities in order to produce higher value products. Its goals are to increase China’s domestic content of core materials to 40% by 2020 and 70% by 2025. These initiatives are being implemented across a range of high-tech fields such as automotive, aerospace, semiconductors, IT and robotics.

Meanwhile, the growth of die casting will be heralded by Metal + Metallurgy China’s first independent fair dedicated to the subject. Called the China International Die Casting Industry Exhibition, the fair will bring together various types of die casting parts, machines, alloys and auxiliary materials as well as post-processing equipment for die casting parts. A number of well-known die casting companies will be involved.

Continued discussions of the ‘new normal’ markets Metal + Metallurgy China 2019’s agenda coincides with two ongoing state initiatives. Firstly, the State Council’s (China’s cabinet) ‘Three Year Plan for Winning the Blue Sky War’ which aims to tackle air pollution by 2020. Secondly, the Industrial Green Development Plan that is expected to herald an imminent green transformation and upgrading of China’s metallurgy and foundry sectors. Related opportunities and developments in the ‘new normal’

13

Eurocoke remains a leader for coke, coal and steel markets The 15th edition of the Eurocoke Summit takes place between April 2 to 4, 2019 at the Novotel Amsterdam City hotel in Amsterdam, the Netherlands.

Eurocoke brings together experts and industry leaders from the metallurgical coke, coal and steel supply chains for two full days of learning, networking, discussion and debate.

The main topics of discussion will include the latest market trends and technical and operational developments within the industry. They include methods through which coke producers might reduce emissions from cokemaking, and case studies from plant managers on how to operate successfully against today’s challenges.

Speakers in previous years have included representatives from ArcelorMittal Group CTO, Gerdau, Tata Steel and JSW Steel. Last year’s summit was an unprecedented success, say organizers, and attendance levels in April are expected to exceed the 200 industry professionals that took part in 2018. Those who wish to visit can register via Eurocoke’s website.

Contact: www.metcokemarkets. com/eurocoke-summit

markets will also be discussed. They include finding new and intelligent ways to foster green, healthy and sustainable development of the industry as a whole. Such developments are reflected by a sharp increase in the number of environmentally-friendly metallurgical and foundry exhibitors at this year’s event.

Rise of the robots, plus automation For the first time, the international hall will host a robotics and automation exhibition to examine where these technologies, along with green concepts, can be implemented into the metallurgical and casting production process. International companies from Italy, France, Belgium, Germany and other countries will showcase robotic arms and other products.

MPT International 1 / 2019

14

››› INTERNATIONAL INDUSTRY NEWS

German Design Award 2019 given to 3D spray head for forging plants SMS group of Düsseldorf, Germany, has received one of the world’s most prestigious design awards for its small machine component made with the latest developments in additive manufacturing. The recognition is likely to open up new ways of thinking about the design and functional layout of components.

SMS group, the plant and mechanical engineering company, has received the German Design Award 2019 for an innovative spray head that is used to cool dies in forging presses. The German Design Award is organized each year by the German Design Council which, formed 65 years ago, is today regarded as one of the world’s leading design institutions. The award recognizes innovative products and projects, and the companies or individuals who have fabricated and designed them.

Aside from the relevancy of the spray head itself, which was nominated in the award’s ‘Industry’ category, the Council’s judges chose the component because it exemplifies the various aspects of additive manufacturing. The recognition symbolizes how additive processes, such as 3D printing and powder metallurgy, are opening a whole range of new possibilities for the design and functional layout of components.

For SMS group, the award-winning spray head contributes towards a common goal of adopting an entirely new approach to the design and production of machine components. Axel Roß­ bach, research and development extrusion and forging presses at SMS group, said: “Winning the Design Award makes us extremely proud. It is a recognition of many teams within SMS group whose work is characterized by a highly interdisciplinary approach.

SMS group GmbH, Düsseldorf, Germany Contact: sms-group.com Email: thilo.sagermann@sms-group.com

MPT International 1 / 2019

The spray head is a milestone innovation, marking a new era in the design of plant and machine components enabled by the game-changing potential of 3D printing and function-optimized design. The design of a machine part is, today, no longer limited by the constraints imposed by conventional, process-optimized form­ing and machining techniques.” SMS group’s approach is supported by the latest software developed by the company itself.

This combines with computer technology to give the component an exact design that, in the words of Mr. Roßbach: “Fulfills its designated function in the best possible way.”

heavy and complicated to produce, their heavy weight impairs the productivity of the forging press. Instead, the new component was designed with a view to how it can fulfill its function in the most efficient way. It is significantly smaller, features flow optimized channels and cools the dies specifically to meet the requirements of each individual case. In simpler terms, SMS group’s spray head can be applied specifically, so that die areas subjected to intensive heating are cooled at a correspondingly and precisely calculated higher rate than less hot areas.

“Although the spray head is only a small component, it nevertheless ideally represents the potential of additive manufacturing,” said Mr. Roßbach.

“The innovative manufacturing methods enabled by 3D printing form the basis for Industry 4.0. The example of the 3D printed spray head makes this clear and measurable.”

In terms of added value and the potential for process optimization, the 3D spraying system’s advantages are key to its readiness for Industry 4.0.

Mr. Roßbach explained that, because the spray head is made of plastics, it has only a tenth the weight of a conventionally manufactured component. A 3D printed spray head made of metal weighs up to 70% less, in comparison. Overall, the component is less expensive, more efficient and can be easily customized. A further advantage is that it can be produced virtually instantly and just in time.

One tenth the weight of a conventionally produced component

New ways of optimizing components for specific functions

Another important factor behind the new spray head component is that SMS has used a new material for its manufacture. Not only are common spray heads

The new spray head solution produced by 3D printing is the result of a joint effort by the Forging Plants Department, the Additive Manufacturing

SMS group has won the German Design Award 2019 in the category ‘Industry’ for the additively manufactured 3D spray head

‹‹‹

INTERNATIONAL INDUSTRY NEWS

15

Markus Hüllen, vice president of the 3D Competence Centre of SMS group (far right), shows Peter Joerdell, MPT’s Deputy Editor (far left), the possibilities of additive manufacturing grade metal powder

Pilot plant is likely to propel a new growth sector The new possibilities of 3D printing and powder metallurgy are already in evidence in Mönchengladbach near Düsseldorf, Germany, where SMS has set up a pilot plant for the industrial scale production of additive manufacturing grade metal powder. The demonstration plant is the first of its kind where customers can experience the complete process chain of additive manufacturing – from production in the powder atomization plant, powder handling, 3D printing, heat treatment and machining through to inspection, quality checks, logistics and automation systems.

SMS has worked with Additive Industries, a developer and provider of selective laser melting systems for 3D metal powder printing, to develop processes that keep the powder under a vacuum during all the process steps. This prevents contamination and ensures that the components produced will be of the highest quality.

From the vacuum induction melting (VIM) atomization process that reaches temperatures of 350 °C via a 3 mm nozzle (small compared with the 15 mm nozzles used in conventional powder plants), the powder emerges with very specific properties. It is extremely homogenous in order to form the basis of additive manufacturing and consists of perfectly round, minute spheres that

measure just 15 to 45 μm (1/1000 mm).

The burner nozzle itself is designed to optimize the powder’s weight and function [2].

It might be hard to imagine how such microscopic particles are produced in a 13 meters tall and complex high-tech plant. Markus Hüllen, vice president of the 3D Competence Center of SMS group, explained that the larger size is key to ensuring that high-quality 3D printed metal components are the end result.

He said: “Our objective is to master, and allow our customers to master, the complete process chain of this innovative technology. This is why we deliberately chose to not build a small-scale, but an industrial-scale, pilot plant. Only this way can we test the process under realistic conditions, i.e. at high temperatures and pressures and in long production campaigns.”

The 3D printer at Mönchengladbach measures 420 x 420 x 400 mm on the inside. For now, its size is the only limit to the future possibilities and significant growth potential of additive manufacturing. Additively manufactured components are already used in a number of so-called ‘enabler’ industries such as aerospace, automotive, medical engineering, prototype and tool making, and plant and mechanical engineering. >>

HOT MILL

LASER THICKNESS MEASUREMENT C-frame laser gauges now also for hot mill applications:  Thickness up to 15.75 inches (400 mm)  Temperature up to 2192 °F (1200 °C)  Accuracy ±5 microns

Micro-Epsilon laser gauges established in hot mills, cold mills and processing lines

Tel. +49 8542 1680 MPT International 1 / 2019 www.micro-epsilon.com/metal

16

››› INTERNATIONAL INDUSTRY NEWS

Project Team and the simulation technology experts of SMS group.

The benefits of additive manufacturing can provide numerous advantages for drop forging operations. Drop forging presses are being constantly optimized with a view to achieving shortest cycle times and maximized service life of the dies. Spray heads for cooling and lubricating the dies perform a key function in the forging process as, without them, the dies would not be able to withstand the constant and extremely high stress acting on them during operation. The spray heads are introduced between the open dies awaiting the next forging stroke.

SMS’s component enables not only a reduction in weight and costs, but also reduced wear of the supporting arms which introduce the spray heads between the dies. Because a significantly lower than usual mass is to be accelerated, cycle times of the – usually automated – processes can be shortened.

Another key advantage for the press operator is the possibility of producing customized spray heads ‘on demand’ – i.e. through 3D printing processes the spray heads can be available in virtually no time, without incurring the high costs of keeping them physically in stock. Furthermore, there are environment benefits as the production of the spray heads consumes no more material than absolutely necessary.

In the future, SMS plans to also print current-conducting elements and sensors into the spray heads. This will make it possible to actuate the valves electrically and generate condition messages of the systems.

The technology is advantageous in a product development context, said Erdem Karakas, technology engineer at SMS group: “Because of non-existent manufacturing restrictions in additive manufacturing, we found a way to implement the form-follows-function principle in this special design.”

‘Filigree shape’ proves successful under harsh operating conditions One of the first customers using the new spray head in practice is Bharat Forge, a forge operator located in Ennepetal, Germany. For Bharat Forge, the spray head was designed specifically to allow switching between water and a graphite-based spraying fluid.

MPT International 1 / 2019

This entailed a ‘filigree’-like design with twisted heads.

Both the customer and SMS group say they are extremely satisfied with the component’s performance. As a result, Bharat Forge has been able to achieve a far more homogenous spraying pattern. The dies are cleaner and, consequently, the overall consumption of spraying fluid has decreased.

Furthermore, the customer has reported that handling is easier than with the conventionally manufactured spray

Nina Uppenkamp, a member of the R&D project team at SMS group: “It is very important that our colleagues solidify this new way of thinking. In the future, the technology will increasingly change the shape of SMS products.”

Unlocking the potential for future-oriented technologies Although the new spraying system for drop forging plants is only a small object, it offers a prize example – in the truest sense of the word – of the excit-

“Although the spray head is only a small component, it ideally represents the potential of additive manufacturing.

The innovative manufacturing methods enabled by 3D printing form the basis for Industry 4.0.”

Axel Roßbach, research and development extrusion and forging presses, SMS group

heads. Accumulations of material – as frequently occurred inside the former spray heads – have not been found due to the flow-optimized design of the fluid channels.

Exploring the overall concept of additive manufacturing Aside from its award-winning spray head, SMS group has undertaken a number of other plans and strategies in additive manufacturing. The company says these are intended to go beyond the design and production of machine components towards integrated solutions for the complete additive manufacturing process chain.

A main area of additive manufacturing is, of course, the 3D printing of metal. In 3D printing, a laser melts fine-grained metal powder at selected, exactly defined locations and the component is then ‘built’ layer upon layer.

A wafer-thin layer of metal powder is spread out on a powder bed and then melted by the laser at programmed spots. When this has been completed, another thin layer of powder is applied and this process repeats. With this technique, it is possible to make components of a complexity that is not feasible with conventional techniques.

However, complex additive manufactured components definitely require a new way of thinking, explained

ing developments that the plant and mechanical engineering sector is going to see in the very near future.

With its corporate-wide strategy program, ‘New Horizon’, SMS plans to extend its metallurgical know-how to industries outside of metals including using its access to metallurgical companies to establish new products [1]. To this end, the group is bundling its future-oriented activities in connection with additive manufacturing, digitalization, Industry 4.0 and new hightech materials.

The idea behind this, according to SMS, is that all the areas are interconnected and can therefore only be advanced within a concerted approach.

The strategy has worked out well, so far, and numerous projects – such as learning steel mills, plants for the production of high-performance materials, and environmental technology for both ecological and economic benefits – have already been successfully implemented.

The new 3D printed spray head is a further addition to this category.

References 1. MPT International 6/2018 (December), ‘SMS group unveils its plans to become the leading provider in digitalization’, pp28–31 2. MPT International 4/2018 (April), ‘Metal powder production technology to feed 3D printing factories’, pp24-29

‹‹‹

ROLLING MILL TECHNOLOGY

17

New automatic roll mark detector improves cold rolling mill performance The innovation developed by SR-Instruments and ArcelorMittal could save cold rolling mills from costly roll mark defects. The solution is an on-line installation into the exits of cold rolling mills that automatically inspects every coil for roll marks – even non-visible marks which normally require manual chalking.

Roll marks have been a constant issue for cold rolling mills since the beginnings of cold rolling technology. Their greatest impact is one of the industry’s most profitable: exposed products. The total cold-rolled production in Europe is roughly 45 million t, of which about 20% dedicated to exposed parts (~9 million t) [1]. The numbers are very similar in North America. In some plants, more than 5% of cold-rolled products can be affected by these defects. The non-quality costs associated with roll mark defects come from: • products sent to customers and leading to claim costs, • defective products detected before shipping to the customer, with high reallocation costs.

The global cost estimate for Europe is greater than 225 million €/year. Today’s preventive measures and roll mark inspection practices have proven to be very costly. A common practice is to manually inspect one coil out of every four or five when rolling exposed material. The short cycle time of the mill, versus the 12 to 15 minute delay of the manual inspection result, always leads to multiple coils being affected by a single roll mark. Human factors with missed marks increase this cost. In ad-

Mikael Kurth and Seppo Pyörret, SR-Instruments Oy, Kangaskontiontie 10, Oulu, Finland Email: mikael.kurth@sr-instruments.com Contact: www.sr-instruments.com Gabriel Fricout, ArcelorMittal Global Research & Development, Maizières Process, Maizières-lès-Metz, France Email: gabriel.fricout@arcelormittal.com Contact: www.arcelormittal.com

a

b

c

Figure 1. An unacceptable roll mark on a sample (a) is often invisible at the tandem mill exit, and only barely visible after sanding (b). But it is very visible and detectable for the new roll mark detector (c). The defect image is captured at full tandem mill speed, and placed on the photo to highlight the sensitivity of the system

dition to this, rolling capacity is lost – hundreds of hours every year – because of only half-speed rolling while waiting for the results from the manual inspection.

Due to the nature of the rolling process, most roll marks have no contrast, making them very difficult to find in the exit of the cold mill. Coating can allow the marks to become more visible, but the harm to productivity has already been done. The real potential for productivity improvement is to be able to block the affected coils at the exit of the cold rolling mill and take immediate corrective actions to return the mill back to quality.

Industrially proven performance for detecting roll marks Despite numerous tests and trials with the classical automatic surface inspection systems, a satisfactory solution to detect roll marks on-line has not been found. A completely new approach was chosen in order to solve this challenge.

The cornerstones of this system innovation are: • use of measuring instead of vision approach; use of sensor technology instead of camera technology,

• multi-reflectivity measurement to reach a higher detection rate and detect all types of roll marks, • detecting the work roll roughness print from the strip surface, • fast data filters preserving the surface roughness information, • building of accumulated and residual images for the algorithms, • a compact installation to fit in the mill exits and manage the environment.

