MPT International 3/2019 (June)

Metallurgical Plant and Technology G 25074

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ISSN 0935-7254

June 2016 2019

KOCKS: On the way to a fully autonomous self-learning RSBÂŽ (page 42)

Deep Learning for Steel Quality Inspection at Tata Steel Ijmuiden (page 28)

Impressive performance for new slab caster at voestalpine (page 20)

DIGITALIZATION Visit us at

In times of rapidly changing markets, you want

METEC 2019

to optimize your plants to stay ahead. We

Hall 5, Booth E22

listen. We learn. We deliver: our automation and Digitalization specialists will help you implement learning mills that will boost efficiency, lower operating costs, and increase productivity. Whatever you envision, we will make it happen for you.

Leading partner in the world of metals

www.sms-group.com

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EDITORIAL

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How can we lower CO2 emissions and preserve resources? How can we digitalize work processes in a meaningful way? How can we utilize artificial intelligence? What possibilities does additive manufacturing offer? The steel industry is dealing with technological questions, as well as with economic challenges such as trade wars, Brexit and excess capacities. The timely discovery of suitable solutions will be a deciding factor in determining the sustainability of the industry.

This development is also reflected in the topics we’ve chosen for this issue.

Artificial intelligence is one of the big - though still somewhat vague - drivers of innovation in the industry. Tata Steel explains how exactly Deep Learning is being used for quality control, while an interview with Marcel Fasswald, CEO of thyssenkrupp Industrial Solutions, sheds some light on the role of digitalization in the world of large-scale plant construction. The question of what changes plant manufacturers can expect as a result of digitalization is being examined in a study conducted by the VDMA.

Torsten Paßmann

Danieli and voestalpine describe how the steel manufacturer’s factory in Linz put its new CC8 Slab Caster into operation and how it performs; Andritz talks about the fluid flows of industrial furnaces with the help of Computational Fluid Dynamics; and ArcelorMittal, Salzgitter and ABB discuss current projects designed to support climate protection.

Additive manufacturing opens up new worlds. The company Deutsche Edelstahlwerke takes a closer look at the specific possibilities goods “made with a printer” can offer, while Fraunhofer presents a research project about superalloys in the additive manufacturing process.

More answers and solutions regarding the questions we asked in the beginning can be found at the METEC in Düsseldorf and at the 4th European Steel Technology and Application Days (ESTAD), which both take place at the same time.

In an interview with Dr Hans Bodo Lüngen from the Steel Institute VDEh, he talks about what we can expect from this year’s two industry highlights.

We will continue to monitor these exciting developments - in our editorial office as well as on location.

On this note, we hope you’ll enjoy your reading experience. Maybe we’ll see each other in Düsseldorf. We’d be delighted!

Torsten Paßmann Chief Editor, MPT International

MPT International 3 / 2019

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››› CONTENTS

Events 15 METEC and ESTAD: Interview with Dr. Hans Bodo Lüngen, Steel Institute VDEh What can the participants of the "European Steel Technology and Application Days (ESTAD)" expect?

Dr. Hans Bodo Lüngen gives an outlook.

Steelmaking – Metallurgy 20 Impressive start and performance for new slab caster at voestalpine Stahl GmbH Danieli and voestalpine describe the project of planning and commissioning the new slab caster CC8 at the Linz steel mill.

COVER STORY: KOCKS RSB® 5.0 and 4D EAGLE® profile measurement system currently operating in China.

Contact: Kathrin Dahmen Email: marketing@kocks.de

QUALITY INSURANCE 28 Deep Learning for Steel Quality Inspection at Tata Steel IJmuiden Tata Steel and BrainCreators have been exploring the transformation of the steel industry by taking the latest deep learning techniques from the academic world and applying it to real-world production systems.

Steelmaking – Metallurgy 36 Complex numerical flow simulation of industrial large-scale furnaces using Computational Fluid Dynamics Computational Fluid Dynamics (CFD) can be a powerful tool for investigating the effects of heat transfer mechanisms. For this article, a detailed CFD model of a large-scale walking beam furnace was developed by Andritz.

Reducing and Sizing 42 Reducing and Sizing Blocks ensure increased Production Friedrich KOCKS has been remarkably successful in China: Sixteen special steel companies have ordered new Reducing & Sizing Blocks in 5.0 design in the past two and a half years. What is the secret of this success?

Additive Manufacturing 46 Printing ongoing, steel component coming Deutsche Edelstahlwerke has investigated the use of additive manufacturing for medical applications, aviation and the automotive industry.

MPT International 3 / 2019

50 Additive machines discover superalloys Scientists at the Fraunhofer Institute for Material and Beam Technology IWS in Dresden have developed innovative methods enabling more materials to be processed in additive manufacturing than ever before.

Digitalisation

Climate Protection

52 Benchmarking study forecasts significant market changes

56 Going Green

In the course of ongoing digitalization, the construction of large-scale plants is facing significant market changes. This is the core result of a benchmark study by the VDMA Large Industrial Plant Manufacturers’ Group (AGAB) and PwC Capital Projects & Infrastructure.

54 Interview with Marcel Fasswald, CEO of thyssenkrupp Industrial Solutions The Chief Executive Officer of thyssenkrupp Industrial Solutions Marcel Fasswald talks about current opportunities and challenges and about what large companies can learn from startups.

Steel producers and plant builders are investing in new methods and technologies to reduce CO2 emissions and save energy. In this article we look at three examples of ArelorMittal, Salzgitter and ABB.

Columns 6

International industry news

60 Technical innovations 62 In the next issue 62 Imprint

Advertiser’s index ABB 34 AIC 41 Asmet 12 BM 53 Braun 53 Combilift 35 DMT GmbH & Co. KG 55 Eirich 61 Eredi 13

Friedrich Kocks 27 Frigor 48 Küttner GmbH 58 Lechler GmbH 17 Maschinenfabrik Gust 47 Nextsense 39 Nuova Carpenteria 49 Polytec GmbH 59 Redecam Group 31

SMS group GmbH 2 Stein 57 TML 33 TMT 63 Velco 51 Venti Oelde 9 Vesuvius 45 Wurth 64 Zumbach 25

MPT International 3 / 2019

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››› INTERNATIONAL INDUSTRY NEWS

Americas Mexico Recently, Mexican steel producer Altos Hornos de Mexico, S.A.B. de C.V. (AHMSA) issued the Final Acceptance Certificate (FAC) for a twin RH vacuum degassing plant supplied

by Primetals Technologies. The 150ton RH plant was installed in AHMSA´s converter Steel Works # 2 in Monclova.

It is able to handle 50 charges per day, the equivalent of about two million metric tons of liquid steel per year. The RH plant is operated with a dry mechanical pump solution. This saves operation costs and increases flexibility for integration in the production process. A space-saving combined vessel ladle lifting system (CVL) is also part of the RH plant. The new plant allows AHMSA to produce steels with very low hydrogen content, required for applications in the oil and gas industries.

USA Nucor Corporation orders water-treatment plants from Danieli. The two new water-treatment plants will complete the MI.DA. minimill projects being supplied by Danieli at Nucor Sedalia (Missouri) and Nucor Frostproof (Florida). Each MI.DA. plant has indirect cooling circuits of about 4,000 m3/h for EAF, FTP, CCM, and direct-cooling circuits of about 1,400 m3/h for caster and rolling mill. The selected technologies comply with Nucor’s request for minimised civil-construction cost and time, easy and fast erection, reliable and flexible operations, and high-level process control.

Zero-scale pits reduce 900 cubic meters of civil construction related-costs, avoiding the usual large and deep underground pits for settling mill scale.

Installing just three DanFilter™ units ensures high-quality water circulation.

Containerised electrical cabins and package cooling towers are preassembled before delivery, ready to connect.

Asia Primetals Technologies receives first SRD segment slab caster order in China from Angang Iron & MPT International 3 / 2019

Steel. Chinese steel producer Angang Iron & Steel Group Co. (Angang) has placed an order with Primetals Technologies to modernize a continuous slab caster at its Anshan plant. The modernized caster will replace the existing CCM 1 in its steel works No. 1.

The objectives of the project are to improve the slab quality for use in the subsequent plate mill and to increase maximum slab thickness from 300 to 360 millimeters. Furthermore, flexibility will be improved by installing SRD segments in the horizontal strand guide, which marks the first application of SRD (Single-Roll DynaGap) segments in a caster in China. The modernisation is scheduled for completion in the third quarter of 2019. The “Connect & Cast” principle, based on preconfigured and pretested packages forms the basis for a fast plant start-up.

Europe ArcelorMittal prepares to further reduce primary production in Europe. Further to the announcement made on 6 May, ArcelorMittal announced its decision to take additional steps to adjust its European production levels to further align its production to the current market demand.

The company continues to be impacted by weak market demand and high import levels in Europe. As a result, ArcelorMittal will reduce primary steelmaking production at its facilities in Dunkirk, France and Eisenhüttenstadt, Germany; reduce primary steelmaking production at its facility in Bremen, Germany in the fourth quarter of this year, where a planned blast furnace stoppage for repair works will be extended; extend the stoppage planned in the fourth quarter of this year to repair a blast furnace at its plant in Asturias, Spain. Commenting, Geert van Poelvoorde, CEO, ArcelorMittal Europe – Flat Products, said: “This is again a hard decision for us to have taken but given the level of weakness in the market, we feel it is the prudent course of action. This will be a temporary measure that will be reversed when market conditions improve. In the meantime, our employees remain our utmost priority and we are doing everything we can to ensure that the right social measures are in

place to support them and their families during this difficult time.”

Belgium The largest turbines installed so far in the Belgian North Sea are based on steel from Dillinger: At water depths of 22 to 36 meters, the 55,000 metric tons of thermomechanically rolled heavy plate in the form of monopile foundations weighing up to 1,250 metric tons ensure that the Rentel offshore wind farm is standing securely. The wind farm is located about 40 km north of Ostend in the Belgian part of the North Sea and covers an area of 22.72 km². It consists of 42 wind turbines with an output of 7.35 MW each. Heavy plate from Dillinger (1,150 tons of thermomechanically rolled plate in thicknesses from 30 to 100 mm) is also contained in the monopile foundation of the farm’s electrical substation.

Czech Republic Heinrich Georg Maschinenfabrik has received an order from Vítkovické Slévárny, spol. s r.o. for the supply of a roll lathe, the third lathe so far supplied by GEORG to the Czech roll manufacturer. The new machine will be linked with one of the existing lathes. Thanks to this solution, only one operator will be needed to control both machines. With the new machine, Vítkovické Slévárny will expand the capacity of its facilities in Ostrava, where two other GEORG roll lathes of the ultraturn series have already been in operation for several years. The new machine will be virtually of the same design as the machine supplied in 2013.

Germany In the first quarter of 2019, Germany exported 43.8 billion euros in machinery. This is 2.1 percent more than in the same period last year (42.9 billion euros). Exports to the largest single market, the USA, continued to grow strongly at 10.4 percent. "On the other hand, the uncertainty of our customers caused by the US trade sanc-

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INTERNATIONAL INDUSTRY NEWS tions leaves unmistakable traces", said Dr. Ralph Wiechers, Chief Economist of the VDMA. Exports of goods to the Middle Kingdom increased by only 0.4 percent year-on-year. Exports to the EU-28 also performed comparatively well, rising by 3.9 percent. The EU countries account for a total of 48.7 percent of German machine exports.

Exports to Sweden and Hungary grew at double-digit rates of 10.4 and 11.9 percent respectively. But exports to France - traditionally the most important partner within the EU - also increased significantly (plus 9.6 percent).

Trade with the southern EU states was also very pleasing for the industry: Greece, Portugal and Spain (plus 41.9; 13.9 and 8.5 percent respectively).

New passenger car registrations in Germany maintain high level in April. The German passenger car market proved buoyant again in April.

New registrations totaled 310,700 cars, thus maintaining a high level (-1 percent). Year-to-date registrations of passenger cars come to 1.2 million, which equals last year’s result. Domestic incoming orders made a significant yearon-year gain last month. German customers ordered 12 percent more passenger cars than they did in April 2018. Since January this year 8 percent more orders have been received from domestic customers. By contrast, the German OEMs received 4 percent fewer orders from abroad this April. After the first four months of 2019, the accumulated result was 7 percent down on last year. Economic uncertainty in some European countries – due to Brexit in particular – has held back demand since the beginning of the year, and has, above all, impacted domestic passenger car production. The German auto makers built 414,300 cars in April (-15 percent). Total production since January comes to 1.7 million units (-12 percent). Last month, 305,800 brand new cars were supplied to customers around the globe (-23 percent). So far this year 1.3 million vehicles have been exported (-14 percent).

Poland thyssenkrupp’s Industrial Solutions business area has received a new order for the construction of a fertilizer plant

in Poland. The customer for the project is ANWIL, a subsidiary of PKN ORLEN, one of the largest oil industry corporations in Central and Eastern Europe from Poland. The new facilities for the production of 1,265 metric tons of nitric acid and 1,200 tons of ammonium nitrate per day will be located in Wloclawek, some 200 km northwest of Warsaw, at an existing chemical and fertilizer complex. thyssenkrupp’s patented EnviNOx process will be used to remove green house gases from nitric acid production.

Portugal SMS group has been chosen by MEGASA GROUP for the supply of a new walking beam furnace to be installed in the existing bar mill of SN Seixal Siderurgia Nacional S.A. in Aldeia de Paio Pires, Portugal. The new furnace, rated at 160 tons per hour cold charged and 210 tons per hour hot charged, will include the latest technological packages developed by SMS group. Start-up is scheduled for the end of summer 2020. In particular, MEGASA banks on the SMS Prometheus Level 2 system, the SMS DigiMod combustion management system and SMS ZeroFlame burners. The combination of these three features installed on the sturdy and reliable structure of the SMS furnace will ensure outstanding performance in terms of reductions in fuel consumption, scale formation and pollutant emissions.

Russia Tenova LOI Thermprocess receives follow-up order for HPH® Bell-Type Furnace Plant for Wire Coils by OJSC MMK-METIZ. The company located in Magnitogorsk, Chelyabinsk region, already operates a HPH® Bell-Type Furnace Plant supplied

by Tenova LOI Thermprocess in 2014.

This plant consists of 2 annealing bases, 1 heating hood and 1 Jet-cooling hood with a maximum net charge weight of 36 tons of wire rod or drawn wire coils. In the spring of 2019, a new contract was signed concerning the expansion of the existing plant by a further 2 annealing bases, 1 additional heating hood and 1 Jet-cooling hood.

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News in brief thyssenkrupp Elevator has acquired the Elevator division of Nashville Machine Company. Formerly the exclusive distributor in the Middle Tennessee area for thyssenkrupp Elevator, Nashville Machine Elevator (NME) has 130 employees, all of which will be given the opportunity to join thyssenkrupp.

Daehan Steel Co., Ltd. has awarded SMS group an order covering the completion of the rebar rolling mill in its Pyeongtaek plant. The new equipment will allow Daehan to bundle rebars in small and main packages. Starting material will be billets 130 and/or 150 millimeters square with a length of 12 meters in low and medium carbon grades.

Chinese steel producer Jiangsu Shagang placed an order with Primetals Technologies to install automatic tapping system on two BOF converters in its converter steelworks in Zhangjiagang in Jiangsu Province. This modernization project marks the first commercial implementation of Primetals Technologies´ Automated Tapping system in a steelworks.

Dillinger and Saarstahl are taking a new approach to reducing carbon emissions and are for the first time using hydrogen in the two blast furnaces of ROGESA Roheisengesellschaft Saar mbH (ROGESA). An investment volume of €14 million will be used for an innovative system that significantly reduces carbon emissions at the Dillingen site.

EVRAZ North America, a producer of engineered steel products for rail, energy and industrial markets, has chosen Danieli to supply its new rolling mill for the production of 100-meter-long premium-quality rails. To be built in Pueblo, Colorado, with a production capacity of 670,000 short tons, it will be the most modern rail rolling mill in North America.

MPT International 3 / 2019

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››› INTERNATIONAL INDUSTRY NEWS

The start of production of the new plant is scheduled for the beginning of 2020.

Serbia Primetals Technologies has received an order from HBIS Group Serbia Iron & Steel LLC (HBIS Serbia) to replace BOF converter #2 at its production site in Smederovo, Serbia.

The aim of the project is to improve the process and to raise production capacity. This will be achieved by increasing the converter vessel´s shell volume. At the same time, the critical outer dimensions will remain the same, so that adjacent interfaces may be kept. Modifications of the BOF pedestal or revamping of civil works are not required. The new converter will have a tapping weight of 105 metric tons and will receive, among other equipment, a Vaicon Link 2.0 suspension system and a new tilting drive. Start-up is expected for the second quarter of 2020.

Slovakia International technology Group ANDRITZ has received an order from Elektro Recycling s.r.o. to supply a Universal Cross-Flow Shredder QZ for their refrigerator recycling plant in Slovenská Lupča, Slovakia.

Start-up for the new equipment is planned for the third quarter of 2019.

It will replace the existing Cross-Flow Shredder QZ2000 supplied by ANDRITZ in 2006. After the upgrade, Elektro Recycling will be capable of processing up to 90 refrigerators per hour with the larger QZ2500. No cutting tools are needed at the shredder – the machine breaks down the input material quickly and gently using rotating chains so that the individual fractions are exposed and can be separated easily from one another.

United Kingdom British Steel is still open for business. To protect the future of British Steel Limited, the Company was placed into compulsory liquidation on 22 May 2019. The High Court appointed the Official Receiver as liquidator of the MPT International 3 / 2019

Company on the petition of the Company’s directors. Simultaneously, the Court also appointed S J Woodward, R H Kelly and A M Hudson as Special Managers to support him. The Company continues to trade as normal under the control of the Official Receiver whilst a sales process is undertaken to find a new owner for the business. The Company’s subsidiaries including British Steel France Rail SAS, FN Steel BV, Redcar Bulk Terminal, The Steel Company of Ireland Limited, TSP Projects Limited and TSP Engineering Limited are not in insolvency and are continuing to trade as normal.

development overall in the first quarter of 2019. Order intake amounted to just under 1.7 billion euros and was thus approximately 8% higher than the previous year’s reference period.

Sales and EBITA each increased by around 15%. From today’s perspective, the ANDRITZ GROUP continues to expect a significant increase in sales for the 2019 business year compared to the previous year. The main reasons for this are the continuing positive trend in orders and the resulting high order backlog as of the end of March 2019 as well as the sales contributions made by the companies acquired in 2018.

Companies

JFE Steel Starts Mass Producing JATT® High-strength, High-elongation Steel Sheet for Packaging Applications. JFE Steel announced that it has begun mass producing its new JATT® (JFE Advanced Thin-gauge Tin-mill Products). The company used its proprietary materials design expertise to develop JATT, which achieves both an excellent elongation of up to 20% relative to the average of 3~5 % of conventional DR (“Double cold-Reduced”) steel sheet and the same level of strength as DR steel sheet. JATT improves formability in the can making process and contributes to the gauge reduction of can products. JFE Steel begins full-scale supply of JATT steel sheets to a wide range of customers in the near future.

Acerinox obtained profits totalling 33 million euros in the first quarter of 2019 after taxes and minority interests, a figure which represents an increase of 103% compared with the fourth quarter of 2018 and a fall of 44% in relation to the first quarter of 2018. Chief Executive Officer Bernardo Velázquez states that “stocks in Europe and the United States are at reasonable levels, according to the information available, and we expect imports to remain under control in both regions”. The Group’s turnover (1,202 million euros) rose by 6% with respect to the previous quarter and fell by four percentage points in comparison with the same period of 2018.

AK Steel reported a net loss of $4.5 million, or $0.01 per diluted share of common stock, for the first quarter of 2019, which included a $77.4 million charge for the Ashland Works closure. Excluding this item, adjusted net income was $72.9 million, or $0.23 per diluted share, for the period. For the first quarter of 2018, net income was $28.7 million, or $0.09 per diluted share. “Our solid first quarter operating performance benefitted from our annual customer contract renewals. A higher proportion of contractual sales helps to reduce the volatility in our business and this was reflected in our first quarter results,” said Roger K. Newport, Chief Executive Officer.

International technology Group ANDRITZ saw satisfactory business

Jindal Stainless registered an increase of 6% in its net revenue for the sequential quarter, up from Rs 2,333 in Q3FY19 to Rs 2,361 in Q4FY19.

EBIDTA and PAT in Q4FY19 stood at Rs 217 crore and Rs 66 crore, growing by 8% and 19% respectively. Encouraged by stainless steel demand from railway, metro, and value added segments like blade steel, precision strips, and coin blanks, JSHL continued to maintain its top line, despite challenges in export markets amid increased trade protectionism across the globe. Managing Director, JSHL, Mr Abhyuday Jindal said, “JSHL is India’s only producer of specialized grades of stainless steel products. These offerings, coupled with augmented domestic stainless steel demand, helped the company maintain its revenue despite challenging macroeconomic situations.”

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INTERNATIONAL INDUSTRY NEWS

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Kaman UK have invested over £1m in a new chemical treatment line which will deliver surface treatment techniques to the aerospace industry. Christopher Morris, Kaman UK’s Managing Director sees the new chemical treatment line as an excellent addition to the existing production processes. He said: “This is a significant stage in the development of the Darwen site which will bring extensive benefits to our customers. There is a huge demand for treatments capability in the industry and this line will deliver an efficient and cost-effective solution.” The new line is computer controlled with fully automated loading, immersion and transfer capabilities through the 3ft, 5ft and 8ft baths.

HEAVY METAL

Klöckner & Co SE reports lower earnings in first quarter of 2019. Klöckner & Co reports price-driven sales growth of 4.6% to €1.7 billion in the first quarter of 2019.