The solution was developed from scratch by SR-Instruments and ArcelorMittal with additional funding from the European Union (EU). Industrial targets were defined by the industry, specifically the future end users. To perform successfully: the detection rate requirement was set to be greater than 80%; the over detection rate to be below 10%; and the alarming time to less than the rolling time of one coil. Today, all targets have been met and this innovation is the only system solution in the world with industrially proven performance for detecting roll marks.

A new and ‘significantly different’ technology The system provides images similar to classical automatic surface inspection >> MPT International 1 / 2019

18

››› ROLLING MILL TECHNOLOGY

Figure 2. Detector beam with an array of 20 detector units. Beam is in off-line (rollout) position with covers open

systems (ASIS), but the technology developed and used is significantly different. Instead of image acquisition cameras, the receivers are a measuring technology: silicon photo diode arrays.

This approach allows several necessary system features that are required to

meet the application requirements and, ultimately, satisfy the user needs.

The roll mark system is a stand-alone, single-beam installation, utilizing an optical reflection method. It is delivered with standardized integration equipment for survivability and main-

Figure 3. Multi-reflectivity measurement principle as used in the roll mark sensor MPT International 1 / 2019

tenance. The measuring system itself consists of three main components: 1. The detector beam: • this incorporates an array of independent imaging detectors with onboard processing, • also, three full-width LED light beams with necessary optics, 2. A control cabinet with three computers, 3. A user interface for the operators.

Three full-strip-width light beams are used to emit photons to the strip surface. A single detector array is used to pick up the reflecting photons from the strip surface. The LEDs in the light beams are electrically modulated to operate in certain frequencies. Typical frequencies used are, for example, 60, 120 and 240 kHz as no other light sources in the same environment with the system operate in these frequencies.

By locking the detectors to only be sensitive in these frequencies (emitted by the LEDs), several benefits are achieved.

First of all, because all background light gets filtered from the measurement, the maximum possible signalto-noise ratio is achieved in the measurement. Detectors can only collect light from the given three frequencies, and no other.

Secondly, the modulation of the LEDs allows the utilization of a socalled multi-reflectivity measurement

‹‹‹

ROLLING MILL TECHNOLOGY

19

method. All three illumination geometries (bright field, dark field and side light) are needed and used to achieve the required detection rate of more than 80% of all roll marks. The principle layout of this method, with the three inspection geometries, is shown in Figure 3. In this method, three images are produced perfectly simultaneously without the strip moving in between the images: one image is produced in dark field configuration (DF); one in bright field configuration (BF); and one in side light configuration (SL). Every pixel gets three values: a value from each optical geometry.

The result is a higher detection rate, as various roll marks diffuse photons differently and are only visible when viewed in certain optical geometry.

The human eye will look for the same capacity when a person rotates a roll mark sample in their hand, in order to see the mark better.

The third advantage from the modulation is that the system can be kept very compact. All three light geometries can be read out with a single sensor array.

Inspecting a large surface area, backed with data algorithms The measuring of the photons reflecting from the strip surface is performed with independent but identical detector modules which pan over the full strip width. Each detector views 100 mm of strip (in width), overlapping with the neighbouring detectors to provide 100% inspection coverage for the system. The technology inside the receivers – the aforementioned silicon photo diode arrays – is more typical for equipment that, previously, has not been found to perform measurements in imaging resolutions; e.g. highly sensitive optical laboratory instruments. In high-speed applications like the roll mark application, the new imaging sensor outputs a signal-to-noise ratio that is 20 times higher than the classical surface inspection camera technology; e.g. CCD (charge-coupled device) or CMOS (complementary metal-oxide semiconductor) cameras.

The raw data produced is 14-bit, upon which the detection algorithms operate. This sensitivity is needed to detect the roughness maps which the work rolls produce on the strip surface. By

Figure 4. A defective work roll (a) and the corresponding screenshot from the user interface with detection results (b)

being able to read and detect these periods, the algorithms can work very efficiently.

Another unique feature is that the total sensor surface – or the active light collecting surface of the silicon sensors – is very large. The silicon photo diodes cover 66% of the strip width, giving the system a superior ability to collect light compared with the classical CCD elements in the ASIS system. This becomes beneficial especially in high speeds, when there is less time to collect photons into the pixel array before the strip moves again and a new set of photons is needed to produce the data into the next array of pixels. Also, this sensor technology allows for continuous measurement to be performed.

Sensors are not speed-dependent in the

same way as the classical CCD or CMOS cameras used in surface inspection systems.

Instead, in the roll mark detector, the detectors perform constant measuring and the image is produced with the tachometer input continuously delivered to every 100 mm detector module. The modular 100 mm detector design also allows the inspection geometries to be kept the same over the entire strip width.

All data processing takes place inside the 100 mm detector units. So, where the data is produced, it gets locally processed. Each detector unit includes a six-core digital signal processing unit and 2 Gb of memory to host the algorithms and system management software. With this type of distributed data >> MPT International 1 / 2019

20

››› ROLLING MILL TECHNOLOGY

processing, the data transfer rates are kept to a minimum, as well as the amount of processing hardware inside the PC and control cabinet. The cabinet contains only three normal computers.

Dedicated filtering algorithms make use of the periodicity of the defects to strongly enhance their contrast prior to the detection stage. This reveals objects that are almost invisible, in both the raw data and strip samples, without stone brushing. The algorithm, which uses only the images as inputs, is able to filter out emulsion patterns. It can thereby adapt to period fluctuations – which come from reduction rate variations and slipping of the strip – and identify, without ambiguities, which roll is responsible for the mark.

The measurement cycle. The system runs a repeating measurement cycle to inspect every coil. To start a measurement cycle, the roll mark system checks the value of two signals: a strip tension signal and a mill ready signal. Only when both signals are equal to 1 will the system start the measurement cycle. On the other hand, if the value of either of these signals changes (from 1 to 0) before the completion of the measurement then the measurement, and thus the cycle, is aborted and the system is protected from any abnormal situations.

The guard window is opened by the system’s own logic and the sensors start to collect data. Data is collected from 70 m of strip length (out of a total coil length of 2,000 to 3,000 m) and over the full strip width. This is sufficient for the system to perform its analysis, and the guard window is closed. The system is exposed to the strip for less than five seconds per coil – this supports the maximum availability, as in keeping the system clean and well-protected 95% of the time. After closing the protective guard window, the system shifts into a calculation mode. Obviously, the delivered result corresponds to the 70 m from where the data was collected. If the roll mark appears later in the coil, it can only be revealed by the subsequent measurement or, in other words, the next coil.

With a roll mark being a mechanical and periodic defect, it is not necessary to monitor the entire strip length to detect it because the mark does not disapMPT International 1 / 2019

pear on its own. In a situation with stops, the system can make several measurements on the same coil.

In principle, this first measurement should always be performed from the beginning of the coil. There is no constraint on the strip speed during the measurement: the strip speed can be constant or variable. A tachometer provides the speed signal to the roll mark system. Measurements can be performed at up to 1,650 m/minute with good image quality. The data processing is started in each detector module.

The steps are: 1. normalization, 2. filtering, 3. calculation of first period (length of the last stand’s work roll circumference), 4. corresponding accumulated and residual images, 5. roll mark detection.

The same sequence is then conducted for a second period (the second-to-last stand’s work roll circumference). The data and the results are also sent from each detection module to the so-called RTM (real-time computer) which collects and synchronizes them. The RTM integrates the strip edge positions and generates the detection result images for the database and the user interface.

Then all detection results (image and data) are transferred to the master computer, which is also located inside the electronics cabinet, to be stored and sent to the client computers for their display. After that, the system is ready to start a new measurement cycle and, as soon as the conditions are met, the strip is on the coiler and the mill is ready.

System integration. The system was designed from the beginning to operate in cold rolling mill exits. Its features, functionalities and diagnostics support this. Standardized equipment is used to integrate the installation into the line. Integration equipment consists of structures with certain functionalities, such as the rollout between on-line and off-line positions, and the guard with an opening and closing protective window.

The detector beam is fed with fan air to produce a positive pressure inside the detector beam. This prevents the pollution from entering the system and pro-

vides the necessary cooling to help ensure maximum component lifetime.

Other integration requirements are a few PLC (programmable logic controller) signals, a tachometer input and a TCP/IP (transmission control protocol/internet protocol) communication to level 2.

In 2012, a full-sized pilot was installed on a continuous 1.9 million t, five-stand tandem cold mill exit (shown in Figure 5). After completing the software and algorithm development, the system was handed over for operator use in September 2015. Industrial approval was received in December 2015. Finally, the calculation speed was upgraded with a detector swap in January 2018 to increase the system capacity to inspect every coil. The system is integrated with level 1 and level 2 connections and fully follows the mill operation. Abnormal situations are handled by the system automatically.

During rolling, a coil database is collected on all coils, and an alarm sound is implemented to focus the attention of the operators whenever a roll mark is suspected on the coil rolled at that particular moment.

In case of an alarm, the mill operators use the user interface and roll mark image(s) to judge if the rolling can be continued or should not. The decisions depend on many criteria, like the material and customer, but the system has allowed the team to step on a learning curve to keep the operations process focused. Operators could learn the system in a matter of minutes because, ultimately, it is just an alarm system – its ease of use being another key advantage. In the simplest operating mode, the system could block all suspected coils automatically.

Feedback from the pilot plant The management at the pilot plant reported that it took about six months for their operators to build trust and get a feeling for which marks were acceptable, and which marks required immediate corrective actions.

For example, during the integration to the operations, the sensor regularly detected marks that were not possible to confirm by chalking (stone brushing) operations, but were effectively revealed after finishing operations. Nowadays, the instructions are to use the sensor information and to change the rolls, even if the mark is not detected

‹‹‹

ROLLING MILL TECHNOLOGY during the stone brushing operation.

The proportion of roll marks detected directly at the exit of the tandem mill, instead of the exit of the galvanizing line, has increased by 20%. This represents a significant decrease in nonquality costs.

It should be noted that, at the pilot mill, the operator team is very experienced and is allowed to take decisions on roll marks. User experience and learning allows for improved operating practices for different situations. Ultimately, it is mill-specific depending on operator experience and the decision-making hierarchy.

A five-year track record in on-line conditions has proved that the system requires only limited maintenance operations. Its maintenance follows the normal maintenance program. Main periodical work includes the wiping of the protective glass window from the outside, every six weeks. The fan unit should be checked every six months and the air filters inside changed once a year.

coil is inspected if the system is located before the shearing machine. Every other coil is inspected if the system is located between the two coilers.

Earlier detection. In the case where roll marks are missed by the chalking (stone brushing) inspection, the defect is most commonly detected at the exit of the finishing lines which results in a very high reallocation cost. An average figure is to detect 50% of the coils affected by roll marks at the exit of the finishing lines. For earlier detection, the roll mark detector has proven able to detect roll marks that have not been detected by stone brushing, but are instead re-

21

vealed at the exit of the finishing line (or even at customers’ facilities).

The value creation linked to the use of the sensor is clear in this case. In particular, reallocation costs are much lower when it is done at the exit of the tandem mill.

For a mill with fewer marks, the payback comes from increased rolling capacity and a reduced need to reprocess suspected coils. By inspecting every coil, the rolling may be continued at full speed even while waiting for the manual inspection result. On an annual basis, typical waiting times and low-speed rolling accumulate to between 400 and 1,000 h, depending on mill type.

Improved mill performance While it is clear that the roll mark system will not prevent roll marks from happening, it does offer a means to improve mill performance without any parallel investment needs. Considerable savings and capacity increases are achievable when the installation is backed up with certain improvements of operating practices and corresponding training. Following the installation, operators are delivered valuable information in near-real time, thereby giving them the missing tool to keep their operations process-focused. Quality-focused activities, such as dealing and processing defective coils, are reduced on all downstream processes.

By inspecting every coil, the detector will help to spot the roll marks faster, leading to fewer affected coils. Detecting them earlier, at the exit of the tandem mill instead of the finishing lines, can allow for better reassignment possibilities for the affected coils. For a mill with roll marks, the payback comes from decreasing reallocation costs, avoiding large series of coils being affected by roll marks, and better service to the customer thanks to an improved lead time.

Faster detection will come from an improved detection rate. Every

— 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

MPT International 1 / 2019

>>

22

››› ROLLING MILL TECHNOLOGY

Figure 5. Roll mark detector integrated in the exit of a five-stand tandem mill, inspecting all coils to the second coiler (on the left side)

As an example from the pilot plant, an improved operating practice is to change the work rolls after two consecutive detections by the system, even if the mark is not confirmed by chalking (stone brushing). This practice was only applied during part of 2016, yet the proportion of defective coils detected at the exit of the tandem mill rose from 50% to 70%. It is also known that 50% fewer roll marks were produced within 2016 compared with the previous year. All of these figures, which lead to significant value creation, are expected to improve further with the enhanced computing capacity that is now also available in the pilot system.

Effects on stone brushing Stone brushing operations will, of course, not be stopped after the installation of the system since the last upgrades were completed only recently.

In addition, because the pilot installation is inspecting the secondary side instead of the guaranteed side, the detection rate is expected to stay at about 90% since approximately 10% of marks will not be duplicated (and therefore become detectable from both sides).

Indeed, the system will complement the stone brushing operations. It also MPT International 1 / 2019

transforms, by many times, a ‘detection’ stone brushing into a ‘verification’ stone brushing.

Because of this, operators only need to verify the relevancy of the sensor detection. This reduces the area of steel surface that requires stone brushing and lessens the inspection time.

Summary The industrially approved roll mark detector already has a proven track record of a few years, both in terms of detection performance and achievable returns: • use of the detector has significantly improved the performance of a 2 million t cold rolling mill, • downgrading costs are reduced when roll marks are detected faster, • faster detection allows more responsive and timely corrective actions, and saves the following coils from being affected by the same mark, • with the detector, affected coils are also identified earlier than before, • reassigning after the tandem mill, instead of after the finishing lines, results in considerable savings in reallocation costs, • inspection of every coil at the exit of the mill allows the cost of the pre-

cautionary measures to be reduced, such as slowing down the mill while waiting for the results from manual roll mark inspection.

Records from the full-sized industrial pilot (since the detector handover in 2015) show major savings in downgrading costs and more full time rolling. Better reassignment for the fewer affected coils, higher-scoring customer key performance indicators, and many more cost benefits have been experienced. These advantages result from keeping the rolling operation more process-focused.

With the high performance levels noted in the results, the sensor is demonstrably a very valuable tool, and one which continues to help mills improve their overall performance [2].

References 1. The European Steel Association, “European Steel in Figures,” 2016 Edition, April 2016 2. G. Fricout, “On-Line High Sensitive Roll Mark Detection System: Industrialization and Assessment Report,” European Commission Research Program of the Research Fund for Coal and Steel, 2017

‹‹‹

ROLLING MILL TECHNOLOGY

23

First reverse cold mill worldwide upgraded to a Hyper UC-mill by Primetals Technologies Started up at Masteel, in Maanshan, Anhui province, Eastern China, the Hyper Universal Crown (UC)-mill upgraded by Primetals Technologies employs smaller diameter work rolls for reduced rolling loads. Masteel can now produce harder and thinner materials with improved product quality.

In August 2018, the first coil was produced on a reverse cold mill (RCM) modernized by Primetals Technologies at the cold rolling plant of Chinese steel producer Magang (Group) Holding Co (Masteel). The mill, at the Maanshan production site, represents the first upgrade to a Hyper Universal Crown (UC)-mill worldwide and was officially inaugurated later that month.

Hyper UC-mills employ smaller diameter work rolls, thus reducing rolling loads. This allows for the production of harder and thinner materials with improved product quality. In addition, the mill concept saves investment and maintenance costs.

The upgrade enables Masteel to meet the growing demand for electrical steels spurred by increasing requirements for end uses in e.g. vehicle electrification.

Primetals Technologies had received the order to revamp the RCM in April 2017. Masteel is a large-sized iron and steel complex in China's Anhui Province which was founded in 1958. The company's production amounted to 19.7 million t (2017). Its iron and steel business is mainly engaged in ferrous metal smelting, rolling and processing

Primetals Technologies, London, United Kingdom Contact: www.primetals.com Email: rainer.schulze@primetals.com

Picture: Primetals Technologies

Meeting the growing demand for electrical steels

Akira Goto, director, Primetals Technologies Japan (left) and Ding Yi, chairman of Maanshan Iron & Steel Co., Ltd., Magang (Group) Holding Co. (right) shake hands in front of the first reverse cold mill (RCM) upgraded to a Hyper UC-Mill

as well as product sale and support services. Masteel owns top production lines for thin strip cold-rolling and thin strip hot-rolling, strip hot-galvanizing, strip colour coating, silicon steel, H-beam, high-quality wire and rod, train wheel, and more.

Primetals Technologies' main scope of supply for the RCM upgrade included the project block, mill rolls, roll chocks, drive spindle and drive gear box. In addition, Primetals Technologies was responsible for the supervision of erection and commissioning.

The upgraded mill processes silicon steel grades with product thicknesses between 0.3 and 0.65 mm in a width range of 900 to 1,280 mm.

High performances of strip gauge and flatness control for HSS The Hyper UC-mill was recently developed by Primetals Technologies to achieve high performances of strip gauge and flatness control for High Strength Steel (HSS) rolling. This technology is also applicable for rolling high grades of non-grain oriented silicon steel and thin products.

The technology is based on an optimized roll diameter combination (small work, intermediate and back-up rolls), a “work roll driven system” to achieve high flatness controllability, and the development of a high strength small diameter spindle to drive the work roll.

MPT International 1 / 2019

24

››› STEELMAKING – IRONMAKING

The thyssenkrupp Schwelgern plant, located in Duisburg, Germany, equipped with blast furnaces 1 and 2

thyssenkrupp introduces a new oxygen technology for the blast furnace process In recent years, thyssenkrupp has developed an innovative blast furnace oxygen injection technology, the Sequence Impulse Process (SIP) which uses Induced Shock Waves. The world’s first plant of this type has been under construction at the Schwelgern 1 Blast Furnace in Duisburg, Germany, and is to be commissioned in 2019.

A prerequisite for blast furnaces processes is continuous, and almost unvarying, operation. This is especially the case with large production units like the Schwelgern 1 Blast Furnace in Duisburg, Germany, which operates near the minimum thermodynamically possible consumption of energy and reducing agent and at near nominal capacity.

Dr. Rainer Klock, Thomas Mölleken and Michael Peters, thyssenkrupp Steel Europe AG, Duisburg, Germany Email: rainer.klock@thyssenkrupp.com Contact: www.thyssenkrupp.com Hans-Heinrich Heldt, Gerd König and Werner Langkabel, thyssenkrupp AT.PRO tec GmbH, Essen, Germany Email: hans-heinrich.heldt@ thyssenkrupp.com Contact: www.thyssenkrupp-raw-materials.de

MPT International 1 / 2019

At the same time, greater flexibility is required in production planning – e.g. more frequent production adaptations due to changed operating points. The problem is that any larger intervention in the blast furnace process will necessitate a long phase before it is possible to again approach the optimum operating point. As a consequence, most of the prerequisites for operating a blast furnace near the thermodynamic optimum are then no longer satisfied.

This has a direct effect on raw material efficiency, i.e. raw material costs and CO2 emissions.

Blast furnaces also require a consistently high quality of the raw materials used, the causes of which are largely to be found in developments in the raw material markets. The availability of high-quality raw materials is already severely restricted and this results in compromises regarding raw material quality and costs. The market has become more dynamic, contract dura-

tions are shorter, and it is necessary to purchase spot quantities. These factors mean that raw material grades, and the burden structure, change frequently.

Moreover, fluctuations in the chemical analyses and physical properties of the raw materials supplied have dramatically increased. It can be assumed this trend will continue during the coming years and represents a major challenge for managing the blast furnace process.

The foundations for efficient blast furnace operation One possibility for overcoming at least some of the challenges mentioned above is the use of oxygen impulse technology for the blast furnace. To this end, thyssenkrupp has devised a process principle that is based on injecting a large amount of technical oxygen, via lances through the tuyères, directly into the raceway of the blast furnace.

‹‹‹

STEELMAKING – IRONMAKING

25

Pressure reducing unit and filter station for 25,000 m3 (S.T.P.)/h of oxygen (left); new platform for the SIP boxes in the east of the cast house (right)

The foundations for efficient blast furnace operation, gasification and drainage are all laid down in the raceway.

Therefore, it is in the raceway that periodic oxygen injections of the blast furnace – with oxygen impulse technology – can have a positive effect on chemical-physical processes [1]. thyssenkrupp has based its detailed concept regarding the mode of action on numerous investigations and operating experiments. The company expects a significant improvement of blast furnace gasification and drainage as a result.

Plant concept and Sequence Impulse Process (SIP) boxes Following an extensive development of the process over several years (as shown in the text box on page 26), comprehensive steel construction work was undertaken on Blast Furnace 1 to position and install the new oxygen impulse system and its components. This mainly involved: new stage constructions for Sequence Impulse Process (SIP) boxes in the cast house; and the pressure reducing unit and filter station for the oxygen.

The SIP boxes, by thyssenkrupp AT.PRO tec, inject technical oxygen into Blast Furnace 1 using an oxygen impulse system with Induced Shock Waves. For this purpose, an additional lance for oxygen injection is being installed in each of the 40 tuyères, or nozzle elbows, of Blast Furnace 1.

Each of the 40 lances has its own injection unit for the technical oxygen with a necessary safety function. In addition to the actual periodic injections of oxygen, the SIP box continuously supplies the lance with the necessary quantity of oxygen between pulses to ensure cooling of the lances in the hot blast current. Each lance is supplied with nitrogen via its SIP box to keep it cool when the oxygen injection is switched off, or in case of problems.

The 40 SIP boxes are supplied with up to 25,000 m3 (S.T.P.)/h of oxygen from the site network via a pressure reducing unit and filter station, with a 50 m³ buffer tank and a ring main around the blast furnace. The nitrogen supply takes place via a filter station and a ring main that is also distributed by the site network.

The plant is equipped with a safety function which, when required, diverts the oxidizing medium oxygen away from the blast furnace via a vent pipe and the system is flushed with nitrogen.

Meanwhile, the plant is controlled by the Siemens CPU (S7-1500) controller for automation, which is described by the manufacturer as its fastest with a 1 nanosecond (ns) big processing time in the CPU. Visualization is achieved through a Siemens Totally Integrated Automation Portal (TIA Portal) system and via a coupling to the blast furnace’s existing control system (Scalink).

Physical and metallurgical process principle The injection of oxygen directly into the raceway takes place intermittently, with a large quantity injected given the short time of an injection process.

The gas-dynamic phenomenon at the lance discharge point is mainly determined by the pressure difference between the injection unit and the furnace, as well as by the valve opening velocity and opening duration. This involves a supersonic open jet with a transient start-up process and preliminary shock wave [1].

As mentioned, thyssenkrupp’s process is based on a number of comprehensive investigations and operational experiments, plus experience gained from the cupola furnace activities.

These are explained below: Conventional coal and oxygen injection using coaxial lances Since 1986, the Schwelgern 1 Blast Furnace has been operated with combined

injection of coal and oxygen by means of a coaxial lance. The tip of the lance juts out into the tuyère. The coal for injection comes into contact with the coaxial oxygen upon leaving the lance, and the flow of coal ignites at its surface.

The coaxial lance oxygen only serves to improve the reactive behaviour of the injected coal. The quantity of coaxial oxygen is far too low for the stoichiometric reaction of the injected coal. Because of this, the coal is incompletely chemically transformed – e.g. due to the short retention time of the injected coal in the raceway and insufficient mixture generation.

Coal particles that do not, or only incompletely, undergo the reaction are either deposited in the coke bed behind the raceway, or are carried even farther into the furnace. Small particles from the coke circulation are also deposited behind the raceway and these deposited particles have a negative effect on the gas flow of the blast furnace.

These effects considerably reduce permeability, flow resistance rises, and the direction of escaped gas shifts towards the sides of the furnace. Particles can also get into the blast furnace hearth. There is a negative effect on the flow-off behaviour of the liquid phases of iron and slag along the entire path, from the melting zone to the tap holes. These effects are stronger when coke qualities are insufficient [7,8,9,10,11].

Supplementary use of the oxygen impulse process During the set-up of the oxygen impulse system in Schwelgern 1, a second lance is to be installed in the nozzle tips of each tuyère. This will be constantly provided with a continuous flow of oxygen to cool the lance itself. Due to the positioning of the lance, the oxygen flow comes into direct contact with the flow of coal whose surfaces have already been ignited by the coaxial lance oxygen. A >> MPT International 1 / 2019

26

››› STEELMAKING – IRONMAKING

certain amount of optimization of the conversion behaviour of the injected coal is to be expected, from the added supplementary oxygen as well as from the mixing effects due to this inflow.

A shock wave precedes the actual oxygen injection. The effects of the shock wave – e.g. influencing and massively amplifying turbulences – have a positive impact on the kinetics of the chemical reaction. Shock waves can

The development of thyssenkrupp’s blast furnace process The periodic injection of oxygen using the Sequence Impulse Process (SIP), developed by thyssenkrupp AT.PRO tec GmbH, has been successfully applied to cupola furnaces – the iron foundries' melting furnaces based on scrap and coke – for some years [2,3,4]. Basically, three levels of development were carried out to enable use of the process on blast furnaces. They are briefly described below: THE GERMAN FEDERAL MINISTRY OF EDUCATION AND RESEARCH (BMBF) JOINT PROJECT ASIPGO (2007-2011). The Automated Sequence Impulse Process for Large Shaft Furnaces project (ASIPGO) was run by the blast furnace group (consisting of thyssenkrupp AT.PRO tec GmbH, thyssenkrupp Steel Europe AG and RWTH Aachen University's Department of Ferrous Metallurgy under the Chair of Professor Dieter Senk). Its aim was to create the scientific and technical basis for converting the technology for use with blast furnaces. Within this framework, numerous technical experiments – among other things – were carried out using the coke bed simulator at the Department of Ferrous Metallurgy at RWTH Aachen, and comprehensive field tests were performed at a tuyère of the Schwelgern 1 Blast Furnace [5].

FURTHER RESEARCH AND DEVELOPMENT ACTIVITIES (2011-2014).

After completion of the ASIPGO research project, thyssenkrupp Steel Europe AG widened the scope of its investigation with operational experiments on the Schwelgern 1 Blast Furnace. The positive experimental results were confirmed, and the idea of using shock waves was born and pursued independently by thyssenkrupp to further improve blast furnace reactions. Com-

MPT International 1 / 2019

prehensive investigations were carried out, or commissioned, so that the necessary technical developments could be implemented. Thus, it was possible to generate targeted shock waves and induce them in the blast furnace [6]. thyssenkrupp AT.PRO tec GmbH and thyssenkrupp Steel Europe AG jointly worked out a concept for equipping the Schwelgern 1 Blast Furnace with an oxygen impulse system. Special injection units were developed – the so-called SIP boxes – and the new knowledge regarding shock waves was incorporated in this development.

Next, a prototype was put into operation and optimized during an endurance test which lasted several years. It was therefore possible to jointly develop an innovative oxygen injection technology for the blast furnace – the Sequence Impulse Process with Induced Shock Waves. The basic engineering for such an oxygen impulse system was created for Schwelgern 1.

STRATEGIC CO-OPERATION (SINCE 2015). In September 2015, a cooperation agreement on the ‘development, construction and operation of an oxygen impulse system on the Schwelgern 1 Blast Furnace’ was signed between thyssenkrupp AT.PRO tec GmbH and thyssenkrupp Steel Europe AG. The detailed engineering was completed in 2016 and the approval process initiated (Article 16, Federal Immission Control Act (BImSchG) – change in operating licence for Blast Furnace 1). On receipt of the licence for the delayed construction start, work commenced on setting up the plant in mid-2017.

The building measures are a particular challenge; however, because they have been taking place during running production, 70% of the plant is now finished.

also make a considerable contribution to enabling ignition conditions [12,13].

When the oxygen injection leaves the lance, it first comes into direct contact with the coal flow exiting the coaxial lance. In relation to the mass of the injected coal flow, the oxygen injection contains approximately four times the excess oxygen necessary for a reaction of the injected coal. In addition, the conditions for mixing coal and the injected oxygen are ideal because of the transient open jet. The injected coal can, temporarily, be completely chemically converted locally.

As the oxygen advances into the raceway, stationary conditions return behind it. On its way through the raceway, the injected oxygen comes into direct contact with the coke and injected coal particles. These are picked up by the flow and react as a result of the excess oxygen, thereby forming carbon dioxide (CO2).

The transient supersonic open jet has a very high kinetic energy, compared with that in the blast flow. Therefore, the majority of the oxygen can reach the end of the raceway and penetrate the coke bed. As a result of the reaction-kinetic conditions, the oxygen and carbon dioxide already created react with the fine particles deposited in the coke bed.

Very high temperatures exist here in the short term – although these are screened from the raceway and the edge of the furnace by the coke bed.

The level of porosity in the coke bed increases and permeability rises. The raceway also gradually enlarges.

Comparing the conditions on the tuyère level Figures a), b) and c) – as shown on page 27 – compare the described stages with a schematic representation of the relationships on the tuyère level, as well as the course of gas temperature and gas composition as a function of the distance from the tuyère tip: Figure a) shows the combined coal and oxygen injection from the coaxial lance with the deposited particles in the coke bed and the gas discharge from the raceway in the direction of the furnace sides. This would ideally be in a stationary state. The gas temperature gradually rises with the decrease in oxygen concentration in

‹‹‹

STEELMAKING – IRONMAKING

27

the oxidation zone, starting with the temperature of the blast (Tw). The carbon dioxide content increases in parallel. The maximum gas temperature (Tmax) is reached when the carbon dioxide content reaches its maximum.

The excess oxygen is used up and the carbon dioxide created is reduced to carbon monoxide by the carbon in the coke and coal particles in the raceway.

The reaction is endothermic and the gas temperature falls until, finally, all the carbon dioxide has been converted to carbon monoxide.

Figure b) shows the local and temporary effect of an oxygen pulse. This constantly repeated effect lengthens the raceway and ideally keeps the coke bed free of small particles. With large quantities of cold pulsed oxygen escaping from the lance, the temperature is below that of the blast (Tw). As a result of the temporary complete conversion of the injected coal, the oxygen concentration sinks somewhat and the gas temperature, corresponding to the concentration of carbon dioxide, rises in the area of the tuyère tip.

As the oxygen injection advances through the raceway, the carbon dioxide concentration and the gas temperature gradually increase due to the chemical conversion of coke and coal particles. The majority of the oxygen finally reaches the end of the raceway and penetrates the coke bed. Here, the oxygen is very quickly converted to carbon dioxide due to the large reactive surface area available (enhanced by the smaller particles).

As a result, there is a brief high-temperature peak in the coke bed behind the raceway. The large reactive surface area is also responsible for the gas temperature falling rapidly due to the endothermic reaction of carbon dioxide to form carbon monoxide.