Operating income (EBITDA), at €34 million, was below the €56 million recorded in the first quarter of 2018. While Klöckner & Co benefited from a very positive price environment in the first quarter of the prior year, earnings in the first three months of fiscal year 2019 were impacted by negative price effects. Demand was also down, primarily due to the weakness of the European automotive sector.

Compared with net income of €21 million in the prior-year quarter, the net loss amounted to €10 million. As a result, earnings per share were €-0.10 (Q1 2018: €0.21). Digitalization of the supply and value chain as well as expansion of the XOM Materials independent industry platform are core components of the “Klöckner & Co 2022” strategy. The proportion of sales generated through digital channels further increased to 27% in the first quarter of 2019 (Q1 2018: 19%).

LEHVOSS commissions new laboratory and pilot plant building. The relocation of major laboratory and pilot plant facilities to the new laboratory building at the Hamburg-Wandsbek site has now been successfully completed ahead of schedule. A total of more than € 4.5 million has been invested in the new building, which is equipped with state-of-the-art laboratory and pilot plant facilities and modern building services. These facilities are used for quality testing of raw materials and sales products, for the development of our own products and for formulation development based on our products as support for our customers.

“Since its foundation, Lehmann&Voss has paid great attention to maintaining a high level of expertise in its business units and to marketing products tailored to the individual customers”, explained Managing Partner Dr Thomas Oehmichen.

Outokumpu and CG Gruppe AG have signed an agreement regarding the sale of Outokumpu’s real estate in Benrath, Germany. The value of the transaction is EUR 90 million. The deal is expected to be closed in the third quarter and the cash proceeds will be used to reduce debt. The positive impact on EBITDA from the transaction is expected to be approximately EUR 68 million which will be reported as an adjustment in the third-quarter results. The sold land has been unused since 2016 when Outokumpu closed its cold rolling operations in Benrath as part of the restructur>> ing of the company’s European operations.

MPT International 3 / 2019

MADE IN GERMANY

Phone: +49 2173 9575-100 Fax: +49 2173 9575-400 eMail: info@tml-group.biz www.tml-group.biz

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››› INTERNATIONAL INDUSTRY NEWS

Outotec has sold its fabrication and manufacturing businesses in South Africa and Mozambique to SPS Holdings Company. The transaction has become effective as of June 1, 2019.

The parties have agreed not to disclose the acquisition price. The South African facility in Brits serves primarily ferrochrome plants and the Mozambique facility provides services and spare parts for the aluminum industry.

The combined annual sales has been approximately EUR 15 million. Majority of the 255 employees are working in fabrication and manufacturing and will transfer as old employees.

SCHMOLZ + BICKENBACH with lower EBITDA in a challenging first quarter. The Sales volume increased according to the company to 551 kilotons from 545 kilotons in Q1 2018; additional volumes from Ascometal level out reduced demand. The adjusted EBITDA of EUR 42.2 million was lower than in Q1 2018 at EUR 70.3 million. Net debt increased to EUR 752 million from EUR 655 million at year end 2018; this was due to seasonally higher working capital and the firsttime adoption of IFRS 16, which contributed EUR 59 million to the increase. For 2019 SCHMOLZ + BICKENBACH expects an adjusted EBITDA between EUR 190 million and EUR 230 million. CEO Clemens Iller commented: “As expected, the start to the 2019 financial year was restrained.

After a significant decline in business activities towards the end of last year, the dip in growth in our sales markets continued in the first three months.

There are no clear signs of a rapid recovery in the current low demand, particularly from the European automotive industry.”

Stalatube’s new stainless steel production facility in Poland is preparing for ramp-up. Stalatube’s new production facility manufacturing stainless steel tubes in special dimensions and further processed stainless steel products, is moving into ramp-up phase. This investment in Lodz, Poland, together with the new production line in Finland, will enhance the company’s competitiveness through capacity increase and significantly shortened delivery times and a closer reach especially to central EuroMPT International 3 / 2019

pean markets. The investment sum in total is 20 million Euro. The investments increase Stalatube’s production of tailored sized I-beams and further processed products, such as stainless steel hollow sections, both of which are intended for demanding structural end-uses. The production of pre-fabricated components for the growing transportation sector will also be expanded.

The Salzgitter Group generated earnings before taxes of € 125.9 million in the first quarter of 2019 (Q1 2018: € 95.9 million). Along with the very satisfactory pre-tax result of the Strip Steel Business Unit, all other business units and the participating investment in Aurubis AG, a company included at equity, contributed to the positive start to the year. “We can look back on the best first quarter since 2008 with a result that was also better than expected at the turn of the year due to accounting-related effects. Key stimulus determining the steady uptrend in the last five years has been derived from the successful implementation of our own measures. We therefore have every reason to be confident. We will continue to forge ahead in a focused manner in the future as well,” states Chief Executive Officer Prof. Dr.-Ing. Heinz Jörg Fuhrmann.

Sandvik Board of Directors has decided to initiate an internal separation of the business area Sandvik Materials Technology. The intention is to increase Sandvik Materials Technology’s structural independence from the Sandvik Group and thereby put greater focus on the business’ future development possibilities as well as create flexibility. The Board of Directors has also decided to explore the possibility of a separate listing (Lex Asea) at the Nasdaq Stockholm Exchange, which should strengthen Sandvik Materials Technology’s position and future development. “The decision to initiate an internal separation of Sandvik Materials Technology is based on the board’s belief that each part will develop more favorably by itself, increasing opportunities for profitable growth and improving long-term shareholder value,” says Johan Molin, Chairman of the Sandvik Board of Directors.

PAO Severstal has announced that it has entered into a definitive agreement with Abinsk Electric Steel Works LTD for the sale of Mini-Mill Balakovo. The consideration of the transaction will be $215 million. The transaction is expected to complete in first half of 2019 following the receipt of approvals and other standard conditions. Alexander Shevelev, CEO of Severstal, commented: “Following the sale of Mini-Mill Balakovo, we plan to focus on developing steel production at our main asset, the Cherepovets Steel Mill. We are confident that this will enable us to streamline our internal processes to successfully execute our updated strategic priorities successfully.”

Supervisory Board of thyssenkrupp AG confirms new strategy.

The Supervisory Board of thyssenkrupp AG approved the Executive Board's plans for a fundamental realignment of the company. Martina Merz, Chairwoman of the Supervisory Board of thyssenkrupp AG: "The Supervisory Board today unanimously approved the proposed realignment of the Group. We have agreed that the Executive Board will now work out the concrete plans and begin the implementation. As the Supervisory Board, we are convinced that the Executive Board is on the right track with the new strategy. This enables us to meet the interests of employees, customers and shareholders equally." Guido Kerkhoff, Chief Executive Officer of thyssenkrupp AG: "With the approval of the Supervisory Board, we can now tackle the strategic realignment. The new strategy focuses on the economic success of our businesses. With the IPO of the elevator business, we are strengthening our capital base so that we can press ahead with the further development of the individual companies within the Group." The Executive Board and Supervisory Board have also agreed on a timetable for the implementation of the new strategy. thyssenkrupp will provide further details of its strategic realignment with the publication of its quarterly figures in August 2019. voestalpine opens high-tech steel research facility in Donawitz. At its pilot facility in Leoben-Donawitz, Austria, voestalpine is now conducting research into the production of new high-performance steels which are sub-

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INTERNATIONAL INDUSTRY NEWS sequently processed into special rails, quality rod wire, and extremely high-resistant OCTG by the Group’s companies in Styria. Over EUR 18 million has been invested in the “Technikum Metallurgie” (TechMet), a metallurgy technical center, which is a complete but miniature steel plant. It represents the largest research investment at this site to date. It will further extend voestalpine’s global technological leadership in sophisticated product solutions in steel. In the automotive industry new and ultra high-strength steels are helping to reduce vehicle weight whilst simultaneously increasing vehicle safety. In rail transport highly stress-resistant high-tech steels can almost double the service life of rails and turnouts. Together with increased track availability, reductions in material input also have a positive impact on the life cycle assessment.

Personalities Franck Adjogble and Wolfgang Spies, both SMS group engineers, received the AIST James Farrington Award 2019 in Pittsburgh, Pa., USA, for their work entitled “Holistic Approach of High Quality Flat Steel Production – Dynamic Production Scheduling in Respect to Process Quality, Control System and Plant Condition”. The AIST James Farrington Award was established in 2005 to honor James Farrington, founder and first president of AISE and his vision for iron and steel companies to join together, present papers, share mutual problems and set standards for the improvement of electrical machinery and processes. The award was presented to the author of the paper Franck Adjogble, and Co-Authors Harald Rackel, Gregor Schneider, Klaus Pronold, Wolfgang Spies, Hans-Georg

Franck Adjogble and Wolfgang Spies

Jentsch. The paper was judged by the Electrical Applications Technology Committee to be the best technical paper submitted for the AIST conference.

The Steel Division of the voestalpine Group supplies its customers around the world with steel products from its base in Linz. Following former Technical Director Hubert Zajicek’s recent appointment as the new Chairman of the division’s four-member management team, succeeding Herbert Eibensteiner who replaces CEO

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Solutions business area. With his understanding and engagement in the business area’s strategy and action plans I trust that he will ensure a solid performance of the divisions in different market situations,” says Björn Rosengren, Sandvik’s President and CEO. POSCO CEO Jeong-Woo Choi was appointed as the new executive committee member of the World Steel Association (worldsteel) during its annual meeting held in Madrid, Spain. The Executive Committee is worldsteel’s top decision-making body setting the path for the organization’s core activities regarding steel promotion, product development, and environmental sustainability. Altogether 13 members serve under the committee. The appointment process of a new Executive Committee

Helmut Gruber

Wolfgang Eder and assumes the chairmanship of the Group as a whole as of July 3, now the future Technical Director who will take his place in the steel management team has been selected: Helmut Gruber (47), who is currently responsible for the technical management of strip production, will take on the overall technical management from Hubert Zajicek on July 3, 2019, advancing to join the Management Board of voestalpine’s largest division in terms of revenue. Helmut Gruber (47), from Upper Austria, began his career with an apprenticeship as an industrial electrician. At the same time he completed part-time studies in electrical engineering at a polytechnic before joining voestalpine Stahl GmbH in Linz as an industrial engineer in 1997.

Lars Bergström, currently Senior Strategy Advisor and Vice President Sandvik Machining Solutions, has been appointed Acting President of Sandvik Machining Solutions as of 1 July 2019. Lars Bergström will have full responsibility for the business area and he will be a member of the Sandvik Group Executive Management. “Lars Bergström is truly one of our most experienced leaders.

I’m confident that he at this point is the best to manage the Sandvik Machining

Jeong-Woo Choi

member follows: the five-membered Nominating Committee first makes recommendations. The nominated candidates then undergo the voting processes by the Executive Committee and the Board of Directors. Once appointed, the members serve a three-year term.

Liberty Steel USA, part of Sanjeev Gupta’s global GFG Alliance, has made two key management appointments as it continues its expansion in the USA. Revansidha ‘Rohit’ Gulve, who led the successful reopening of Liberty Steel Georgetown in South Carolina last summer, is moving from his role as general manager there to become general manager at the larger Liberty Steel Peoria in Illinois.