Figure c) shows the state that is found after the effect of one oxygen injection and before the next oxygen injection. At this point, only the supplementary but low-volume flow of cooling oxygen from the lance has an effect. The quantity of oxygen required for operating the oxygen impulse system on the Schwelgern 1 Blast Furnace is obtained by means of a shift in volume. This means that the quan-

Comparison of the conditions on the tuyère level: Figure a) shows coal injection with coaxial lance (constant process); b) during the effective period of oxygen injection (transient process); c) between oxygen injections, with only the cooling oxygen of the lance (quasi-constant process)

tity is deducted from the enrichment of the blast. Despite the supplementary cooling oxygen, a lower total oxygen concentration is fed to the furnace during the pause between injections than during the state shown in Figure 3a. The gas concentration in the raceway is lowered in this state between oxygen injections, leading to a lower gas temperature.

Conclusion and prospects The investigations and experiments carried out speak for the positive deep effect of oxygen injection using the SIP system with Induced Shock Waves developed by thyssenkrupp for the blast furnace. In particular, on the basis of the operational experiments on a tuyère of the Schwelgern 1 Blast Furnace, it can be expected that part of the dead man zone (the ‘dead’ layer of metal liquid in the hearth) can be activated, and that the drainage and gas flow in the blast furnace can be improved.

Commissioning of the oxygen impulse system currently under construction for all 40 tuyères of the Schwelgern 1 Blast Furnace will take place in 2019. An adjustment phase is planned after the actual commissioning to allow for co-ordination of the operating point of the oxygen impulse system and blast furnace process control. A trial phase will then be carried out and compared with a reference.

References 1. Klock, R.: Hochofenbetrieb mit periodischer Sauerstoffinjektion, Dissertation RWTH-Aachen (2013) 2. König, G.; König, W.; Babich, A.; Gudenau, H.W; Senk, D.; Heldt, H.-H.: Schachtofen und Verfahren zum Betreiben eines Schachtofens, DE 102007029A1 3. König, G.; König, W.; Babich, A.; Gudenau, H.W:; Senk, D.; Heldt, H.-H.: Verfahren zum Betreiben eines Hochofens und für dieses Verfahren geeignete Hochöfen, DE 102005053505A1 4. Heldt, H.-H.; Ilgner, C.: Einsatz des Sequenz-Impuls-Prozesses im Kupolofenbetrieb, Gießerei 101 (2014), No. 5, pp. 100-103 5. Klock, R.; Johnen, A.; Heldt, H.-H.; Kannappel, M.; Thiede, C.; Feldhoff, M.; Senk, D.; Greibig, R.; Ramtun, J.: ASIPGO-Automatisierter Sequenz Impulsprozess für Großschachtöfen, German Federal Ministry of Education and Research (BMBF) Research Report (2011) 6. Kannappel, M.; Klock, R.: Verfahren zum Betreiben eines Schachtofens, insbesondere eines Hochofens, DE102014102913A1 7. Blomberg, M.; Schumacher, M.; Schott, R.: OxycoalModelstudie am TKSE HO2, Interner Untersuchungsbericht Küttner GmbH & Co. KG und aixprocess GmbH für thyssenkrupp Steel Europe AG (2018) 8. Schott, R.: Optimization strategies for pulverized coal injection into the blast furnace, Stahl und Eisen 136 (2016), No. 3, pp. 39-47 9. Shen, Y.; Yu, A.; Zulli, P.: CFD Modelling and Analysis of Pulverised Coal Injection in Blast Furnace: An Overview, Steel Research 82 (2011), No. 5, pp. 532-537 10. Nightingale, R.J.; Dippenaar, R.J.; Lu, W-K.: Developments in blast furnace Process Control at Port Kembla Based on Process Fundamentals, Metallurgical and Materials Transactions B 31 (2000), No. 3, pp. 993-1003 11. Schwalbe, R.; Klock, R.; Janhsen, U.; Schmöle, P.; Peters, M.: Influence of intentionally deteriorated coke properties on performance of Blast Furnace #2 Schwelgern, Proceedings METEC& 2nd ESTAD (2015) 12. Gruening, C.; Mayinger, F.: Experimental Investigations of Supersonic Flame Stabilisation based on Fuel Self-Ignition, Chemical Engineering & Technology, (2000), No. 10, pp. 909-918 13. Ben-Yakar, A.; Hanson, R.K.: Cavity Flame-Holders for Ignition and Flame Stabilisation in Scramjets: An Overview, Journal of Propulsion and Power 17 (2001), No. 4, pp. 869-877

MPT International 1 / 2019

››› DIGITALIZATION

Foto: SMS group

28

Digitalization holds both great challenges and great potential for all stakeholders, full-stop various latest digital solutions are in place at Big River Steel, a steel complex designed as a Learning Steel Mill.

The steel industry and plant engineering: from digitalization to a digital eco-system Digitalization has been much discussed in the steel industry and plant engineering sector for several years now. Here, Katja Windt, CDO, SMS group, explores its key drivers including digital transformations taking place in numerous processes, and increased degrees of automation and autonomization along production chains.

Digitalization has an impact on strategies, processes, structures and products alike, and will lead to sustainable change in the companies taking part in the value added chain. People, machines and commodities will communicate in real time, and learning algorithms will transform value creation chains into dynamically acting value creation networks.

That will take place in the future. But what are the current development trends

Dr.-Ing. Katja Windt, CDO, member of the managing boards of SMS group GmbH, Düsseldorf, Germany Contact: www.sms-group.com Email: thilo.sagermann@sms-group.com

MPT International 1 / 2019

in the fields of research, plant engineering and steel production, today?

Understanding Industry 4.0 and digitalization The talk and focus on the topics of ‘Industry 4.0’ and ‘digitalization’ are definitely not on the decline – and nor are the discussions about their risks and opportunities.

As the aspects of this topic are extremely diversified, the meanings of the terms used in discussions are still being interpreted inconsistently. People often look for the one and only goal of digitalization, yet there is no such thing. Digitalization only sets out the direction, while the true goal is the digital transformation of the vertical and horizontal value chain [1].

The following three central terms, used frequently in the discussions, make clear what the process of digital transformation is all about: Digitization. This refers to the transfer of analog data and processes (i.e. paperbased) into digital data and processes.

Digitalization. This means the consistent use of digital technologies and data as sources of information with the objective to reduce costs and increase revenues through the transformation of existing business and engineering processes. It also involves the creation of new digital business models and services.

Digital transformation. Takes the above mentioned activities to the

;

5

9

=

5

>

F

G

F

I

g

T

S

K

G

<

D

5

9

8

h

5

?

8

9

5

6

5

V

>

X

D

9

A

>

=

<

>

5

V

> e

B

C

> M

T

T

M

S

K

L

J

M

T

e

Z

T

J

M

G

M

P

F

J 6

<

5

V

W

9

=

8

b

W

<

P

J

[

g

G

F

Q

] N

[

K

G

S

^

I

[

J

c

Coke oven plant

Blast furnace

Converter

N

[

K

G

F

P

[

G

^

T

M

T

T

M

S

W

=

g

[

N

[

K

G

F

f

K

U

M

6 P

K

<

< 5

G

H

Q

V

D

5 F

D

9

5 M

9

7

D

=

<

5

D

X

<

J

Z

e

M

e

K

G

]

[

P

M

S

[

J

]

F

]

?

8

9

5

6

5

8 G

N

M

P

M

J

^

S

[

J

]

N

M

\

G

Z

N

M

X

[

G

T

Q

[

[

G

Q

F

G

K

Z

K

I

M

U

9

<

>

X

>

V

W

=

D

V

B

?

8

9

5

6

5 T

J

[

J

>

=

<

8

<

>

9

<

8

X

5

[

M

R

Q

F

N 7

<

8

6

<

5

<

<

8

?

B

F

T

J T

S

K

G

R

Q

F

N

F

Q

T <

D

5

9

=

W

7

D

V

d

Y

\

G

K

O

Z

N

K

J

F

\

H

T

M

K

Q

]

]

^

T

O

F

J

N

M

L

K

J

I

F

K

7

>

V

d

@

?

B

W

A

7

<

>

`

D

9

`

7

<

_

B

<

D

5

9

8

V

6

>

9

<

5

<

5

a

=

8

F

G

F

E

C

>

B

D

29

C

>

B

8

=

<

5

A

=

5

9

@

?

8

<

8

<

8

7

H

G

F

E

F

J

M

G

F

P

U Y

G

T ]

F

Raw material

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

7

>

=

<

8

;

7

8

:

8

9

8

7

6

5

4

DIGITALIZATIONâ&#x20AC;&#x2030;â&#x20AC;&#x2030;â&#x20AC;&#x2030;â&#x20AC;&#x2030;

Caster

Rolling Mill

Processing

Storage & logistics

Digital transformation illustrated by way of the

example of the value chain in steel production

next level by creating a digital eco-system. Through the use of data-based, self-learning analytical methods, the system improves itself on a continual basis in order to enhance the valueadding processes within a corpora-

+353 +353 47 47 80500 80500

LEADERS LEADERS IN IN CUSTOMISED CUSTOMISED HANDLING HANDLING SOLUTIONS SOLUTIONS

tion and/or along the value creation chain. For a company, this means that it will have to strategically align itself to an agile, yet target oriented and ongoing, adaptation process as digitalization advances.

The company as a digital eco-system The digital eco-system of a company is the highly complex network of business functions and business processes including the manufacturing equipment, >>

30

››› DIGITALIZATION

Data architecture and platform infrastructure of a digital eco-system (schematic)

computers, software functions and human operators. It is permanently communicating, analyzing, monitoring and training itself. The system is, in other words, a de facto omniscient system – i.e. the system knows everything that has happened, is happing and may happen. It knows the consequences of whatever is happening and the costs involved in each case. As it is constantly being trained to get closer to the desired target scenarios, it learns and improves itself on a constant basis.

The ultimate goal of the digital eco-system is to maximize the overall yearly profit of a company along its entire production chain. For this to become achievable, it is necessary to optimize the complete value chain – i.e. the supply chain of the raw material, the media, production planning and production, plant and machinery, and the product quality all the way down to the end customer.

The digital eco-system must be able to master a great many optimizations in a context of different and diverging targets, and balance out any arising conflicts between these targets.

The backbone of a digital eco-system is a solid and flexible data architecture set up on a platform infrastructure.

The eco-system consists of different production entities with different data MPT International 1 / 2019

sources, frequently a mix of newer and older machines and automation systems. The end result is always a “configurable, customized” data model with an application programming interface (API). A further API allows the data model to be altered at runtime.

Characteristics of the data architecture and infrastructure are: Connectivity. Tool-based, real timecapable and safe data exchange with the plant and equipment in place and the original automation, Manufacturing Execution System (MES) and Enterprise Resource Planning (ERP) technologies. The interfaces have to be able to pre-process the data by aggregation, conversion of time to position, units, data relationships, etc. Data storage and archiving have to be structured according to the process and product genealogies, and the requirements of the future application.

Distribution and analysis. Every application-specific data model is created at runtime from a data source description it addresses via scripts. Data retrieval for each element of the data model is either iterative or streamed.

Several data models may co-exist and each data object may have substructures. Data is commonly only retrieved in case it is needed for evaluating the application in the data store.

Modeling, simulation and optimization. A high-capacity software and hardware environment is key to the capability of developing and providing the various application models in a timely manner. Also alterations and adjustments have to be implementable at runtime.

Provision of models and result visualization. Realtime-capable display and communication of the modeled results in the form of individualized dashboards, reports, human-machine interface (HMI) and alarms.

The challenges of a learning steel mill In steel production, a great many challenges have to be coped with and resolved at the same time. There is a direct relationship between the business result and the following issues: • flexible production planning with varying production lots down to single items, while guaranteeing timeliness of delivery, • maximum plant performance at minimum maintenance effort and little locked-up capital, • reproducible attainment of best product quality at high yield and without high inventories.

All this takes place within an environment of changing circumstances: e.g. le-

DIGITALIZATIONâ&#x20AC;&#x2030;â&#x20AC;&#x2030;â&#x20AC;&#x2030;â&#x20AC;&#x2030;

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

31

j

m

k

l

l

k

k

j

j

j

l

l

l

%

m

%

m

%

m

j

%

l

%

m

%

m

j

Challenges and targets of the learning steel plant

gal requirements, environmental standards, resources, costs of raw materials, energy and human resources. The above mentioned challenges are closely linked with one another.

Production planning needs the latest information about the quality and capacity requirements of the planned production, information about the plant condition and information about the achieved product quality in order to be able to ensure compliance with customer specifications. Maintenance needs information about the

current status and condition of machines and components, as well as about resource and capacity requirements for the planned production. It must be checked whether the required product quality can be produced with the current condition of the plant, assessing it against the product planning requirements, documenting it and adapting it if necessary.

In terms of the bottom line: mastering production planning, plant condition and product quality in real time is a key to business success. From this,

the following scenarios of requirements can be derived: Production planning. Generally, the number of orders for small lots has been increasing. So has the number of orders that stipulate specific delivery dates or product quality requirements.

Purchase orders come in online via an internet portal. They have to be embedded into the structure of the corporate IT environment. Customers expect up-to-date and reliable information concerning the production status, de- >>

<50 000 Sensors

TB per month Â&#x17E;

Â&#x161;

Â?

Â&#x2122;

Â&#x153;

Â&#x203A;

Â&#x203A;

Â&#x161;

Â&#x2DC;

Â&#x2122;

Â&#x2DC;

Data collection Â&#x2014;

10 000 per year Customers oders

70 000 per year Coils processed

1.5 million t per year Production volume

Big River Steel in Osceola, Arkansas, USA MPT International 1â&#x20AC;&#x2030;/â&#x20AC;&#x2030;2019

32

››› DIGITALIZATION

Quality control using the Product Quality Analyzer (PQA)

livery date and product quality. Production planning has to be updated continuously on the basis of real time information. For this reason, products, plants and machines, and production processes need to be represented in a digital map. Ad hoc re-scheduling must be possible at short notice. Provisions have to be made to allow the consequences of re-scheduling activities on the sequence of processed orders and other key performance indicators (KPI) such as resources, efficiency, output, delivery data, etc. to be specifically evaluated and forecast (concerning the customer order, quality, plant location, supply chain network etc).

Plant condition monitoring. Retrofittable, smart embedded systems equipped with high-performance sensing equipment and featuring IoT interfaces monitor the status and condition of components and plants. The remaining lifetime is predicted and the performance capability in terms of capacity and quality assessed. Functional checks are performed in order to determine and validate the plant’s capacity and capability to produce specific steel grades and dimensions. The thus collected information is shared with the production planning, and the quality evaluation and execution systems. Spare parts supply takes place in a timely manner without any or with only very few spare parts in stock. In-process replacement and wear parts, as well as production materials are tracked consistently.

Monitoring and assuring product quality. All information relevant for MPT International 1 / 2019

the quality of the product are aggregated along the entire production chain.

Quality-related product information can be correlated under functional and dimensional aspects, and tracking throughout all production plants takes place in real time. Evaluation of the product quality is a largely automated process, with the attained product quality being rated against the quality specifications in the purchase order in a multi-stage procedure. The system commu­nicates in real time with the production planning and plant scheduling systems.

In conventional plants, centralized, rigid, hierarchical, short to medium or long-term production planning are normally characterized by unspecific prioritization. In the learning steel mill, this is replaced by real time optimization of production.

This is an agile, peripheral process based on real time data from the production process. It operates within a rather short-term cycle, while continuously and flexibly optimizing itself in line with specifications of clearly defined KPIs. This means that the planning status is being continuously reviewed, taking into account any changes in circumstances that may have occurred (e.g. new incoming orders, imminent maintenance activities, quality deviations) while simulating and evaluating the various possible alternative scenarios.

The thus obtained new ‘optimum’ will be automatically transmitted to the production process. The basis of all optimizations is the unique data source of truth, which constantly up-

dates itself in real time and is crosslinked with all subsystems to enable the transfer of data. This data can be raw data, meta data, data of embedded measuring systems, data from automation or Integrated Maintenance Management (IMMS), MES and ERP systems. In a nutshell: the learning steel mill continually optimizes the production process from the raw material all the way down to the finished product, as part of an integrated supply chain. This is based on process knowhow and physical and data-driven models.

Big River Steel: a ‘Learning Steel Mill’ As systems provider, SMS group has supplied all plants for the steelworks complex of Big River Steel in Osceola, Arkansas, USA – complete with all automation systems and associated technology packages [2].

Since the plant start-up at the end of 2016, Big River Steel – with the support of SMS – has achieved a steep ramp-up of its hot strip production. As North America’s most modern steel mill, it is designed for an annual production capacity of 1.6 million t of steel in its first construction stage.

Production planning. Big River Steel employs SMS group’s X-Pact MES 4.0 system. This system has taken over production planning and control from the very first day of production [3]. The system is designed to perform smart, and mainly autonomous production planning, in real time. Should a change occur (e.g. a new customer order, modified

DIGITALIZATION maintenance schedule, or altered quality requirements and so forth), then the system reviews the current planning state and checks in real time, and in consideration of clearly defined KPIs (output, delivery performance, product in stock, cost efficiency), whether the planning could be optimized.

The system takes into account real time data of the product quality and plant condition. As part of its digitalization offensive, SMS group has kicked off a research and development project on intelligent production planning, in cooperation with Jacobs University of Bremen, Germany. The project covers aspects such as dynamic reacting to specific production situations, use of artificial intelligence and self-learning automation systems.

It is planned to integrate the dynamic planning and optimization processes developed during this project into the existing X-Pact MES 4.0 structure already in place at Big River Steel. Improved production planning and ontime delivery performance, as well as a higher yield resulting from reduced scrap and downgrading rates, will fur-

ther enhance the economic efficiency of the steel mill.

Business Intelligence. Another core functional digital element in operation at Big River Steel is the X-Pact Business Intelligence system, which provides interactive analysis options and a comprehensive web reporting system. The latter visualizes the production processes and the related input data in clearly structured dashboard views, while processing the information in the desired level of detail. The challenge is to merge the large amounts of detail data at a central point, i.e. in the form of relevant packages of information, so that a system analysis can be performed or a strategy developed swiftly and at any time desired. The system is scalable, meaning that new modules can be easily added whenever required. KPIs can be made available plant-wide to all operators and engineering staff.

Plant condition monitoring. The ongoing digitalization trend offers numerous useful and innovative options

‹‹‹

33

for monitoring, on a continual basis, the condition and key components of plants. This entails uninterrupted acquisition and provision of real time information about the status and condition of the components, including alarms which suggest action to be taken whenever necessary. SMS group’s Genius CM (Condition Monitoring) system is an online screening systems platform of modular design, capable of monitoring any components within a steelworks’ production chain.

The modular structure makes it easily customizable to specific requirements and the platform design allows individual modules to be added at any time. Therefore it is suitable for all tasks ranging from single-component monitoring through to holistic, plantwide monitoring. By integrating embedded systems, existing plants can be retrofitted – e.g. for gear monitoring – with latest sensing equipment to monitor torques, vibrations, temperatures, forces, and oil volume flows for particle contamination and viscosity.

Unlike other analysis systems, Genius CM does not compare the measured >>

MPT International 1 / 2019

34

››› DIGITALIZATION

values with rigid threshold values, but with expected values and tolerances derived individually for each load case by physical or data-based models.

The result will either directly trigger an alarm message or, via a trend analysis function, a prediction of the probable date of failure for the planned production program. This avoids unexpected downtimes and allows the necessary maintenance activities to be initiated in due time.

Monitoring and assuring product quality. At Big River Steel, the PQA system captures quality data and quality-critical process parameters for all products along the plant’s process chain, from steelmaking down to the finished product.

Immense quantities of process and product data arise at each one of the numerous production stages. All this data

has to be set in proper relation to the products. Provision has to be made for the fact that slabs and strips do not only change in length, but may also be side trimmed and/or turned over. It requires a software solution capable of making the related data transparent and intuitively accessible in real time, to help operators and quality control staff perform their tasks. Here, the PQA software solution provides plant-wide transparency (end-to-end) of the quality and other relevant process data.

Quality monitoring relies on the integration of expert knowledge stored in rule sets. On top of that, the system takes product quality decisions in real time, in order to be able to directly intervene should any deviations be recognized. These decisions are made based on so-called quality orders in which the individual customer requirements and details of the quality

targets for the respective product. including tolerances, are specified.

The current quality status is compared against the quality orders and the result of the comparison evaluated in real time, in the accompanying graphic. As the results are correlated with X-Pact MES 4.0, the manufacturing execution system is in a position to actively respond to quality deviations by re-assigning the product to a new order and initiating the processing of this new order. This greatly supports the make-to-order philosophy.

Analogously, within a further software entity, rules can be set and related to the monitoring of the processes and/or plants. In future, machine learning techniques will enable quality predictions to be made in parallel to the production process and the available data to be continuously evaluated for causes of quality deviations.

In this way, the main aim of self-learning quality monitoring processes become reality as part of the PQA system.

Working towards an improved bottom line SMS group follows the course of combining technology with smart logistics and digitalization solutions in order to create added customer value.

In this way, the company helps its customers get the most out of their machines and processes. Already today, SMS group’s product portfolio offers new products and services based on digital technologies, generating efficiency optimization along the entire supply chain.

NEW!

Future-o riente IO-Link d interfac e

Expert for precise optical temperature measurement

The article is based on a paper presented at the 32nd Aachen Steel Colloquium held in Aachen, Germany, on September 13, 2018.

References: [1] Reifferscheid, M.: stahl u. eisen 137 (2017) Nr. 2, pp. 43/48.

[2] Stickler, D. et. al: Managing technology featuring Big River Steel, AIST Conf., 12. − 14. Sept. 2017, Memphis, USA. [3] Runde, W.; Bruns, M.: MES Systems:

KELLER HCW GmbH · Carl-Keller-Str. 2-10 · 49479 Ibbenbüren · Germany Tel. +49 (0) 5451 850 · Fax +49 5451 85412 · its@keller.de

www.keller.de/its MPT International 1 / 2019

Hi-tech steel production planning, Steel Times International, Future Steel Forum, 6. − 7. Juni 2018, Warsaw, Poland, pp.

60/65.

DIGITALIZATION

‹‹‹

35

SMS group’s ‘digital classroom’ could revolutionize virtual learning In December 2018, the SMS TECademy – SMS group’s international training centre for entrepreneurs and companies operating metallurgical plants and equipment – opened its first digital classroom in the Germany city of Mönchengladbach, halfway between Düsseldorf and the Dutch border. What makes the classroom innovative is its use of virtual and augmented reality (VR and AR) applications to train participants in plant processes, including complex maintenance work.

Key to the digital classroom experience is its high immersion factor through which complex maintenance work can be perceived and experienced. With the use of VR glasses and a point and click ‘virtual glove’ remote control, the simulated environment looks and feels – to a degree – like the real workplace.

Aside from making customer learning even more interactive, training on the virtual model does not, of course, disturb the real plant production plan.

Lessons can take place at any time and, importantly, trainees can learn without any risk of error or damage.

In addition to new equipment training, the SMS TECademy offers through its digital classroom a range of specialist training courses on selected dates and topics. They include technology, maintenance and systems en-

gineering as well as e-learning, while ‘individualized’ training programmes can be designed specifically for the needs of customers.

Trainees experience a ‘computeraided extension of reality’ Images are viewed through special AR goggles, and also transmitted simultaneously to a large monitor so that other spectators can experience the process live. For example, in the case of an ‘hydraulic pump’ software application, the wearer receives smart information through AR goggles in their field of vision to the issued hydraulic pump, while also seeing the real pump.

Different scenarios can then be ‘played’ through, e.g. disassembly and assembly of the pump in single steps.

Dynamic parts (such as turned parts) can be ‘exploded’, or separated into their constituent components, and viewed in more detail. The wearer can therefore experience the functionality of technologies in ways that are not visible with conventional drawings.

“Using AR and VR technology, our trainees experience a computer-aided extension of the perception of reality.

This training can be much more efficient or designed,” said Karsten Weiss, General Manager TECademy.

Importantly, components such as the hydraulic pump can be rendered from 3D plant drawings with the appropriate kinematics. Meanwhile, the ‘virtual glove’ remote control can be used as an example for mounting purposes (e.g., tightening screws). The user can go through an AR simulation of a complete maintenance process, without going to the real plant or experiencing the related safety risks.

Significant potential for use in real world plant processes Mr. Weiss said, “I clearly see further advantages in the fact that the glasses can be used not only in our digital classroom, but also on site with our customers. Interdisciplinary course participants – such as mechanics, electrical and automation (E&A) or process engineers – will be able to understand the ‘other’ faculty of their task more easily. In addition, the glasses as a device for viewing new content are flexible and expandable.”

Dr. Mark Haverkamp, Head of Plant Simulation, SMS group, added: “We see great future potential for how these technologies – or ‘Plant Simulation as a Service’ – can be used in future, real world plant maintenance applications.

This is something that we are continuing to research and develop.”

MPT International 1 / 2019

36

››› ENVIRONMENTAL PROTECTION

Figure 1. The basic process scheme of the Energiron Zero Reformer (ZR) process

New Energiron direct reduction process can sustainably decrease CO2 emissions in steelmaking Compared with the traditional blast furnace– basic oxygen furnace (BF–BOF) route, more than 50% of carbon dioxide (CO2) emissions could be saved if steel is produced by means of Energiron direct reduction. The new process is designed to produce high grade steel in an economical and sustainable way.

Customers and the markets are pushing continuously for technologies that enable the production of high quality steels in a more economical and sustainable way.

The blast furnace (BF)-basic oxygen furnace (BOF), which uses iron ore di-

Dario Pauluzzi, Danieli & C. S.p.A, Buttrio, Italy Email: d.pauluzzi@danieli.it Contact: www.danieli.com Stefano Maggiolino, Tenova HYL, San Nicolás de los Garza, Mexico Email: Stefano.maggiolino@tenova.com Contact: www.tenova.com

MPT International 1 / 2019

Figure 2. Equivalent carbon dioxide (CO2) emissions per kilowatt hour (kWh) produced by different energy sources [1]

‹‹‹

ENVIRONMENTAL PROTECTION

37

Figure 3. Energy, mass and emissions balances for a Blast Furnace (BF)-Basic Oxygen Furnace (BOF) and Direct Reduction-Electric Arc Furnace (DR-EAF) integrated mill [2]

rectly as a raw material for steel production, is certainly the preferred way for producing high grade steel. However, when coal is used as a reducing agent, a significant amount of carbon dioxide (CO2) is emitted into the atmosphere as a byproduct of the reduction reactions. Combined with the limited energy efficiency of the process, this route is often incompatible with the restrictions imposed by environmental regulations. The method is also less competitive when compared with alternative solutions.

Contrary to this, environmental parameters are more easily respected when steel is recycled from scrap via electric arc furnaces (EAF). Nevertheless, the price and grade of the final steel might not be competitive due to such factors as scrap availability and quality (caused by market price fluctuations, several residual elements and nitrogen levels). This is why EAF operators have intensified their research into alternative iron materials for use

as feed for EAFs. The findings have revealed that by the use of direct reduced iron (DRI) or hot briquetted iron (HBI), electric mills can produce the types of superior steel grades required by users of automotive, special and tool steels.

Previously, the production of such quality steels has only been possible in integrated mills with BF-BOF. Now, with the use of DRI/HBI, the same steel grades can be achieved by EAFs, while maintaining all of their typical advantages – such as lower capital expenditure (CAPEX), flexible operations and lower environmental impact.

DRI and HBI are produced in direct reduction plants (DRP). Among all of the available technologies, Tenova HYL and Danieli have jointly developed the Energiron direct reduction process which the companies say enables higher energy efficiency levels and lower gaseous emissions, especially in terms of CO2. The carbon footprint of a DRP is intrinsically lower than a BF simply because, in the first case, the re-

ducing agent is typically natural gas (NG) while the primary energy source in BFs is coal.

The basic Energiron process also incorporates a CO2 removal unit. This allows for selective removal of the majority of the CO2 generated by the reduction of iron ores. In terms of emissions, the DR-EAF route grants a 40-60% reduction in CO2 and is no longer limited to producing only commercial steel grades. The route is now also capable of producing DRI in capacities exceeding 2 million t/year. The retrofitting of existing plants could also be possible.

The proprietary Hytemp® System, the world’s first proven technology for continuous hot discharge, transport and feeding of quality DRI to the EAF, provides additional energy savings.

The proven and reliable Hytemp System, and the automated control system, couple the Energiron DRP to the EAF. This results in an efficient, flexi>> ble and reliable integrated mill.

MPT International 1 / 2019

38

››› ENVIRONMENTAL PROTECTION

Using Direct Reduced Iron (DRI) as a reforming catalyst The Energiron Zero Reformer (ZR) process scheme makes it possible to carry out the NG reforming stage within the reactor without an external reformer.

Instead, the DRI itself is used as a reforming catalyst. This improves the process’s efficiency to unmatched levels – most of the energy supplied is taken by the product with minimum energy losses to the environment.

With conventional processes, overall efficiency is generally below 70%.

By comparison, with the Energiron ZR process, efficiency is above 78%. NG consumption is kept as low as 2.35 Gcal/t. After that, oxygen is removed from the iron ore by chemical reactions based on hydrogen (H2) and carbon monoxide (CO). The exhaust reducing gas (top gas) leaves the reactor at about 400-450 °C and is subsequently treated in order to be recirculated at the maximum extent possible.

To allow for this, firstly, the gas must be cleaned from dust and oxidant elements (H2O and CO2) that are generated by the reduction reactions.

The selective elimination of water and carbon dioxide Specifically: the top gas leaving the reactor passes through the top gas heat recuperator (tubes and shell heat exchanger) where its energy is recovered to produce steam. It is then sent through the quenching/scrubbing system. Within these units, H2O (a byproduct of the reduction reactions) is condensed and easily removed from the gas stream and also cleaned out of some dust carried by the gas. Subsequently, after being compressed, the scrubbed gas is treated in the CO2 removal unit where CO2, the other byproduct of reduction reactions, is selectively removed.

From the environmental point of view, the selective elimination of both by-products generated during the reduction process – H2O and CO2 – is one of the inherent and most important features of the Energiron process.

Once both the H2O and CO2 have been removed, the upgraded gas is finally mixed with the reducing gas make-up before passing – firstly – through a humidifier where water content in the gas is regulated. Later, the gas passes through the process gas MPT International 1 / 2019

heater which increases its temperature up to 950 °C. This closes the reducing gas circuit. Finally, direct internal combustion of the reducing gas, by means of oxygen injection, tunes the gas temperature to the desired value at the reactor’s inlet. The continuous gravity flow of the material through the reduction furnace is regulated by a rotary valve, located at the bottom of the vessel. Specially-designed flow feeders ensure the uniform flow of solids within the shaft.

At the end of the process, the DRI is finally discharged, hot or cold, by automated mechanisms which consist of pressurized bins and special valves.

CO2 emissions for the BF-BOF and DRP-EAF routes A comparison between the CO2 emissions generated by the two steelmaking routes, BF-BOF and DRP-EAF, is presented below. This is based on the following assumptions: • the production capacity and the type of product of the two facilities is assumed to be the same. The final product is Hot Rolled Coil (HRC), • the scenario for the BF-BOF route comprises the emissions generated by the coke oven plant, as it provides the reducing agent (coke) for the blast furnace, • the DRP is assumed to be fed by NG. The emissions of CO2 related to the electrical energy requirements of the two facilities are evaluated in grams of CO2 per kWh equivalent. Usually, the BF-BOF is a producer of electrical energy, therefore a CO2 credit will be accounted equivalent to the kWh exported. On the contrary, the DRP-EAF is typically a consumer of electrical energy, therefore the correspondent CO2 will be added to the facility’s emissions.