Both mills are major producers of wire rod, a product in which Liberty is aiming to become a US market leader over the coming year. Liberty reopened the shuttered Georgetown mill in summer 2018 and acquired the Peoria site along with several downstream steel assets >> MPT International 3 / 2019

››› EVENTS

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Baan, CEO of Outokumpu have been elected as Vice Chairmen. Clemens Iller of Schmolz+Bickenbach has been elected as Treasurer.

Revansidha ‘Rohit’ Gulve

from KCI in January 2019. Pending the appointment of a permanent replacement at Georgetown, Liberty has engaged highly-experienced international steel executive Marcio Van der Put as acting general manager. Mr Van der Put ran the South Carolina mill under previous owners ArcelorMittal for three years up until 2009 before taking up senior posts with the firm in Brazil, most recently as chief technology officer for long products in that country.

The International Stainless Steel Forum (ISSF) has elected new office bearers during the 23rd Annual Conference. Bernardo Velázquez, CEO of the Acerinox Group has been elected Chairman of the International Stainless Steel Forum. Hitoshi Ito, Representative Director and President of NIPPON STEEL Stainless Steel Corporation, Timoteo Di Maulo, CEO of Aperam Group, Tak Jeong,, Senior Executive Vice President of POSCO and Roeland

ID 114119252 © Eyewave | Dreamstime.

conducted research in various fields of powder metallurgy. He contributed significantly to the development of the institute into one of the leading application-oriented research institutes in the field of powder metallurgy technologies and materials.

GALVATECH 2020

announcement

Important Dates Abstract submission: September 15, 2019 Notification of acceptance: November 1, 2019 Full paper Submission: January 17, 2020

MPT International 3 / 2019

Dr. Thomas Weißgärber

Lighter, Stronger, Durable: Advances in Zn-Coated Steel Sheet

© SKB, Fotograf A. Koller

1

st

Dr. Thomas Weißgärber has taken over the provisional management of the Dresden branch of the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM. He takes over the responsibility of Prof.

Bernd Kieback, who has been head of the institute for many years and has now retired. Dr. Thomas Weißgärber, a long-time employee of the institute's division, is now at the controls. During his career as group and department head and most recently as deputy head of Fraunhofer IFAM Dresden, he has

Andreas J. Goss leaves thyssenkrupp Steel. The cancelled merger between thyssenkrupp Steel Europe and Tata Steel Europe not only leads to corporate changes at Group level, but also to the Management Board. Andreas J. Goss, who has been the CEO of the steel division of thyssenkrupp since June 2014, will be leaving the company. The first media reports that his contract will be terminated started to appear in the last week of May. When asked for their comment, thyssenkrupp's Corporate Communications stated that, following the cancellation of the envisaged joint venture with Tata , it was now a matter of "setting up thyssenkrupp Steel Europe for the future". In this regard, "discussions are currently underway with Mr Goss on the termination of his contract", with the final outcomes "subject to the approval of the competent bodies". After completing his studies in business administration in Regensburg and Birmingham, Andreas J. Goss, born in 1964, can look back on a professional career built in two groups of companies. He joined Siemens Components in the USA as a financial analyst in 1994. Other positions in Siemens included Chief Financial Officer of the Postal Automation Division in Konstanz from 2001 and at Siemens plc in Frimley (Great Britain) from 2006 onwards. Two years later, Goss became Chief Executive Officer of Siemens UK and North West Europe. He then joined thyssenkrupp Steel Europe as Chief Financial Officer.

12th International Conference on Zinc & Zinc Alloy Coated Steel Sheet June 21 - 25, 2020 Schönbrunn Palace - Apothekertrakt Vienna/Austria CONTACT: ASMET Franz-Josef-Straße 18, 8700 Leoben, Austria Tel. +43 (0) 3842 402 2290 Fax: +43 3842 402 2202 E-mail: galvatech2020@asmet.at Web: www.galvatech2020.org

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››› EVENTS

Events › 25 – 26 September 2019 Budapest, Hungary Organizers: Quartz Business Media www.futuresteelforum.com Future Steel Forum. What is ‘platformisation’ and how does it relate to digital manufacturing? How can cloudbased design help steelmakers improve efficiency and reduce costs? How far can we go with ‘deep machine learning’ without losing our grip on ethical responsibility and what exactly is ‘knowledge engineering’? These are questions that need to be answered if steelmakers are going to gain a greater understanding of the world surrounding Industry 4.0 and its associated technologies. This is the focus of this year’s Future Steel Forum in Budapest. › 5 – 8 November 2019 Stuttgart, Germany Organizers: P. E. Schall GmbH & Co. KG www.blechexpo-messe.de Blechexpo and Schweisstec. The trade fair duo of Blechexpo and Schweisstec takes place on a two-year cycle in the state trade fair centre in Stuttgart (Landesmesse Stuttgart) and is the only event in the world that deals with the complementary technologies of sheet metal processing and joining technology. Within the shortest timeframe, Blechexpo has been able to gain a leading position in Europe and now ranks second in the world on the list of trade fairs for sheet metal processing. The Schweisstec international specialist trade fair for joining technology forms the ideal complement. It presents all of the relevant mechanical and thermal joining and connecting procedures as well as thermal welding processes. › 26 – 28 November 2019 Maastricht, Netherlands Organizers: KCI BV www.stainless-steel-world.net/ ssw2019/ Stainless Steel World Conference & Exhibition. Biennial gathering of the global stainless steel community, bringing together the highest concentration of experts and key stakeholders from across the engineering landMPT International 3 / 2019

scape and supply chain. More than 280 companies present their products and solutions to 6,500 middle-to-higher management visitors. For those seeking to update their knowledge base, the conference affords a perfect setting to catch up on the latest developments, technologies and trends. › 19 July 2019 (one day) Hamburg, Germany Organizers: Meorga GmbH www.meorga.de MEORGA MSR-Spezialmesse Nord.

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

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

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EVENTS

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“European steel producers to reduce CO2 emissions up to 95%” The 4th European Steel Technology and Application Days (ESTAD) are set to take place alongside the metallurgical trade fair METEC 2019 and the accompanying conference organized by the VDEh Steel Institute in Düsseldorf on 24 - 28 June. We spoke to Dr. Hans Bodo Lüngen from the VDEh Steel Institute speaks about the event.

METEC and the 4th ESTAD take place in Düsseldorf in June. Will it be similar to the previous editions or can we expect some changes?

Lüngen: Since the very first edition of METEC in 1979, it is common practice that the VDEh Steel Institute organises a metallurgical steel conference to accompany the event. Since 2015, ESTAD, which was established by the VDEh Steel Institute in 2013, has also accompanied METEC. The event covers all the steps for iron and steel production including cokemaking, iron ore agglomeration, ironmaking, oxygen and electric steelmaking, casting, rolling of flat and long steel products as well as steel materials and their applications. This year, compared to previous ESTAD events, one of the main focuses will be the topic of digitalisation and industry 4.0 in the steel industry.

When did the planning for ESTAD start and how will the event be organised?

Lüngen: The organisation and planning of ESTAD starts two years in advance with the publication and distribution of the first announcement. For the organisation of the event, The VDEh Steel Institute works in close cooperation with TEMA, a company in Aachen. The whole event is carried through with full support of Messe Düsseldorf.

According to public perception two trends dominate the discussion: Industry 4.0 and decarbonization. What can the participants of ESTAD 2019 expect regarding information related to these topics?

Lüngen: Regarding digitalization, the steel industry faces many chal-

Dr, Hans Bodo Lüngen, Steel Institute VDEh.

lenges. The long production chains, production distributed amongst different locations, batch as well as continuous production processes, existing modern process control and automation technologies confirm that the steel industry is well suited for industry 4.0. Forty-five presentations on this topic will inform about state-ofthe-art technology.

Regarding actions against climate change, the steel industry is currently doing every effort to drastically reduce CO2 emissions, especially in Europe.

These activities, which will reduce CO2 emissions during the production of iron and steel, will be presented in the smart carbon usage projects and in the carbon direct avoidance projects.

The target of European steel producers is to reduce CO2 emissions by 80 - 95% in 2050 compared to 1990.

Who are the speakers and where do they come from?

Lüngen: We have 625 presentations from 41 countries and 237 companies and institutions for the different ESTAD categories. The speakers come

from steel producing companies, steel plant manufacturers and suppliers, research institutes, universities and service companies from all over the world.

As ESTAD is accompanying the METEC trade fair, the most important plant supplying companies are presenting their newest technologies at the event, but also the users of these technologies are involved in ESTAD presentations.

Do you have a personal highlight you are looking forward to during ESTAD? Lüngen: At the end of the ESTAD technical sessions on 27 June, in the afternoon, there will be a round table discussion with questions from the audience to those experts involved in the different CO2 mitigation projects in steel production. I expect there to be an interesting discussion on the various aspects in this field.

Thank you for the interview!

This interview was conducted by Torsten Paßmann.

MPT International 3 / 2019

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››› EVENTS

New software makes slag readings available factory-wide

More than 300 systems of the AMEPA electromagnetic slag detection system ESD are already in use in steelworks on ladles and converters worldwide. These systems report an alert as soon as there is a danger that the slag produced in each process step will be transferred to the next vessel.

The AMEPA Report software analyzes the measured values of the ESD sensors with digital signal processing and automatically evaluates the data based on rules. On casting ladles, measured values deviating from the nominal values are detected very quickly, for example in the area of well block, upper nozzle or slide gate. This is done without taking the time to track individual value curves. This evaluation can also be used to schedule maintenance work.

All status messages are presented to the steelworker in table form, and the measurement results in graphic form.

Copyright: Factory photos AMEPA

At the METEC exhibition, AMEPA will present the new AMEPA Report software which automatically analyses the measured values of the slag detection sensors in the steel mill using new methods of digital signal processing.

For example, problems in the area of well block, upper nozzle or slide gate of casting ladles are detected very quickly, and the measured values are available throughout the plant.

The AMEPA Report Software makes data on accompanying slag available to different user groups within the customer network at any time in a customized form.

The results can be sent automatically to previously configured user groups as shift or daily reports in the form of e-mails at specific times.

As part of the increasing cross-process networking, the system stores measurement data and system results in a database. Detailed data, current and historical, is available to users in their company-wide network.

In addition, a web server makes contents of the database available within the customer network which can be accessed at any time with standard web browsers. Thus, the AMEPA Report software makes data about accompa-

nying slag available to different user groups at any time in an adapted visualization.

The software allows the user to adapt the parameters of the ESD system to the user's product range. Remote maintenance and access to data for online customer support by AMEPA specialists are also available.

The new software can be used for existing slag detection systems, ESD 100 S and ESD 200 from model year 2010. This allows customers with older systems to benefit from benefit from the advantages of development in digital evaluation.

Forging manipulators save 30 percent of energy At METEC, Dango & Dienenthal will introduce rail-bound forging manipulators of its SSM series that come with the new ERS Energy Recovery System.