The CO2 generated to produce electrical energy depends strongly on the

location of the steel plant. Each nation has its own composite sourcing of NG, coal, hydraulic, eolic, nuclear, biomass for electrical power generation – and this mixture can change significantly from case to case. Figure 2 shows the equivalent CO2 emissions for production of one kilowatt hour (kWh), according to the LCA (life-cycle assessment technique to assess environmental impacts) method.

For the purposes of this study, it is assumed that the electrical energy is produced from the combustion of NG whereby 500g of CO2 is accounted for each kWh distributed on the local network. This choice has been made based on the assumption that the DRP is fed

by NG. Therefore, it’s reasonable to assume that it is available in good quantities and at a competitive price.

The BF generates fuel by-products, blast furnace gases (BFG), coke oven gases (COG) and basic oxygen furnace gases (BOFG) – all to a significant amount in excess of what can be completely recirculated in the steelworks. A portion of this energy is used for power generation or, in some cases, is even wasted.

Because only a minor part of the electrical power generated from these gases can be used in the steelworks for its own requirements, most of the electrical power is typically exported.

For the selected integrated BF-BOF mill, the specific CO2 emissions – inclusive of coke oven plant, sinter plant, BF and BOF – are approximately 1,810 kg of CO2/t of liquid steel (LS). The exported power of the facility is approximately 330 kWh/tLS and, as a result, the facility is credited with 165 kg CO2/ tLS of equivalent emissions ‘saved’.

The CO2 emissions balance of the BFBOF mill is shown in Figure 3, for a net CO2 emission of 1,615 kg CO2/tLS. In contrast, a DR/EAF mill is able to recover the majority of the energy from the spent gas. But it is a net elec-

Figure 4. Reduction of CO2 emissions for a Energiron ZR direct reduction plant (DRP)

‹‹‹

ENVIRONMENTAL PROTECTION

39

Figure 5. The Energiron ZR uses hydrogen (H2) as a reducing agent: 5a, the process scheme; 5b, CO2 emissions

trical energy importer, the balance of which is also shown schematically in Figure 3. The DRP considered in this case is based on the Energiron ZR process and it is assumed to produce high-carbon DRI (94% Mtz and 4% C) which provides additional energy for secondary reduction of iron (II) oxide (FeO), as 80% feed to the EAF. The comparison shows that the carbon footprint of a BF-BOF mill is approximately double than for a modern DRP-EAF mill. Further improvements in emissions and energy efficiency can be achieved when the DRP is based on the Energiron ZR process.

Energiron ZR: minimum energy request, minimum emissions It is also the case that the Energiron ZR technology further improves the overall energy efficiency of the DRP. Since the reducing gases are generated inside the reactor, most of the energy supplied to the process is taken by the product with minimum energy losses to the environment. It is therefore possible to achieve the aforementioned process efficiency of above 78%, compared with below 70% for other, more conventional processes.

This arrangement ultimately turns into very low NG consumption, even lower than 2.35 Gcal/t. The higher operating pressure of the Energiron plants (~8 barg vs ~atmospheric pressure of other DR technologies) allows for a decrease also in the power consumptions. In fact, because the recirculating gas compressor is the main electrical energy consumer, power consumption is proportional to: the ratio of discharge to suction pressure. So, for the same change in pressure (Δp), the higher suction results in a lower power consumption.

Moreover, Energiron includes in its basic process a CO2 capture system, as previously mentioned, shown in Figure 1. This allows for a further decrease of the DRP emissions by approximately 60%, leading to a carbon footprint of just 156 kg CO2/tDRI. The selectively removed CO2 can then be used by several other industries – e.g. for the production of soft drinks, dry ice, construction conglomerates or for enhanced oil recovery (EOR).

Using hydrogen (H2) to feed Energiron plants While it’s possible to produce high grade steel more economically and sustainably with Energiron technology, additional advantages can be achieved by feeding Energiron plants with H2 as a reducing gas, with no major changes to the proven ZR process. Actually, because Energiron plants are typically working with a H2/CO ratio in the range of 3÷5, they are designed from the beginning to work with high H2 content.

As a matter of fact, H2 has always been the main reductant agent for this technology. Historically, the available reducing sources have been gases with a variable amount of H2 (reformed gas, syngas, BOF, COG), pure H2 is seldom available in good quantity and at competitive price.

New technologies (such as electrolyzes) are being developed to exploit renewable energy sources for the production of H2 – not least because the element is generally considered to be the fundamental element for the future global energy system.

In this context, Energiron is equipped to aid this promising energy trend. A major advantage is that reduction with H2 in Energiron reactors is more effi-

cient and faster from a kinetics point of view, by about five times compared to that based on CO. The solution also allows for minimized CO2 emissions, depending on the extent to which H2 is used in place of CO. In fact: the by-product of iron ore reduction by CO is CO2, while the by-product of reduction by H2 is water.

Strong results Started in 2006, Energiron is a strategic alliance between Danieli and Tenova HYL to develop and implement the most efficient and flexible technology in the current panorama of DRI production, while providing the lowest CapEx and OpEx in any environment.

Due to strong results achieved at such benchmark institutions as Emirates Steel DRI plants I and II (UAE), Suez Steel (Egypt), Nucor Steel Louisiana (USA) and Ezz Steel (Egypt), the alliance has recently been renewed for an additional 10 years. Danieli and Tenova report that Energiron continues to offer the most advantageous way to use H2, without changing its basic process scheme, for complete ‘zero CO2 emissions’ steelmaking.

REFERENCES [1] W. Moomaw, P. Burgherr, G. Heat, M. Lenzen, J. Nyboer, A. Verbgruggen, Annex II: Methodology. In IPCC Special Report on Renewable Energy Sources and Climate Change Mitigation, Cambridge (UK) and New York (USA), Cambridge University Press, 2011 [2] P. Duarte, J. Martinez, By-Products, CO2 Emissions and Hydrogen use in an ENERGIRON DRI Plant [3] D. Pauluzzi, B. Franco, A. Martinis, A. Piccoli, Analysis on Operating Results of ENERGIRON Plants and Focus on the Emirates Steel case, AISTech 2018 MPT International 1 / 2019

››› ENVIRONMENTAL PROTECTION

All pictures: Tata Steel

40

The HIsarna plant in IJmuiden, the Netherlands, where Tata Steel is developing a completely new technology to produce iron with at least 20% lower CO2 emissions

Tata Steel’s new HIsarna technology exceeds expectations in sustainable steel production After a period of long-term testing, Tata Steel has developed a potential substitute for the blast furnace process that could enable future steel production with at least 20% lower CO2 emissions at its site in IJmuiden, Netherlands, Tata Steel has developed. The company believes its impact may be compared to the introduction of continuous casting in the 20th Century.

Tata Steel has designed and developed a new technology which it says could allow for future steel production with at least 20% lower CO2 emissions. The technology could become a game changer that significantly improves steel production sustainability and performance. What’s more, the company believes its impact may be comparable to the introduction of continuous casting in the 20th Century.

Tata Steel, IJmuiden, the Netherlands Contact: www.tatasteeleurope.com

MPT International 1 / 2019

The company has been carrying out long-term testing of its HIsarna plant at the Tata Steel site in IJmuiden, the Netherlands. HIsarna is a completely new technology for producing iron that consists of a reactor in which iron ore is injected at the top. The ore is liquefied in a high-temperature cyclone and drips to the bottom of the reactor, where powder coal is injected. This significantly reduces the number of energy-intensive steps required for the traditional steelmaking process.

The results from HIsarna have already shown this technology can lead to a significant reduction in CO2 emissions from the steel production pro-

cess. During the final test campaign, experiments were done with the use of steel scrap and biomass. This revealed that it was possible to achieve a CO2reduction of more than 50%. The HIsarna technology reduces CO2 emissions and energy consumption through a number of ways, including by using iron ore and pulverized coal without having to pre-process the raw materials in separate coke, sinter or pellet factories. Last year, tests were conducted with the use of steel scrap in the HIsarna reactor. This showed that up to 53% of material added to the process could be made of scrap steel, reducing the requirement for raw materials compared

‹‹‹

ENVIRONMENTAL PROTECTION

41

HIsarna is a potential substitute for the blast furnace process in which the raw materials are injected as powders, directly converting them into liquid iron

to the blast furnace process. Scientists and steel companies from all over the world are closely monitoring the development of HIsarna.

Hans Fischer, Chief Executive Officer and Chief Technical Officer of Tata Steel’s European operations, said: “HIsarna’s results show we can make a significant contribution to improving the sustainability of steel production with this Tata Steel technology.

The development of this technology forges our ambition to become a steel company which is sustainable in all respects.”

Directly converting raw materials into liquid iron HIsarna is a potential substitute for the blast furnace process. To make liquid iron in a blast furnace, iron ore and metallurgical coal (the raw materials) need to be pre-processed into sinter (lumps of iron ore) and pellets (small balls of iron ore) and cokes. According to Tata Steel, the HIsarna process might make this obsolete.

In the HIsarna installation, the raw materials can be injected as powders, directly converting them into liquid iron. If HIsarna can be successfully developed at an industrial scale, then future production of steel with an at least 20% smaller carbon footprint will be possible. In order to develop and test this technology, a pilot plant has been built at the IJmuiden site.

Since 2011, the pilot plant has been through five test campaigns (see page 42) and the results, so far, have been promising. The HIsarna plant has already produced liquid iron and this has successfully been processed into steel. For Tata Steel and its project partners, this represents a success in proving that the process works. Currently Tata Steel, ArcelorMittal, Thyssen Krupp, Voestalpine and technology

supplier Paul Wurth are jointly working on testing and further developing HIsarna. It is believed that the technology may be up and running on an industrial scale within the next seven to ten years.

How HIsarna works HIsarna has been jointly developed with mining company Rio Tinto. Specifically, the cyclone (upper) part of the >>

Facts about the HIsarna pilot plant at Tata Steel’s site in IJmuiden, the Netherlands ANCIENT CELTIC WORD FOR IRON. The name HIsarna is an amalgam of the ancient Celtic word for iron (‘Isarna’) and the name of the melting vessel (‘Hismelt’).

MORE THAN 75 MILLION EURO INVESTMENT. So far, more than 75 million euros have been invested in developing HIsarna. The partner companies have funded 60% of this investment, while 40% consist of support from the European Union, the Dutch Economics Ministry and the European Research Fund For Coal and Steel.

REVOLUTIONARY BREAKTHROUGH TECHNOLOGY. HIsarna is a revolutionary breakthrough technology. Tata Steel believes its impact may be compared to the introduction of continuous casting in the 20th Century, which has made the process steps of ingot casting and rolling redundant (they were virtually completely phased out in the steel industry over a period of 30 years).

ANNUAL PRODUCTION OF 60,000 T. The maximum production capacity of the current HIsarna pilot plant is 60,000 t/year of liquid iron. By comparison, blast furnace no. 7 in IJmuiden produces 10,000 t/day of liquid iron.

MPT International 1 / 2019

42

››› ENVIRONMENTAL PROTECTION

installation has been developed by Tata Steel in IJmuiden while the lower part, the Hismelt vessel, has been developed

by Rio Tinto. Tata Steel has full ownership of the patents on HIsarna.

The technology consists of a reactor with temperatures above the melting point of iron throughout the vessel, so that the injected iron ore instantly melts and converts into liquid iron. In the HIsarna furnace, temperatures are above the melting point of iron throughout the reactor. The process gases in the melting vessel also have a high temperature.

At the top of the reactor (in the cyclone) the temperature is increased further by adding pure oxygen, which reacts with the carbon monoxide present. Because of the turbulence in the cyclone, there is enough contact time for the hot gas to melt the iron ore (which is injected at the top). The iron ore immediately melts and drips into the bottom of the vessel.

That is where the powder coal is injected, causing the oxygen from the iron ore (equalling iron oxide) to bind with the carbon, thus creating pure liquid iron which can then be tapped.

Reduced manufacturing costs The HIsarna production process is more efficient than the current blast furnace one, as there is no need to pre-process ores and metallurgical coal.

A complete production stage can therefore be phased out: coking plants, sinter plants and pellet plants. This could also save a lot of energy, which is good for the environment, and reduces manufacturing costs. HIsarna also enables the use of a wider range of ore and coal qualities that will allow steel companies to produce the same high quality steels using more widely available raw materials.

If the HIsarna technology can be developed successfully on an industrial scale, then Tata Steel anticipates it will take ten years to reach the stage of commercial use and then be applicable in greenfield situations.

Better for the environment HIsarna’s most important environmental benefits are the reduction of energy use and CO2 emissions by at least 20%. Since the HIsarna installation produces almost 100% pure CO2, this is ideally suited for immediate capture MPT International 1 / 2019

and storage without the need for a costly refining process.

Subject to further testing, it is believed that capturing and storing CO 2 could lead to an 80% reduction of CO 2 from the steel production process.

The technology also allows for a wider range of steel production by-products to be reused, which will further close the loop of the steel manufacturing process. A further advantage of HIsarna is the reduction of the emission of fine particles, sulphur dioxide and nitrogen oxide.

Need for support Funding for breakthrough technologies is a burden that the European steel industry cannot face alone, given the huge sums involved. There are also the tough European economic conditions and the global competition with companies that are not faced with emission trading schemes, carbon taxes and high energy and labour costs. In many respects, European steel companies are at a severe disadvantage as long as there is no ‘level’ global competitive playing field. Therefore, financial support from the European Union is indispen-

Timeline: Tata Steel’s long-term testing of HIsarna Tata Steel has been carrying out long-term testing of its HIsarna plant. Before the start of each testing campaign, burners preheat the plant’s reactor to a temperature of about 1,200 ºC. Next, a layer of liquid iron is poured into the bottom of the melting vessel to facilitate the start-up of the process.

1ST TEST: PUTTING THE THEORY INTO PRACTICE. The first HIsarna test campaign took place between April and June 2011. It’s objective was to show that the theory of producing liquid iron without pre-processing of raw materials, works in practice. This was achieved with the first successful tap of liquid iron on May 20, 2011.

2ND TEST: ACHIEVING A STABLE PROCESS. HIsarna’s second test campaign – from October 17 to December 4, 2012 – aimed to produce liquid iron for a longer, sustained period. This objective was met, with production kept at 80% of the design capacity for periods of eight to 12 h. In the last full run, a design capacity of 8 t/h was reached.

3RD TEST: WITH DIFFERENT RAW MATERIALS. From May 28 to June 28, 2013, the third test at HIsarna set out to produce liquid iron for sustained periods, run tests with various kinds of raw materials. The objective was again met and, for the first time ever, steel was made from HIsarna liquid iron.

4TH TEST: SUSTAINED PRODUCTION. The goal of HIsarna’s fourth test – between May 13 and June 29, 2014 – was to achieve sustained, stable production for several days on end. Various kinds of tests and raw materials were used and, in the end, the objective was met.

5TH TEST: SUSTAINED CAMPAIGN OVER SIX MONTHS. The fifth HIsarna test started in October 2017: a sustained campaign, which has now been carried out for more than one year. In preparation for this, the installation has seen a significant overhaul.

A completely new off-gas duct has been installed, increasing the height of the plant by more than 10 m (highest point: 37 m). Next to the pilot plant, a complete coal grinding and a drying and screening facility for ore and limestone have been constructed. Closed conveyor belts have been installed to transport the raw materials from the storage facility to the installation injection points. The raw materials storage capacity has been doubled.

On top of that, a gas analysis lab has been added and the electronic monitoring system has been completely reprogrammed.

‹‹‹

ENVIRONMENTAL PROTECTION sable if the European steel industry is to successfully develop breakthrough production technologies.