While reducing the energy demand of the moving drive by up to 70 percent, the system also reduces the time needed to position the forgings in the press by up to 30 percent. The first of such machines will soon be delivered to a customer in Germany.

MPT International 3 / 2019

During positioning of the forgings in the open-die press, the tongs of Dango & Dienenthal manipulators are carrying masses between 10 and 3,500 kN. In between the press strokes, the moving drive must accelerate and decelerate masses – including the workpiece – of up to 14,000 kN. By introducing the new ERS Energy Recovery System, up to 70 percent of the energy input for the acceleration is recovered: During each deceleration action, the hydraulic fluid flows back into an accumulator from where it will be

extracted for the next acceleration action. This reduces the manipulator’s total energy demand by 25 to 30 percent.

Dango & Dienenthal no longer uses proportional valves in the system but highly dynamic axial piston engines.

These provide a number of advantages. As there is no loss due to throttling, the moving drive reaches its final speed earlier and will come to a halt faster. This results in 20 to 30 percent less time needed for the movements and less forging time per workpiece.

According to Klaus Zillinger, Team

‹‹‹

17

Photo by Dango & Dienenthal Maschinenbau GmbH

EVENTS

From now on, Dango & Dienenthal delivers its SSM forging manipulators with the new ERS Energy Recovery System.

Manager Hydraulics at Dango & Dienenthal, their customers benefit in multiple ways: “In our forging manipulators the tongs and the moving drive form one common unit. Thus the ERS now adds the advantage of lower energy consumption to the benefits derived from our simple and robust mechanical design. Additionally, the highly dynamic axial piston engines allow the manipulator to be controlled much more precisely and accurately than with the previously used proportional valves. Consequently, near-net-shape forging becomes more efficient, reduc-

ing subsequent finishing by machining or grinding.” Last but not least, replacing the proportional valves has dramatically reduced flow losses in the hydraulic system, and the hydraulic fluid heats up less. Consequently, approximately 20 percent less energy is needed for fluid cooling. With a 25 percent lower installed power rating, the ERS achieves a significant increase in speed and a marked enhancement of operating precision. Also running operating costs are reduced because axial piston engines require much less maintenance than systems based on proportional valves.

Laser-optical crossbow measurement optimizes performance At METEC, nokra will launch its new alpha.cb laser-optical system for the measurement of crossbow in strips. The new system can be used, among others, for optimizing the control of stretch-levelers. The company’s further exhibits will include optical gauges for combined inline measurement of thickness, flatness and contour of plates as well as for high-precision strip thickness measurements.

The new system measures crossbow of strip in an inline process. The results from the measurements can be used to optimize stretch-leveler control so as to minimize crossbow formation.

With processes becoming increasingly digitally interlinked, the measurement data can also be used to optimize up and downstream processes - such as hot and cold rolling - by analyzing whether and where cooling strategies or coiling methods may promote crossbow formation.

The system operates according to the light-section method, which uses laser lines projected onto the strip surface.

The measuring frame, which accommodates the transmitter and receiver optics, is low enough to not interfere with the movements of the hall crane.

At the same time, the optical equipment is arranged at a safe distance from the strip surface, ruling out any risk of mechanical damage. The system MPT International 2 / 2019

Energy Efficiency Excellence

= minimized costs

DESCALE MORE EFFICIENTLY. The easiest money to make is the money you don’t spend. Our new configuration and analysis program MillConfig.Descale helps you save a significant amount of energy during descaling while reducing carbon emissions.

See for yourself – at METEC Düsseldorf.

METEC Düsseldorf, Hall 5, booth 5F23 See you there!

www.lechler.com

››› EVENTS

requires no compressed air and no water cooling.

It measures height at an accuracy of 0.1 mm. Together, the two cameras of the system capture approximately 3,200 pixels across the strip width. For a 1,800 mm wide strip, this means a transverse resolution of 0.6 mm.

For plate rolling mills, nokra will show laser-optical gauges for the combined inline measurement of flatness, thickness and contour. The sensor equipment for these measurements has been arranged within a very compact system. These gauges are often used in plate mills at the hot rolling stands to monitor the rolling process, in downstream process stages, for example, at cold leveling machines, and for quality inspection of the finished plates.

Also on display at METEC will be nokra’s alpha.ti 4.0 system, a laser-based, non-contact gauge for high-precision strip thickness meas-

Copyright: Nokra

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The new system measures crossbow of strip in an inline process.

urements. The gauge operates at a measuring accuracy of 0.01% of the measuring range, i.e. over 15 mm the

accuracy is +/- 1.5 µm. It features an automatic monitoring function that makes it MSA-compliant.

Unique kinematics make targeted de-bricking even easier At Metec 2019, TML will be showing its new UNIDACHS 110 de-bricking machine, which it has developed especially for work in the metallurgical industry. The 110 is smaller and more compactly built than its predecessor the UNIDACHS 220 and features the unique 360° boom rotation. The new UNIDACHS can be deployed in very tight areas and where working space and height is extremely restricted.

TML has designed the new UNIDACHS for hot applications in the metallurgical industry. The typical workings areas are de-bricking of smaller ladles, BF-runners, tundishes and furnaces.

The 360° rotary cantilever boom can utilize attachments such as hydraulic hammers, rotary drum cutters or a bucket and can reach every point from which material needs to be removed.

The new UNIDACHS 110 stands out with its compact design, high manoeuvrability and a strong hydraulic drive.

The width of the undercarriage is only 1,315 mm and the height is 1,635 mm.

This allows access to working areas MPT International 3 / 2019

Hot ladle service with Unidachs

that are not easily accessible for other machines. Due to the remote operation, the operator is always at a safe distance.

Compared with mini-excavators with an articulated arm it has a further degree of motion. The 360° boom rotation, combined with the double articulated cantilever boom offers a very high level of flexibility: The attach-

ments can be utilised at almost any required angle of surface to be worked on.

Despite the compact size of the machine, it has a large working reach, depending on the attachment, in combination with the kinematics of the boom a working radius of up to 5,000 mm can be achieved.

Michael Hobden Vice President/ Sales and marketing at TML Technik

‹‹‹

EVENTS GmbH, is well aware of the extreme temperatures that prevail inside a metallurgical plant. "As is the case for all our machines, we have adapted the UNIDACHS 110 to cope with the conditions inside steel works’ hot zones.

This is the reason that our new machines carry the Logo "Heavy Metal".

For instance, the boom is fully enclosed. That means that the components inside the boom - the hydraulic cylinders and the hoses - are perfectly protected from heat radiation and from falling debris.”

With remote control operation, the operator is always working at a safe distance. The remote control system con-

sists of a lightweight control panel with logically arranged elements, which can either be carried on a body belt or incorporated into a control station. If the machine is not visible from the control station, cameras can be installed on the machine as an option, to ensure visual contact with the machine and its environment, displayed on a split screen monitor.

Volker Bongardt, International Country Manager at TML Technik GmbH, sees great advantages for his customers: "The machine users appreciate the combination of the cantilever-boom and the boom rotation, especially the fact that they are able to

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work from a single position and at the same time reach areas that were not possible in the past. Demolition robots and mini excavators with articulated booms do not offer this kind of kinematics. Our customers are now able to profit through the multi functionality known from other machines that we build: the flexibility of the rotary boom and the compact design of the radio remote de-bricking robot."

The machines are available with a choice of diesel-hydraulic or electro-hydraulic drives. Diesel engines have either 26 kW (EU Stage 3a) or 18,5 kW (EPA TIER 4), the electro-hydraulic unit has 25 kW.

Optical gauge measurement accurate to the micrometre Vollmer is presenting the VTLG 101/1 laser-optical thickness gauge for the first time at the METEC. It has been specially designed and developed for the cold-rolling of foils with a thickness between 0.003 and 2.0 mm, and is the only gauge of its type available on the market that can be installed in the immediate vicinity of the roll gap even when rolling foils.

Copyright: Vollmer

While the systems from the VTLG Series to date were employed for strip with a thickness between 0.015 and 12 mm – depending on the measuring range – Vollmer has developed the new system for the rolling of foils.

With a resolution of 0.05 µm, it achieves an absolute measurement precision of +/- 0.5 µm even when installed in the mill.

The VTLG thickness measurement systems are so compact and robust that they can be installed in the mill in the immediate vicinity of the roll gap.

They operate with an internal scanning rate of up to 80 kHz and are thus the only optical strip thickness gauges for use in the mill suitable for highly dynamic thickness control during rolling. As with the other members of the VTLG family, the VTLG 101/1 is also suitable for the rolling of flat products of steel and non-ferrous metals with matt or glossy surfaces. Elke Roll-

er, Sales Manager at Vollmer, sees the new system as proof that Vollmer has taken the right step with the implementation of laser measurement technology: “Since its market launch in 2014, the VTLG has proved its performance and in particularly its suitability for use in cold strip rolling mills in dozens of com-

Vollmer has developed the new system for the rolling of foils.

plex applications worldwide. With the VTLG 101/1, we are now going a step further: With its thickness measuring range of 0.003 to 2,0 mm, the new VTLG is ideal for the rolling of foils.”

Air cleaning systems ensure reliable operation even under the rough environmental conditions in the mill: Both the entry and exit windows of the transmitting and receiving lenses and the beam path are constantly flushed with clean air so that vapours or mists from the mill do not affect the measurement. Vollmer has developed the VTLG not only for measurement

in the mill – it is equally suitable for use on the annealing line, in the finishing shop, on strip millers or in shear lines.

At the fair, Vollmer will also be presenting the classic contact gauges with digital measuring sensors and VTS evaluation that have superseded the amplifiers of the VMF Series and offer a number of further advantages. Spindle motors are no longer required for adjustment of the sensors. Furthermore, a vacuum is no longer necessary in the sensor, thus significantly reducing service work.

MPT International 3 / 2019

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››› STEELMAKING – METALLURGY TEELMAKING – METALLURGY

Impressive start and performance for new slab caster at voestalpine Stahl GmbH Danieli was awarded the contract to supply the CC8 slab caster in January 2015 with the objective of installing a state-of-the-art machine able to produce crack-sensitive steel grades, predominantly for automotive and electrical applications. In October 2018, a nominal productivity of 100,000 t/month was reached.

As part of the production expansion project, the slab caster No. 8 (CC8) at the voestalpine Stahl GmbH - LD3 steelplant in Linz was designed to cast mainly automotive grades for exposed parts to be rolled in coils, focusing on a slab thickness of 225 mm for slab widths ranging between 800 and 1,820 mm.

According to these requirements the roll geometry was finalized as a 9-m radius vertical curved machine with a vertical bender, six bow segments, two unbending segments and six horizontal segments.