HIsarna is one of a number of initiatives to help Tata Steel’s European business achieve its ambition of becoming carbon neutral from 2050. To this end, Tata Steel’s European business has announced a partnership with leading chemicals company Nouryon and the Port of Amsterdam to develop the largest green hydrogen cluster in Europe.

Together, the companies will explore the feasibility of a water electrolysis facility to produce hydrogen and oxygen at Tata Steel’s IJmuiden steelworks. Using renewable electricity, the plant would save up to 350,000 t/year of CO2 – equivalent to the emissions of more than 40,000 homes.

Tata Steel’s plans extend beyond IJmuiden. Also announced recently was the company’s intention to cooperate with Dow Chemical on a pilot project which seeks to convert carbon monoxide (CO) – itself a by-product gas from blast furnaces – into naphtha, a liquid hydrocarbon mixture. The naphtha is expected to be used as feedstock for the production of other chemical products, as a further example of integration into the circular economy.

Mr. Fischer said: “We are already one of the world’s most CO2 -efficient steel companies, but our ambition is to become a carbon-neutral steelmaker.

“The steelmaking industry has a collective responsibility to set bold targets, raise the bar and find opportunities to collaborate in order to drive progress on this front. Simultaneously, we’re making significant investments in innovation as part of our strategy to build a European business that is sustainable in every sense.”

43

Since 2011, a series of test campaigns at the pilot plant in IJmuiden have given promising results

In October 2017, a further test campaign has started at HIsarna, which has been carried out for more than one year now. Its objective is to prove that the installation can produce liquid iron for long, sustained periods of time. Overall, the campaign is expected to cost about 25 million EUR. If the test proves successful, then the project can enter its next phase: the crucial stage of designing, constructing and testing a large-scale pilot plant. This will need an investment

of 300 million Euros. Once it has been built, the large pilot plant will itself have to go through several years of testing. The industrial-sized plant will be two-to-three times the size of the current facility and capable of making up to ten times more liquid iron.

In the meantime, the HIsarna pilot plant has moved away from Research & Development to become part of the IJmuiden production organization.

Next stage The next steps in testing at the HIsarna installation include: • identifying the ideal raw material mix, • investigating the options to recycle steel slag, • testing the use of CO2 to inject raw materials, • investigating the recovery of zinc, • studying the possibilities for capturing and storing CO2 – with the aforementioned potential to reduce traditional steelmaking CO2 emissions by around 80%.

HIsarna consists of a reactor with temperatures above the melting point of iron throughout the vessel. The injected iron ore instantly melts and converts into liquid iron MPT International 6 / 2018

44

››› QUALITY ASSURANCE

3D surface inspection for highest quality in metal production ISRA Parsytec has developed a new system that enables 100% 3D surface inspection and measurement from the first production step. Combined with ISRA’s advancements in software and data use, the system is helping operators spot defects in steels earlier for significant cost savings.

The final quality of metal products is influenced at the earliest production steps.

Initial defects, such as grooves and cracks on the surface or edges of hot slabs, can affect the material’s subsequent quality and, in the worst cases, they can cause a strip brake in the later production stages.

Ideally, defects on the surface of red hot slabs should be detected immediately. It is generally the case that 60% of process-relevant defects already exist in the slab; e.g. longitudinal or transverse cracks which are often covered by the subsequent hot rolling. These imperfections only become visible later in the steel manufacturing process, by which point significant time and effort has already been wasted.

The first production steps have previously been analyzed with contrastbased 2D inspection or the human eye.

Both methods have proven insufficient, especially as many defects cannot be detected on the extremely structured and 1,000 °C hot slab surface.

Failure to spot these defects can result in significant damage of the system, a high amount of scrap as well as additional costs in the hot rolling mill.

For these reasons, the earliest detection of defects is a decisive factor in reducing production costs.

Laser triangulation for 3D surface inspection ISRA Vision AG of Darmstadt, Germany, is a manufacturer of solutions in the machine vision and industrial image processing sector. In response to the shortcomings of 2D and human inspection methods, the company has developed a new solution that is designed to provide

ISRA Parsytec GmbH, Aachen, Germany Contact: www.isravision.com Email: info@isravision.com

MPT International 1 / 2019

spection of metal strips in all the further steps of production, after the 3D slab and plate inspection.

An integrated software filter is also utilized to provide sharp and flawless inspection images. These images combine with sophisticated algorithms which provide not only an accurate picture of the surface but also valuable additional information about the nature of the defect.

The rising importance of predictive analysis Whereas defects cannot be detected in the 2D grey level picture (left), the 3D depth-image (right) shows a significant crack

100% 3D surface inspection and surface measurement from the first production step.

The new technologies by ISRA, offered as the Slab Master and Plate Master, use 3D technology based on laser triangulation to inspect the surface of steels. This process employs a precise laser along with high definition cameras to measure elevations on the material’s surface. The laser light source projects a beam of light onto the steel’s surface, and the cameras then measure the reflected light.

The result is three-dimensional surface inspection. From the resulting images of spots on the surface of the material, operators can derive comprehensive information about a material’s flatness for altogether more reliable detection results.

In addition to the Slab Master and Plate Master, which both use 3D technology, ISRA has also developed the Surface Master. The latter utilizes 2D technology, which is sufficient for flat rolled products, with a Matrix camera and illumination but no laser. The Surface Master is designed for quality in-

Surface measuring systems have become ever more relied upon in the support of crucial decision making during operations. ISRA’s surface measuring system provides information on crucial issues, such as: • whether the product can still be used for its initially intended purpose, • if expenses for unnecessary material waste can be saved in the future.

The software’s capabilities reflect the growing importance – and necessity – of predictive analysis throughout the steel industry. Process-relevant defects that already exist in the slab can be automa-tically detected by its new 3D surface inspection system. For example, in cases were a defect cannot be detected with a 2D grey level picture, the 3D depthimage will instead show a significant crack. From the perspective of manufacturers, the ability to detect these kinds of defects early in the process and on the slab itself creates opportunities for savings in production time, effort and also materials. In addition, repairs and maintenance can also be scheduled in due time with the technology’s predictive capabilities.

Automation to meet quality control requirements A mandatory requirement for fully-automatic quality control is the need to

‹‹‹

QUALITY ASSURANCE

45

ISRA Vision has developed 100% quality control with 3D surface inspection and measurement from the first steps of metal production

maintain a constant distance between the sensor and the surface of the strip.

Previous cases have shown that, should any variation in distance occur between the metal surface and camera, the sensor will not be suitable for a reliable inspection. This presents issues during the rolling of metal strip, where the diameter of a coil increases in layers. An inspection is only possible if the system adapts in equal proportion to the changes in distance – any variations, e.g. at the coiler, are found to make the generation of reliable images impossible.

ISRA Parsytec’s solution was to develop its Constant Pass-line Distance (CPD) technology. Whereas other systems are installed in a fixed position, with the CPD extension the sensor can be moved automatically to keep a constant and stable distance between it and the inspected surface. With this function, the CPD system helps meet mandatory distance requirements for effective quality control.

The technology also opens new installation possibilities, especially in cramped spaces or wherever the socalled pass-line (the distance between the metal strip and a permanently installed system) changes. For example, the available space on the coiler can now be an option for installation.

their production targets are still achievable and customers’ requirements can be reached, • A fast system startup. Reliable defect classification and intuitive user interfaces help operators to engage immediately with the entire process, thereby directly improving their efficiency, • Software for intelligent management decisions. This uses the gathered data for individual reports. Optimization potentials are made easily visible and quality decisions are supported with sound facts.

As the industry increasingly turns towards software to ensure product quality, ISRA Vision brings together its production management with analytics solutions under the abbreviation QMS (quality management system).

The company has designed its software solutions to aid users through increased process transparency; i.e. with root cause analysis of defects, automated quality grading and overall production monitoring. The software also enables the analysis of defects and defect patterns based on inspection and other quality-relevant data, like gauging or laboratory tests, as well as integration, tracking and visualization of third-

party sensor information. With these capabilities, operators can search for the root causes of defects within processes.

The QMS is scalable and designed to support single, recurrent tasks such as the quality evaluation of a product.

The system can therefore be scaled up to provide networked solutions which cover the complete production chain, with quality monitoring or enterprise-wide (advanced) reporting.

Lower production costs through defect detection For Tangshan Steel Group Ltd. based in Hebei Sheng, China, the in-depth analysis of products and production management capabilities of the QMS system have opened up considerable benefits.

Advantages for the company range from halting investments into products of minor quality, to implementing quality grading methods which thereby reduce customer complaints. Because users can now reap the savings potentials in their own production, and simultaneously increase the quality of their output, it is possible to realize the system’s return on investment in a short time.

“The profound metal industry background and their strong project management capabilities were our main >>

Searching for the root causes of defects ISRA Parsytec has based its new technology’s measurement capabilities on experiences that it has gained through installing more than 700 metal surface inspection systems. (Beyond metal inspection, its parent company, ISRA Vision AG, has been responsible for 3,000 installations all over the world.) In addition, the company has optimized its 3D surface inspection and surface measurement solutions for use in harsh metal production environments.

The system’s key features include: • Documentation of all the production steps. Now manufacturers can know, much sooner than before, whether

The 3D depth measurement with triangulation technique can detect all possible defects from various angles MPT International 1 / 2019

46

››› QUALITY ASSURANCE

The Slab Master allows a 100% surface inspection already on the hot steel slab and reduces scrap material and costs in production

reasons to partner with ISRA. Having a partner that is diligently familiar with the processes of metal production really speeds things up,” said Changhai Li, sector head of the department of manufacturing at Tangshan Steel.

Also developed within a short time after the implementation of the QMS were the system’s customer-individualized functions. Features such as the mill database as well as the quality grading and reporting systems were up and running, while quality issue tracing and product inspection were also on track.

With the system, Tangshan has found that defect detection is decisive for reducing the costs of production.

Assessing product quality based on process insights While advanced detection and automation are well-established as being integral to the daily challenges of quality management, data is another important factor. To its portfolio, ISRA has added a variety of advanced digital assistance and reporting tools to display and evaluate production data.

The company’s Expert5i software modules – part of the QMS platform – use data collected from the inspection MPT International 1 / 2019

process to actively demonstrate the optimization potential of steels. At Tangshan Steel, the quality decision process has been specifically optimized by implementing the Expert5i software.

Prior to the implementation of Expert5i, Tangshan’s quality engineers had to rely on laboratory results as well as isolated process and inspection data. Instead, with the QMS, Tangshan steel can now integrate all of this data into one united platform. The collected information is accessible from any user terminal with the company’s network. This can provide detailed information wherever it is needed, including in the board room or directly to the production line. The accessibility of data, or placing the information about processes into the cycle of quality decision making, was the first step at Tangshan, said Changhai Li. “QMS has changed the practice of analyzing problems based on experiences. It is much more convenient for users to check the production data, to judge product quality based on process in-sights.”

Through the advantages made possible by the QMS, Tangshan’s facility is

now established as its quality management centre. The company can successfully avoid quality issues – e.g. those arising from zinc and oil films – by closely monitoring process deviations.

Conclusions Through its product portfolio, ISRA Vision AG is enhancing the ability of operators to make correct quality decisions based on best inspection performance.

The company’s 3D surface inspection and surface measurement systems – the Slab Master, Plate Master or Surface Master – are facilitating improved process control through the earliest possible inspection of flat steels; top and bottom side inspection advantages; plus the generation of flawless inspection images. This is yielding tangible advantages for operators for reduced expenses and lower material waste to time and cost savings.

This, along with the company’s advancements in software and data usage through its QMS, are enhancing the ways in which quality assessment can – and should – be integrated into the steel manufacturing process, from the earliest to final production steps.

‹‹‹

ROLLING MILL TECHNOLOGY

47

NEW SERVO DISC PACK COUPLING SCL

GREAT PRECISION WITH GREATER FLEXIBILITY When more flexibility is needed: the new servo disc coupling from R+W. – Higher misalignment compensation – Tolerant of chemical interaction and extreme temperatures – Easy handling More info at www.rw-couplings.com/servo-disc-pack-couplings/

Visit us at Hannover Messe 2019, 1-5 April, 2019 Hall 25, Booth C30

MPT International 1 / 2019

48

››› TECHNICAL INNOVATIONS

Data analysis down to the smallest detail for targeted process optimization PROCESS INSPECTION piaOptimum by PIA Automation Holding of Grambach, Germany, is an advanced software application, that identifies bottlenecks in complex, interlinked assembly plants. The technology allows for the rapid and sustainable optimization of production efficiency thanks to the greatest possible level of data transparency. The performance of both individual units and sections of the production line, or the entire plant, can be assessed. piaOptimum can be flexibly conpiaOptimum stands nected to all types of automation systems, when new plants are set up or out out due to the as a retrofit version for existing prodetail of its data duction lines. Along with cycle analanalysis yses for individual units, it can also record and evaluate partial cycles for each individual movement or sub-movement. All reports and errors are also recorded. That means process results can be evaluated in detail and sequences can be compared. With just a few clicks, piaOptimum shows which unit and partial movement has

changed and affected overall output. The tool also offers numerous standard analyses. The second decisive advantage, compared with competing products, is the simple configuration of all required data points via the software’s webbased user interface. That does not require any changes to the programmable logic controller (PLC) configuration. Instead, piaOptimum allows completely flexible data connection using the OPC-UA (United Architecture), the machine to machine communication protocol. Access is also flexible: data can be evaluated by service technicians on site, or accessed remotely. The raw data is also compressed so that it can be stored for long periods, while remaining comprehensible.

The software offers extensive functionality and allows specific data and analyses to be made available to different target groups – from production management and maintenance to system optimization. A plant knowledge database is available for use in troubleshooting and process optimization, so operating instructions for individual units can be saved along with internal notes.

Contact: www.piagroup.com

Mazak unveils its latest generation 5-axis machining centre SPECIAL EQUIPMENT In the United Kingdom, subcontract manufacturing provides the supply chain backbone for so many sectors of industry. With an increasing number of subcontractors diversifying their sector mix in recent years, the need for machine tools which can adapt to a variety of different applications, materials and batch sizes has never been greater.

With this in mind, the Integrex i-400S multi-tasking machining centre by Yamazaki Mazak, UK, is designed for higher performance machining and greater workpiece capacity than other multi-tasking machines in its size range.

The Integrex i-400S is designed The i-400S features a large 1,500 mm machining bed with for performance above any other machine in its size range a completely new design offering. At the heart of the machine is a 30 kilowatt (kW) 3,300 rpm main spindle, supported by a The integrated second spindle also reduces the amount of powerful 26kW 4,000 rpm second spindle. These combine to non-cutting time and set-up times, for further improved deliver the high-speed, high-accuracy machining of medium productivity. This ensures that the i-400S can be used across to large workpieces of up to Ø658 mm and 1,519 mm in length. small batch, prototype work in addition to volume producThe Integrex i-400S is equipped with SmoothX, the tion. According to Yamazaki Mazak, it is through these caworld’s fastest CNC, which not only contributes to im- pabilities that the machine is able to deliver outstanding proved cycle times, but can also reduce programming and productivity and performance above and beyond any othset-up times to provide unsurpassed productivity. er machine in its size range.

In addition, the Integrex i-400S combines the capabiliThe Integrex i-400S has been tailor made for subcontracties of a high-powered turning centre and full-functioning tors seeking diversification. It is recommended for automachining centre. It can produce a wide range of complex sport and automotive applications. components, from fully prismatic to round or highly conContact: www.mazakeu.co.uk toured parts, in one single set-up.

MPT International 1 / 2019

‹‹‹

TECHNICAL INNOVATIONS

49

Schoeller Werk adds a high-performance measuring machine to its quality department MEASURING EQUIPMENT Suppliers, particularly in the automotive industry, have to meet demanding requirements and quality demands before parts are allowed to go into mass production. With this in mind, Schoeller Werk of Hellenthal, Germany, which specializes in longitudinally welded stainless steel tubes, has added an efficient high-precision measuring machine to its quality department.