An advanced automation features an L1 system based on DCS technology (providing a centralized software maintenance environment) that works in coordination with an innovative L2 system integrating a large set of Technological Packages including: Q-COOL (dedicated to control the secondary cooling in order to maximize the product quality), Q-CORE (dedicated to carefully control the Soft Reduction Practice), Q-MAP (to prevent the BO maximizing the machine perfor-

Authors Gabriele Paulon, Danieli Loris Busolini, Danieli Automation Thierry Gautreau, Danieli Rotelec Herbert Moser, voestalpine Stahl GmbH Peter Hodnik, voestalpine Stahl GmbH Contact: Gabriele Paulon Email: g.paulon@danieli.it

MPT International 3 / 2019

Machine Area

Roll Pitch range, mm

Roll Diameter, mm

Bender

182 ÷ 185

Ø 150

Bow segment type 1

239 ÷ 248

Ø 200, Ø 220

Bow segment type 2

259

Ø 220

Unbending segments

280 ÷ 290

Ø 240

Horizontal segments

300

Ø 260

Table 1: roll pitches and roll diameters arrangement

mance), Q-MOD (to measure the mold displacement), Q-Level (to reduce the level fluctuations reducing bulging phenomenon by using enhanced control algorithm), Q-MAS (segments

measuring and comparing geometry device). This important project consolidates Danieli technology both in the mechanical and in the Electrics and Automation field.

Figure 1: Water model is used to study the natural flow pattern of liquid steel into the mold. Argon injection is modeled thanks to air injection in the stopper rod and the flow is traced with methylene blue (1). Meniscus shape is detected through digital camera level topography (2) and results are analyzed to reconstruct the wave (3). Sub meniscus velocities are measured with an Ultrasonic Velocity Profiler (4), allowing a complete characterization of the flow pattern.

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STEELMAKING – METALLURGY

Figure 2: Nailboards.

Roll diagram Based on these requirements the main guideline for the roll diagram design was to consider reducing as much as possible the slab bulging between the rolls to avoid mold level fluctuations that could lead to inclusions and mold powder entrapments. This is particularly important for the automotive exposed parts products, in which the subsurface inclusions lead to sliver defects during rolling, worsening the final coil surface quality.

Thus, the values of the roll pitches are defined to be as tight as possible followed by a roll-axis design showing reduced roll diameters to keep enough gap for the sprays to reach the slab surface as necessary. Roll pitch and diameter values are reported together with the caster segment arrangement in Table 1.

mould to reduce the steelmaking defects. To determine the natural flow associated with different casting conditions of casting speed, slab width, SEN immersion depth and argon flow, different methodologies and models have been developed, including CFD simulations and real-scale water modeling (Figure 1). However, on continuous casters, nailboards and paddle methods are used to capture the steel flow direction and intensity at the meniscus. According to these measurements

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(Figure 2 and Figure 3) the proper control functions, like slowing down, accelerating or stirring, are applied by the Multi-Mode Electromagnetic Stirrer at the correct intensity. The system controls automatically the steel flow inside the mold to maintain as much as possible the optimal steel flow with the appropriate magnetic forces generated by the stirrers in all the different casting conditions. The general procedure for MM-EMS automatic control can be summarized as follows: A meniscus steel velocity is issued according to the casting conditions, the nailboards mapping and four parameters (casting speed, slab width, SEN immersion depth and argon flow). Then, from this velocity and through the master files, the stirring function and the current intensity are calculated and applied (Figure 4).

Based on first quality results, the adoption of the MM-EMS shows an improvement in the quality results in terms of sliver occurrences. At present, Multi-Mode tests are still on-going on the CC8 caster in collaboration with voestalpine stahl and the quality data are collected from the downstream process lines to consolidate the results and fine-tune the process further.

Strand Electro Magnetic Stirrer (Strand-EMS) Moving from the mold down along the strand, the focus moves as well from

Electromagnetic devices Mold Multi-Mode Electro Magnetic Stirrer (MM-EMS) As is well known from many years of experiments on continuous slab casters, an optimal steel flow pattern in the mold is the starting point for achieving the best surface and sub-surface product quality, reducing defects from inclusions and mold-powder entrapment to the lowest level. MM-EMS provides intelligent control of three functions for slowing down, accelerating and rotating the liquid steel in the

Figure 3: Paddle measurement with EMLS, slowing down function.

MPT International 3 / 2019

>>

22

››› STEELMAKING – METALLURGY

Figure 7: Independent control of spraycooling sections across the slab width.

Figure 4: Control of stirring function based on meniscus steel velocity measurements.

Figure 5: Internal slab quality samples sketch

Figure 6: Equiaxial zone percentages.

surface and sub-surface to internal slab quality. In order to improve the equiaxial zone extension a box-type strand stirrer has been installed in voestalpine Stahl GmbH-CC8 slab caster.

Internal distribution of equiaxed grains is a crucial parameter for the final quality of steels used for electrical applications. For voestalpine Stahl GmbH - CC8 product mix the main targets are the silicon steel grades with MPT International 3 / 2019

a Si content of about 2.32 %. In this case the EZ is enlarged by more than 50% (Figure 5, Figure 6).

Secondary cooling design To reach the required quality levels in terms of internal and surface quality for all the different slab sections, the cooling system has been designed with the ability to control in the smoothest possible way the water distribution

across the width. For this purpose, the common arrangement in spray-cooling sections across the width has been enhanced by adding the ability to control the spray nozzles independently by means of dedicated control loops, with separate valves for both air- and water-flow control (Figure 7).

To get a controlled situation the spray nozzles have been carefully designed to compensate both the overlap effect across a single row and the total water density at the end of the spray cooling zone given by the overlapping of all the nozzles along the length of the caster (Figure 8, Figure 9).

To measure and check the surface temperature distribution across the slab width in the different casting conditions, a special design pyrometers system is installed between two straightening segments to collect the temperatures in a dense distribution of points across the slab width.

This measurement, coupled with the ability to control the flow rates separately at the different sprayed width zones, allows levelling of the peaks and valleys of the temperature profile measured so that internal quality control improves as well (Figure 10).

This control capability coupled with the secondary cooling solidification model makes it possible to tune the solidification end-shape along the casting direction to avoid side elongations that lead to uneven centerline across the width, with higher segregation near the narrow sides (Figure 11, Figure 12).

Based on real measurements performed by the nozzle supplier (Figure 13) each single nozzle feature has been implemented within the detailed model (Figure 14) so that a full picture of the secondary cooling system is completely considered by the solidification model, providing a complete 3D map of the solidification conditions of

‹‹‹

STEELMAKING – METALLURGY

Figure 8: Total water density across the width at bender zone exit.

23

the slab along the caster strand (Figure 15).

Together with the spray cooling, roll cooling is considered in detail and implemented in the model to get full control of its influence on solidification.

To reduce to the minimum any unevenness resulting from a systematic overlapping of spray cooling concentration, a staggering of the sprays has been considered, alternating even and odd numbers of nozzles across the width for the subsequent rows of nozzles along the length of the caster.

Finally, to simplify the design and reduce investment and operational costs, no slab spray-cooling has been considered in the horizontal part of the slab caster, only internally cooled rolls.

Dry casting

Figure 9: Total water density across the width at Segment 7-8 zone exit.

Figure 10: Surface temperature measurements middle Seg 7-8 zone.

Crack sensitive and high-quality steel grades slabs are prone to develop cracks when they pass through two critical areas of a vertical curved design machine: the bending zone and the unbending zone (Figure 18).

To avoid the formation of cracks in this area it is important to control the stress created by deformation together with the slab temperature.

Temperature is a critical factor whenever it drops down in the ductility drought area, where even relatively low values of stress can induce the formation of cracks.

If the bending part of a vertical curved caster the slab is still not too far from the meniscus to have issues with the temperature, for the unbending area, especially for the higher radius machines, the distance from the mold (meniscus) becomes significantly more important and the control of temperature drop more difficult. To withstand this issue, the concept of dry casting can be applied. The idea is very "simple" and involves switching off slab secondary cooling to reduce as much as possible the heat extraction from the slab. This "simple" action has considerable drawbacks, like: • exposing the machine equipment to higher temperatures, which in principle could significantly compromise the life of rolls and bearings; and, • losing control of the solidification process, introducing internal defects like centerline segregation and cracks. >> MPT International 3 / 2019

24

››› STEELMAKING – METALLURGY

Figure 11: Model computed surface temperature.

Figure 12: Model computed centerline solidification.

Therefore, the key factors are the design of the equipment in terms of roll and bearing cooling, to contemporaneously protect the parts and introduce the minimum required contact cooling effect on the slab; tight roll pitch, to ensure proper containment to control bulging and segregation; tuned application of soft reduction to achieve an even centerline quality, as well as to limit conditions resulting from the significant removal of spray cooling.

Internally cooled PDR rolls design together with a controlled and tuned internal cooling-water flow have proven to be successful in reaching higher temperature values at the unbending area, with an acceptable distribution across the slab width. The slab internal quality that is achieved is in line with expectations and comparable to other less critical steel grades.

Figure 13: Real nozzle cooling density distribution.

Dry casting condition The CC8 is equipped with special PDRrolls from segment 3 to segment 8. This allows dry casting conditions without negative effects on the roll life time in this area. Some trials where necessary to evaluate the influence on the slab temperature and the effect on the roll cooling during dry casting conditions.

Several tests with different conditions were tested.

For this reason, the driven rolls from segment 3 to 8 on the inner bow where equipped with additional thermocouples to measure the influence on the cooling water temperatures of the PDR rolls. During dry casting the 3 scanners showed a full temperature profile over the width and also some hand pyrometer measurements were made.

The output of these trials was an optiMPT International 3 / 2019

Figure 14: Modelling the nozzle cooling density distribution.

‹‹‹

STEELMAKING – METALLURGY

Figure 15: Modelling segment nozzles and

Figure 16: Temperature change on machinery cooling during

rolls arrangement.

dry casting (segment 3 to 8).

mized cooling flow for the PDR-rolls (machinery cooling) to be sure that dry casting will not lead to any roll damages. Some additional software changes related to machine safety rounded up the final set up for dry casting.

Technological packages To fully control the machine equipment and the casting process the latest-generation technological packages have been fully implemented. An important role is played by the solidifica-

tion model and the dynamic soft reduction control model, merged together in a unique advanced model that controls both spray-cooling flows and segment positioning dynamically, according to the different casting conditions, either steady and unsteady.

The development of a meshless algorithm for the computation of the heat exchange equations makes it possible to reduce the computational time enough to allow the handling of a full

25

two-dimension slice model in real-time conditions.

Therefore, it has been possible to implement within the model the behavior of each individual nozzle across each individually sprayed row, providing a full map of the cooling behavior over the entire slab surface and a full picture of the solidification progress within a slab section at any distance from the meniscus.

Coupled with a flow-control split across the sprayed width, the model al- >>

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››› STEELMAKING – METALLURGY

Figure 17: Slab surface Temperature change during dry casting (pyrometer measurement between segment 7 and 8).

Figure 18: Surface temperature profiles, predicted and measured.

lows a fine-tuned control of the temperature distribution to reduce the differences across the width.

Detailed curves with the metallurgical properties for different steel grade compositions have been generated to cover the full range of product mix.

Each curve is properly selected according to the steel-grade target composition. Therefore, the spray-cooling practices are defined directly by Level 2 based on the production schedule.

Coupled with the slab-cooling control, the model integrates the functionality for applying dynamic soft reduction. According to the different compositions, different thickness reduction profiles can be assigned on the three main areas of liquid core, mushy core, and solid core.

Again, based on the steel target composition, the proper thickness reduction curves are dynamically applied according to each roll position, to achieve the correct application.

The specific possible positions of the segments are considered by applying several quality protection limitations that adapt the desired thickness reduction application to the real-time casting conditions, reconfiguring the segment position if necessary.

Figure 19: Top, segment gap in casting condition applying soft-reduction; Top, 1.3 m/min; Bottom, 0.8 m/min.

MPT International 3 / 2019

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28

››› QUALITY ASSURANCE

The Brain Creators team, together with Tata Steel, explored the use of Deep Learning.

Deep Learning for Steel Quality Inspection at Tata Steel IJmuiden Tata Steel and BrainCreators have been exploring the transformation of the steel industry by taking the latest deep learning techniques from the academic world and applying it to real-world production systems. In this article, they briefly introduce the field of artificial intelligence to illustrate the value it can deliver, highlight the steel quality inspection case at Tata Steel, and describe their process of implementing this solution.

Authors Jasper Wognum, Brain Creators Johan Bernard, Tata Steel Europe

MPT International 3 / 2019

BrainCreators is a highly skilled team of machine learning and software engineering professionals based in Amsterdam, the Netherlands.

Working closely with international research scientists and engineers, their knowledge and experience is applied to support enterprises on

their journey into AI. BrainCreators serves a worldwide client base which includes Tata Steel, DHL, Vodafone and many more.

Tata Steel is one of the world’s most geographically diversified steel producers, with operations in 26 countries and commercial offices in over

‹‹‹

QUALITY ASSURANCE sion, sectors that have already relied on these technologies have seen significant transformation. One such sector is the steel industry, which has relied on computer vision-based quality inspection methods for decades. However, due to the high risk factors involved with steel production, adaptation of artificial intelligence in actual production systems has been rather slow.

Tata Steel and BrainCreators have been exploring the transformation of the steel industry by taking the latest deep learning techniques from the academic world and applying it to real-world production systems. In this article, we will briefly introduce the field of artificial intelligence to illustrate the value it can deliver, highlight the steel quality inspection case at Tata Steel, and describe our process of implementing this solution.

Artificial Intelligence: A Brief Overview

35 countries. In Europe they are one of the largest steel producers. But it’s not just their size that sets them apart. What makes them different is their approach to business. Tata Steel believes their strength is how they build collaborative relationships that create new success for their customers in construction and infrastructure, automotive, packaging and engineering, Artificial intelligence is a new critical asset changing the way organizations plan, operate, and evolve.

Untapped business opportunities for machine learning exist across all sectors and application areas. However, the challenge remains for enterprises to stay up to date and convert the latest research developments into profitable business cases in order to stay ahead of the competition.

With artificial intelligence revolutionizing the field of computer vi-

Artificial intelligence is a blanket term that refers to systems that leverage both machine and deep learning and other types of algorithms to augment human intelligence. Therefore, any system which produces a behavior that can be considered intelligent by humans is an artificial intelligence system. Deep learning comprises a large part of artificial intelligence and is part of the larger domain of machine learning. Machine learning works by learning rules directly from features, which are hand-crafted by engineers and domain experts, sometimes via prior knowledge or trial and error. Deep learning, on the other hand, learns the most effective feature representation and the rules directly from the data.

29

The current state of deep learning is built on nearly 60 years of research around the more general topic of artificial intelligence, starting from work on artificial neural networks (ANNs) in the 1950s. Thanks to computational power growing at a steady rate, mainly due to advancements in graphical processing units (GPUs), the very large amount of data generated by digital devices such as cameras and internet products, combined with the progress in open source software libraries, allowed deep learning to revolutionize the field of machine learning, and more broadly, artificial intelligence, in a very short period of time.

The Advantages of Deep Learning To understand the difference in approach between traditional machine learning and deep learning, let’s look at the example of developing an image classifier, tasked to assign an input image to a predefined set of categories.

A traditional machine learning approach would take the following steps: 1. Data collection: identify the data sources which can provide images of the different categories to be identified • Data sources could be live feed from cameras, images acquired in a laboratory or existing in a database 2. Data labeling: assign labels to each collected image to one of the categories the classifier should recognize • This step is often very time consuming as it requires both expert knowledge and review of a very large number of examples 3. I mage feature design: design an algorithm which transforms the raw

The project has opened up new perspectives.

>>

30

››› QUALITY ASSURANCE

Figure 3: A simplified flow of the key difference between machine learning and deep learning.

pixels an image is composed off into a vector of numbers which can be used to differentiate between the different categories • Typical examples include Gabor filters, Haar wavelets, histogram of oriented gradients (HOG), local binary pattern, etc • The specific type of feature which allows to successfully build a classifier is often not known before a classifier is built and requires experience and experimentation, which results both in a slower pace of development and lower performance 4. Train a classifier: split the full dataset into a training set and a test set, then select a model to train and use the labeled data to automatically learn which combination of features is best at assigning images in the training set to the category with which each image was labeled (the target) 5. Test performance and iterate: apply the classifier to the test set and calculate how well the model performed • If model performance is not sufficient, step 1-5 would be repeated until the desired performance level is achieved

The main difference between the two methodologies is shown in Figure 3. When approaching the same problem with a deep learning system, step 3 and 4 are combined and a neural network with a large number of layers is selected as the classifier. The deep neural network will learn at the same time the most efficient feature representation and the optimal weights (rules). This allows deep neural networks to outperform traditional machine learning methods, especially when a large amount of data is available.

The team of researchers and engineers at BrainCreators have been working in machine learning for years before the deep learning revolution began to develop. The combination of experience in traditional machine learning and experience starting from the origins of deep learning, alongside the continuous investment in research allows us to provide best in class solutions based on the latest research and technology available.

Pickling Line Steel Quality Surface Inspection Steel production is comprised of a series of steps that take the raw inputs

(iron ore, coke, and lime) and transform them into finished sheets that can be used in a variety of ways. Towards the end of the production process, soon after leaving the hot mill where the steel is rolled, steel sheets are commonly processed by a pickling line before being sold into the market or sent along for further processing. In this step, strong acids (referred to as pickling liquor) such as hydrochloric acid are applied to the surface of the steel to remove oxides (rust), stains, inorganic contaminants and other impurities.

In this specific case the pickling line is the last step before the steel is sold to the market, therefore a human inspector is required who continuously monitors the strip after pickling, flags surface defects, and determines the type of defect. Defects can range in severity from minor scratches to significant surface deformations. Knowing the specific type of defect provides Tata Steel the opportunity to decide how to deal with the coil, considering the next production step and/or customer application. Thus, there is a direct link between the surface quality inspection procedure and business value creation.

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››› QUALITY ASSURANCE

Figure 4: Examples of severe (left) and minor (right) defects

Existing Process Tata Steel installed a camera inspection system comprised of 9 cameras placed above and below the production line and a software program to detect the location and classify possible defects from a set into 50 classes. The inspectors use the detected location and classification provided by the software program on the pickling line to augment their manual inspection process to ultimately decide the proper action to take, which includes releasing the coil to the customer or the next step in the production process for further processing, cutting out part of the coil and sending it back to normal production or to the customer, or rejecting it entirely.

While this system provides a lot of additional information as input to the manual inspection process, its limitations are numerous:

• It requires approximately 3 - 6 months months to bring the system to full and stable operation • The accuracy of the classification is not sufficient to fully automate the inspection. Some harmful defects which only occur once or twice per coil are sometimes misclassified. Inspection experts can show these kind of examples • Inspector involvement is still necessary to monitor a lot of defects to make the decision about coil release on surface aspects.

For these reasons, Tata Steel wanted to explore new technologies to come up with alternative solutions.

Challenges To improve upon the existing process, severe intrinsic and extrinsic challenges of the problem at hand had to be taken into account. Some of the key in-

trinsic challenges which were faced included: • Class imbalance: the most critical defect types are also the most rare, thus training a classifier with very few samples of the classes of interest is a challenging task • Distributional changes: due to complex and stochastic interactions on the production line, defect classes can change significantly over time and thus, a good surface inspection system must be robust to these effects • Visual complexity of defects: many defect classes exhibited high intra-class variance, thus making the classification problem more difficult Extrinsic challenges stemming from the context of the process include: • Bootstrapping the solution from the limited and uncertain outputs of the existing process

Figure 5: overview of the typical process BrainCreators follows when developing solutions.

MPT International 3 / 2019

‹‹‹

QUALITY ASSURANCE

33

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• Introducing a new data labeling process to the inspector line • Quantifying the performance the system with respect to the previous process and generated business value

Approach The initial step entails the review of the existing production process and the corresponding quality inspection approach already in place. AI experts worked together with steel surface experts to identify which processes are the best candidates to benefit from a state-of-the-art deep learning inspection system. The end of the pickling line in the cold mill was identified as a key step in the overall process which was suitable to benefit from a deep learning based quality inspection system.

To reach a solution we follow the standard process shown in Figure 5: 1. Definition phase: a. In-depth analysis of current quality inspection solution alongside domain experts b. Review of the target Key Performance Indicators targets c. Solution design that includes our R&D team, machine learning engineers, and senior technical architects: this includes both hardware setup and software development d. Review of the proposed solution with the customer, potential iterations on the design and agreement to proceed

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Process and hot gas fans Figure 6: A comparison of the manual, previous, and current surface inspection systems. In the manual inspection case

Process gas dust collection

(top), a crew of inspectors were required to standby and

Process gas cleaning plants

visually inspect the steel surface for defects 24/7. In the

Secondary fuel technology

current system (middle), the burden of visual inspection was

Belt drying plants

shifted to an improved surface inspection system which, still requires the crew of inspectors to standby 24/7. Developed solution (bottom), the burden of inspection will be alleviated by the robust DeepSense defect classifier and continuous improvement via a human-in-the-loop feedback cycle.

MPT International 2 / 2019

Vapour exhaust plants

34

››› QUALITY ASSURANCE

2. Configuration phase: • Inspection of the hardware required to start acquisition of the data a. Configuration according to the solution design. This is now part of the BrainMatter solution b. Data collection and model-aided labeling of the data by a quality inspector from Tata Steel c. Model fine-tuning and labeling iterations 3. Deployment phase: • Inspector training: once the system is ready to be deployed, the

end users of the inspection system will be trained to take full advantage of the system and be able to provide feedback for continuous learning a. Process integration b. Live production rollout with real-time monitoring via dashboards and alerts 4. Maintenance & support

Solution Taking into account the existing process and aforementioned challenges,

a robust multi-stage solution to tackle the key problem areas has been developed.

First, the customizable DeepSense defect classifier wasintroduced, which is a configurable Deep Learning-based image classification model. Given the class imbalance and visual complexity of the defect classes, DeepSense was able to train a model that was up to 15% more accurate for the most critical defect classes.