The STRATO-Apex 9106 by Mitutoyo is designed for the systematic recording of test and measurement results. The coordinate measuring machine (CMM) is used among others in the preliminary phases of the mass production of tubes including, among others, initial sample inspection to automotive standards. In addition, STRATO-Apex 9106 can also be used to ascertain shape and positional tolerance. Going forward, it will be more simple for Schoeller Werk to measure even the more complex tube geometries and proceed with its own calibration of testing equipment before it is used.

The new CMM makes it possible to achieve precise, reproducible results without user involvement. The STRATO-Apex 9106 not only performs extensive measurements of tube geometries but records the results systematically as well. The same also applies to the CRYSTA-Apex C 547 coordinate measuring machine, a smaller version that is used in production for a longer period of time. For Schoeller Werk, it made sense to purchase another CMM that is compatible with its existing machine and therefore opens up additional programming possibilities.

After corresponding programming, the CMM ascertains the necessary coordinates. In just one step, the measuring machine then calculates all the tube characteristics stipulated by customers in drawings or specifications, also including shape and positional tolerance.

The new CMM will also be used to calibrate testing equipment and is able to perform statistical process control (SPC) measurements to define tolerances and stipulate the performance capability of machines being used in tube production. A special calibration room has been set up in Schoeller Werk's Quality Department with constant ambi-

The STRATO-Apex 9106 by Mitutoyo is designed for the systematic recording of test and measurement results

ent parameters so that the measuring machine consistently produces exact results.

Contact: www.schoellerwerk.de

20 of the 20 Biggest Steel Manufacturers Trust in IMS

3D INSPECTION OF PROFILED MATERIAL 33 Combined shape measurement and 3D inspection 33 High resolution inspection of the entire surfaces

4000+ 690+ 60+

33 Automatic defect detection and classification (severity, position, geometric data incl. depth)

Measuring Systems in use World Wide

33 Cost savings through defect detection before further processing

Customers in

IMS – World Market Leader in Measuring Systems

Countries

→ More Information: www.ims-gmbh.de

MPT International 1 / 2019 IMS Messsysteme GmbH | Dieselstraße 55 | 42579 Heiligenhaus | Germany Phone: +49 2056 975-0, Fax: -140 | info@ims-gmbh.de | www.ims-gmbh.de

50

››› TECHNICAL INNOVATIONS

Precise machining of high-performance mass production parts SPECIAL EQUIPMENT When manufacturing large quantities of high-performance components – such a s for automotive applications or hydraulics and pneumatics equipment – one of the top priority issues is how to reduce cycle times in the mass production of complex parts.

DMG Mori, one of Germany's largest manufacturers of cutting machine tools, has designed its NZX 1500 and NZX 2000 turning centre-based multi-axis turning machines so that either can be equipped with up to three turrets, each of which comes standard with the milling function. The NZX machines are equipped for the high-efficiency machining of complex parts by utilizing the Y-axis function which can be mounted on all three turrets.

The NZX 1500 and NZX 2000 are designed with the innovative concept of handling an entire machining of complex parts on one machine. The NZXs incorporate a variety of features which, according to DMG Mori, can deliver unmatched efficiency and productivity in bar machining.

A BMT (Built-in Motor Turret), used for all the turrets, provides powerful milling, and the turtleneck structure employed on the Y-axis of Turret 2 ensures excellent chip disposal. Additionally, with a touch screen user interface CELOS, the NZX 1500 and NZX 2000 can flexibly handle any conceivable situation in every production process.

The NZX 1500 and NZX 2000 employ Spindle 2 as standard and provide a variety of specifications such as T type (with 3 turrets) and Y type (with a Y-axis). Because the machines offer flexible specification options, customers can select the ideal preferences according to their workpiece or production requirements for enhanced versatility on any production floor.

For the Y-axis feed structure of Turret 2, an ORC (Octagonal Ram Construction) is used to offer superior damping

The NZX 1500 and NZX 2000 are designed to reduce cycle times in the mass production of complex parts

performance and greater rigidity. The octagonal structure enables the slideways – which are located diagonally opposite each other – to generate heat evenly and offset thermal displacement. The thick and robust structure guarantees high-precision, chatter-free machining as well as a thermally stable high-speed feed.

Both Spindle 1 and Spindle 2 feature through-spindle holes of w61 (w2.4) mm on the NZX 1500 and w73 (w2.8) mm on the NZX 2000. For Spindle 1 of the NZX 2000, w91 (w3.5) mm is optionally available. In addition, the high-torque specification is offered as an option for both models and spindles to maximize each machine’s performance in bar machining.

The automatic complete machining of complex workpieces is also possible when the machines are used in combination with a loader, bar feeder or workpiece ejector.

Contact: uk.dmgmori.com

New Sinamics G120X converter series is optimized for SPECIAL EQUIPMENT Siemens has launched a brand new converter series. The converters of the new Sinamics G120X series have been optimized for use in pump, fan and heating, ventilation, and air conditioning (HVAC) applications. They are well-suited for infrastructure markets and industries; e.g. building control and water/wastewater environments.

With a power range of 0.75 to 630 kilowatts (kW), Sinamics G120X converters can be operated with any motor. The converters are at their most effective running with synchronous reluctance motors from Siemens. Sinamics G120X are configured throughout for cost-optimized and resource-saving operation across all voltages and supply networks, and their characteristic compact design saves space in the control cabinet. Although not featuring an additional output reactor, the converters enable motor cable lengths of up to 150 m. The integrated safety functions are certified to SIL3.

MPT International 1 / 2019

Siemens has launched a brand new converter series optimized for use in pump, fan and HVAC applications

‹‹‹

TECHNICAL INNOVATIONS

51

Leading Industry 4.0 players join forces to help accelerate digital transformation KEY EXHIBITION McKinsey & Company, SAP, Siemens and TÜV SÜD have announced a collaboration to support companies, both big and small, scale the adoption of Industry 4.0 technologies. The new initiative will launch at the Hannover Messe 2019 Singapore Economic Development Board (EDB), in Hannover, Germany (between April 1-5). The collaboration aims to develop tools and offerings that can accelerate the digital transformation of manufacturers in Singapore and internationally. This is achieved by leveraging the companies’ collective expertise, as follows: • EDB, the lead economic agency of Singapore, will focus on industry development and ecosystem building to transform its industries and create good job opportunities for Singaporeans, • McKinsey & Company, a leading global management consulting firm, will serve as a Knowledge Partner with its experience in helping companies undertake process redesign, technology road-mapping and organisational capability development, • SAP, a world leader in business software and digital technologies, helps manufacturing companies become more intelligent with end-to-end process agility and business innovation, • Siemens provides a holistic and industry-specific portfolio for the digital transformation of the discrete and process industries. It comprises automation as well as industrial software, communication, security and services including consulting over the entire lifecycle to help manufacturers to implement their individual digital transformation project, • TÜV SÜD, a global testing, inspection, certification and training company ensures that Industry 4.0 solutions are safe, secure and reliable.

The Smart Industry Readiness Index is the world’s first Industry 4.0 tool that enables the transformation of industrial sectors

In 2017, EDB and TÜV SÜD launched The Smart Industry Readiness Index (or ‘the Index’), a world-first Industry 4.0 tool developed by the Singapore Government to enable the transformation of industrial sectors, at both the enterprise and national levels. The Index has been substantially applied in Singapore and is being rolled out in Indonesia, Thailand, India, the USA, Europe and Japan.

As a next step, EDB, in collaboration with McKinsey & Company, SAP, Siemens, and TÜV SÜD, will enhance the Index with a computational tool that helps companies identify and recommend focus areas and digital initiatives.

These can be prioritized based on their individual readiness score and current financial performance.

This 'prioritisation matrix' will be launched at Hannover Messe 2019, alongside a white paper detailing its concept and development.

Contact: www.siemens.com

infrastructure applications The Sinamics G120X series offers outstanding ease of operation and is simple to commission using the Sinamics Smart Access Module and the IOP-2 operator panel. The converters can be selected and ordered using only a single purchase order number in the Siemens drive technology configurator.

Their integrated DC link reactor enables Sinamics G120X converters to run with the utmost stability under all network conditions. This robust, drip-proof new series comes in the form of a painted module as standard, with an additional 3C3 contaminant-resistant coating as an optional extra. A high C2 (optionally C1) Electromagnetic Compatibility (EMC) category and a protection rating of IP20 (optionally IP21 in UL open type) ensure the converter can be reliably used in any kind of industrial environment.

The converters are in compliance with all relevant EU energy-saving standards, and offer an operating efficiency level

of above 98%. There is a comprehensive range of integrated application-specific functions. They include Flux Reduction for adjustment in line with the actual load; Eco Mode which ensures best possible performance and minimal losses coupled with low dynamic loads and optimized output power; or Keep Running Mode which reduces speed prior to a shutdown.

Sinamics G120X converters can be linked to MindSphere – the cloud-based, open internet of things (IoT) operating system from Siemens – over Sinamics Connect 300, offering users the opportunity to analyze valuable operating data gathered from the converter, the drive train and the machine using the MindSphere app, Analyze MyDrives. Users can visualize and analyze status information, and glean valuable data for use as the basis for optimizing processes and maintenance strategies.

Contact: www.siemens.co.uk MPT International 1 / 2019

52

››› TECHNICAL INNOVATIONS

Fast and flexible fiber laser cutting machine SPECIAL EQUIPMENT LVD of Belgium has developed a topof-the-line fiber laser cutting machine for ultra-high-speed processing and high flexibility, including flexible automation. The Electra FL 3015 is designed to cut as fast as the thermal process allows, and is able to process a wide range of ferrous and non-ferrous metals, including copper and brass.

The system offers 2G acceleration during cutting, ‘on the fly’ cutting in light gauge materials and an IPG YLS fiber laser source with multiple kilowatt (kW) options - 6 kW, 8 kW or 10 kW - that are virtually maintenance-free. The system can process a maximum sheet size of up to 3,000 by 1,500 mm. Its other advantages include a high wall plug efficiency of 30% and an integrated automatic shuttle bed system.

LVD has equipped the Electra FL 3015 with a touch screen control and user interface, the Touch-L, which makes the system easy to set up and operate. The system can also be used with the compact tower (CT-L) automation that effectively keeps pace with the Electra’s high output.

The system utilizes CADMAN-L programming software that is designed to help operators realize the full potential of a computer numerical control (CNC) laser cutting machine. The software provides fully-automatic, semi-automatic or manual offline programming, including nesting, optimization of cutting and

Progress begins one step at a time MPT International 1 / 2019

machine parameters. The computer aided manufacturing (CAM) software provides the optimal technology parameters or offers the flexibility to configure the type and value lead-in/lead-out for different contours, depending on the material and thickness to be processed. A highly customizable graphical user interface (GUI) lets users of all skill levels achieve the best laser cutting results.

Contact: www.lvdgroup.com

An ultra-high-speed laser cutting machine with more power to process ferrous and nonferrous materials

LITERATURE SERVICE

‹‹‹

53

'New horizon': strategies for the markets of the 21st century 36 pages, English SMS group portrays its 'New horizon' offensive in this comprehensive brochure. Growing complexity, volatile markets and disruptive technologies demand new ways of thinking. SMS group focuses its core business - metallurgical plant and machinery construction - on challenges such a digitalization and the fourth industrial revolution. Interesting projects abound in extractive metallurgy, powder production and additive manufacturing as well as new digital products.

Contact: www.sms-group.com · Email: communications@sms-group.com

Top 10 innovations in measuring systems 16 pages, English IMS Messsysteme GmbH of Heiligenhaus, Germany, is a name to be reckoned with when it comes to surface inspection systems. This new brochure shows the current top 10 innovations currently brought to market by IMS, from force measuring systems to camera cluster systems, dimension measurements for slabs and heavy plates and more. The brochure juxtaposes the technological challenges on the client-side and the solutions developed at IMS. Contact: www.ims-gmbh.de · Email: info@ims-gmbh.de

Additive manufacturing at Deutsche Edelstahlwerke 8 pages, English Deutsche Edelstahlwerke (DEW), a part of Schmolz + Bickenbach Group, portrays its competence cluster for Additive manufacturing in this brochure. Using laser powder bed fusion, DEW is able to atomize and test powder alloys in a very short time according to customer specifications. More than 200 grades are already produced by powder metallurgy for use in the latest additively manufactured solutions and innovations.

Contact: www.dew-powder.com · Email: horst.hill@dew-stahl.com

Experts in powder metallurgy with wide product range 8 pages, English Metal powder technologies ranging from atomized aluminium and aluminium alloy powders to pure magnesium and its alloys and, of course, solutions for steel: mtec powder has it all. The brochure gives an overview of services and solutions offered in the areas of steel, hot metal desulphurization, steel desulphurization and secondary metallurgy.

Contact: www.m-tec-powder.com · Email: info@m-tec-powder.com

Portrait of a global authority in metals excellence 16 pages, English Primetals Technologies came about when Mitsubishi-Hitachi and SIEMENS VAI Metals Technologies joined forces in 2015. A globally operating enterprise with a world-class product portfolio was established. This brochure sets out to tell the story once more, detailing both the vast product portfolio and the technological legacy. As an interesting aside, some information on the company structure is also to be found.

Contact: www.primetals.com · Email: contact@primetals.com MPT International 1 / 2019

54

››› IN THE NEXT ISSUE...

EVENTS AISTech 2019 remains the steel industry’s premier technology event This year’s Iron & Steel Technology Conference and Exposition (Pittsburgh, USA, May 6-9) will feature technologies from all over the world that help steel producers compete more effectively in today’s global market. It is unmissable for gaining new perspectives on solutions and engineering expertise to power a sustainable steel industry.

CONTINUOUS CASTING 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).

ADVANCED MANUFACTURING Reduced handling thanks to new reel hole fixation robot from Tebulo For cold coiled steel coils with material thicknesses from 0.13 to 0.5 mm, the inner flap regularly drops down when it comes off the mandrel. Sometimes there is even the risk of coil collapse. After a successful feasibility study, Tebulo Industrial Robotics of Hamilton, Canada, has engineered a new reel-hole fixation robot for the steel industry.

This preview may be subject to change.

Metallurgical Plant and Technology

IMPRINT IMPRINT

MPT International is published by

Circulation: 6,000 copies

Maenken Kommunikation GmbH,

Peter Joerdell (Deputy Editor)

Phone +49(0) 22 03/35 84-120

Cologne/Germany.

Unit price:

Internet: www.mpt-international.com

see cover, plus forwarding expenses

Publishing House:

Publisher:

Wolfgang Locker, Phone +49(0) 22 03/35 84-182

(responsible for editorial, advertising,

Dr. Wieland Mänken

wolfgang.locker@maenken.com

production and circulation)

Phone +49(0) 22 03/35 84-0

peter.joerdell@maenken.com Advertising Team:

Katharina Flick, Phone +49(0) 22 03/35 84-136

Maenken Kommunikation GmbH Von-der-Wettern-Straße 25

Publication Manager:

51149 Cologne/Germany

Wolfgang Locker

www.maenken.com

katharina.flick@maenken.com Susanne Kessler, Phone +49(0) 22 03 / 35 84-116 susanne.kessler@maenken.com

Phone +49(0) 22 03/35 84-0

Editorial Team:

Fax +49(0) 22 03/35 84-185

Alex Manford (Chief Editor)

Print Shop:

Phone +49(0) 22 03/35 84-124

Griebsch & Rochol Druck GmbH

alex.manford@maenken.com

Gabelsberger Straße 1, D-59069 Hamm

Frequency: 6 x per year

MPT International 1 / 2019

PIONEERS AT HEART

KNOW-HOW FOR TOMORROW