Tata Steel proposed to use a human-in-the-loop feedback system.

Which was deployed as a customised instance of the BrainMatter platform. It allowed the inspectors on the pickling line to interact with the DeepSense defect classifier and flag when potentially new defect classes arise. Additionally, BrainMatter contains an intelligent data labeling module powered by active learning, which greatly reduces the labeling burden by only selecting the most informative defects for the classifier. This effectively solved the so called “needle in the haystack” problem that the inspectors previously faced with when labeling data. More than than 99% of the images parsed by the system did not contain any defects, thus labeling without any intelligent sampling was very time and cost inefficient.

Conclusion

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MPT International 3 / 2019

Tata Steel positions itself as an innovation and digital transformation leader by embarking on a journey into deep learning technology and this is only the beginning.

Given BrainCreators’ success with numerous industrial imaging projects, and the experience in quality inspection for Tata Steel, the company are confident they can increase the robustness and effectiveness of quality inspection systems for a diverse range of manufacturing processes.

The field of artificial intelligence is progressing at a tremendous pace and according to a MIT Sloan report from 2018, companies pioneering in the artificial intelligence field by adopting this technology earlier than competitors are investing more than their peers, widening the gap from their competitors.

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36

››› STEELMAKING – METALLURGY

Complex numerical flow simulation of industrial large-scale furnaces using Computational Fluid Dynamics In the field of industrial furnace design, thermal studies are of great interest in order to interpret the behavior of furnace systems and to achieve effective technical improvements.

Computational Fluid Dynamics (CFD) can be a powerful tool for investigating the effects of heat transfer mechanisms and is able to uncover potentials for design and process optimization in industrial furnaces. In this study, a detailed CFD model of a large-scale walking beam furnace was developed, which takes into account gas radiation, turbulent combustion as well as the movement of the heated steel material inside the furnace chamber.

In the field of industrial furnace design, thermal studies are of great interest in order to interpret the behavior of furnace systems and to achieve effective technical improvements. Computational fluid dynamics (CFD) can be a powerful tool for investigating the effects of heat transfer mechanisms and is able to uncover potentials for design and process optimization in industrial furnaces. [1] [2] The development of simulation models for large-scale continuously working furnaces is associated with several challenges due to the complex chemical and physical heating process of the steel material: • Large computational domain and complex geometry • Boundary conditions and admissible simplifications • Simulation of turbulence flow • Simulation of heat radiation • Simulation of turbulent combustion • Modelling of the transient steel block motion In the process of this study, a CFD model of a continuously operating, natural gas fired, walking beam fur-

Figure 1: Structure and boundary conditions of the furnace model

nace was developed with the aim to predict the heating process and the final temperature distribution of the steel material. The results of the simulation were validated with experimental data of a performance test.

Furnace model

Niklas Wichmann, Dr. Krzysztof Hornig, Andritz Maerz GmbH, Germany Email: niklas.wichmann@andritz.com

MPT International 3 / 2019

The solution domain of the furnace model built is shown in figure 1. The geometry of the furnace has been simplified for block-structured mesh generation, but its basic structure has been retained according to the technical furnace documentation. The furnace model is divided into three geometrical model areas. The upper and lower

fluid zones are separated by a moving fluid zone, which contains the solid steel blocks to be heated. During the simulation process, the sliding mesh zone is moved successively through the furnace chamber to simulate the material transport inside the furnace.

The model consists of the half furnace chamber with a symmetry constraint in the longitudinal axis as illustrated in the simulation layout in figure 1. The heating system of the furnace is divided into six control zones, in which allocated burner groups provide the heating of the zones. In total, 9 side burners, 10 front burners as well as 28 flat flame burners in the ceiling

‹‹‹

STEELMAKING – METALLURGY

Figure 2: Modelling of the skid system

37

Figure 3: Longitudinal section of the test block with thermocouple positions

of the heating and soaking zone are included in the model.

Since the skid system and the associated radiation shielding have a significant effect on the temperature distribution in the steel blocks [3], the skid system has been considered in the furnace model, which is shown in figure 2.

The transient simulations were performed with the solver ANSYS Fluent 19.0 on a high-performance computing cluster (HPC), whereby a parallelization study was carried out for an effective utilization of the available computational resources.

For the calculation of the predominant physical phenomena, the recommended models in model has been used to calculate the turbulence flow. The heat radiation is simulated by the discrete ordinates model in combination with the weighted sum of grey gases model.

Non-premixed turbulent combustion was calculated through the steady laminar flamelet model with a reduced skeletal combustion mechanism. The implementation of the block motion during the transient simulation has been accomplished by the use of a sliding mesh zone to avoid the recalculation

Figure 4: Flow field of the numerical simulation with indication of the block temperatures

of a dynamic mesh. The entire model has been meshed block-structured with approximately 4.88 million cells.

The modelling of the material properties of the exhaust gas and the carbon steel was realized with temperature-dependent functions.

Results and validation The validation of the furnace model is based on experimental data collected during a performance test at the tech-

nical acceptance of the furnace. For this purpose, a test block was equipped with a total of twelve thermocouples which recorded temperature data during the heating process. The exact positions of the test block thermocouples are shown in figure 3.

In addition to the test block temperatures, other operational data such as the furnace chamber temperatures or the natural gas consumption were recorded. These operational data were

>>

Figure 5: Bottom view of selected steel blocks in the furnace at different points in time MPT International 3 / 2019

38

››› STEELMAKING – METALLURGY Deviation Furnace zone

Thermocouple Ref. to [K]

Ref. to [°C]

Convective zone

TC11

3,55 %

4,62 %

Preheating zone

TC12

3,73 %

4,61 %

Heating zone

TC13

1,87 %

2,25 %

Soaking zone

TC14

4,81 %

5,75 %

Table 1: Comparison of CFD simulation

Table 2: Comparison of CFD simulation and experimental data of the furnace

and experimental data of the test block

temperatures

temperatures

used as input boundary conditions of the simulation model.

Figure 4 shows the flow field of the CFD simulation within the furnace chamber, where the solution domain is mirrored over the longitudinal center axis of the furnace. The course of the block heating can be viewed in more detail in figure 5, where the underside of the steel block is plotted over the course of time. The temperature profiles t1 to t4 show the formation of the skid marks in the convective and preheating zone. From time t5 on, the spatial offset of the skid system becomes apparent, which is indicated by a displacement of the temperature profile to the right. The intensity of the skid marks increases particularly in the range of the heating and soaking zone beginning at time t5. To the end of the simulation, the block temperature profiles homogenize in the area of the soaking zone. Based on the temporal temperature progression of the steel blocks over time, it can be demonstrat-

ed that the model is capable of reproducing the skid marks that are caused by the water-cooled skid system due to heat radiation shielding.

To validate the model, the temperature deviations at the end of the heating process between experimental data and simulation results were first compared according to table 1. The evaluation of the results shows that the block temperatures are generally overestimated between 1.34% and 3.40 %.

The furnace chamber temperatures are overestimated between 2.25% and 5.75 %, whereby the average temperature deviation amounts to 4.31 %.

Due to the overestimation of the temperatures in the furnace chamber, the block temperatures are above expectations.

Since heat losses through the furnace walls and door openings were neglected in the modelling with theoretically 3.91 %, the temperatures determined for the block temperatures are in a permissible range. With regard

to the temperature distribution in the test block, the formation of the skid marks could be reproduced, with their intensity increasing especially in the heating and soaking zone.

A second step in validating the model was to compare the experimentally determined heating curves with the simulated ones. The heating curves of the two thermocouples TC1 (near-surface) and TC2 (core) are compared exemplarily in figures 6 and 7, since the the other measuring points show similar heating profiles. The course of the heating curves of the test block thermocouples in the convection and preheating zones shows downward deviations of up to 20 % despite higher furnace temperatures. In the further heating behavior, in the region of the heating and soaking zone, a close accordance with the heating curves determined experimentally can be found, whereby the lattice transformation of the carbon steel is achieved with close approximation.

Figure 6: Comparison of experimental and simulation

Figure 7: Comparison of experimental and simulation

measurements of TC1 (near-surface)

measurements of TC2 (core)

MPT International 3 / 2019

>>

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››› STEELMAKING – METALLURGY

Since the heat transfer is dominated by radiation, it can be assumed that the emissivity of the carbon steel, which was modelled with a temperature-dependent function, was too small in both the convective and the preheating zone. According to the results of the simulation, the total heat transferred by radiation is 92.68 % and the heat transferred by convection lies at 7.32 %, which is in accordance with the values obtained in literature.

In summary, it can be stated that despite the overestimated furnace temperatures at the end of the experiment, the block temperatures show good agreement with the experimentally determined data.

Parallelization Nowadays, high-performance computers are used to calculate complex flow simulations with solvers as ANSYS Fluent. In the field of high-performance computing, local workstations or high-performance computing clusters with multiple computing cores are applied. [4] When it comes to the use of multiple computing cores, the calculation problem is broken down and equally distributed among the number of the available computing cores. Thus, the mesh and simulation data are split into multiple partitions and then assigned to different compute nodes. The number of partitions is exactly the amount of computing cores set. Each computing core solves the CFD equations of the assigned partition. [5] However, the doubling of the computing cores does not automatically lead to a halving of the computing time. This has several causes such as central processing unit (CPU) cache communication, memory bandwidth and network latency [4]. A measure of the effectiveness of the parallelization process is the so-called solver speedup.

The solver speedup provides a benchmark for the degree of the parallelization of computational fluid dynamics

Table 3: Technical data of the HPC cluster MPT International 2 / 2019

Figure 8: Solver speedup

calculation processes with high-performance computing clusters.

In order to use the available computational resources as efficiently as possible, an investigation of the parallelization behavior in CFD simulations is of interest. For the execution of the simulations, an HPC cluster was used, whose technical data is summarized in table 3.

The results of the parallelization study are presented in table 4. Since the furnace simulation could not be simulated on a single core due to the complexity and the memory requirement, the case with 8 cores is set as reference for the determination of the solver speedup and efficiency.

A visual representation of the solver speedup with a comparison of the ideal solver speedup is shown in figure 8.

With a number of 32 cores, the parallelization is 17.87 % above the ideal solver speedup and represents the most economic ratio between the usage of

computing resources and computing time.

With 64 cores, the solver speedup decreases to 88.24 %, but still shows a time advantage of 33.21 % compared to 32 cores. The speed advantage of 128 cores over 64 cores is about 8.70 %, which can be measured in the significantly reduced solver efficiency of 48.32 %. Furthermore, the results show that from about 76,500 cells per core the solver efficiency decreases clearly and a further reduction of the number of cells per core is not recommended.

Conclusion In the process of this study, a CFD model of a selected, natural gas fired, walking beam furnace was developed to predict the heating process and the final temperature distribution of the steel blocks.

The final CFD model of the furnace consists of the half furnace chamber

Table 4: Evaluation of the parallelization study

‹‹‹

STEELMAKING – METALLURGY

with a symmetry constraint in the longitudinal axis. The model comprises a total of 9 side burners, 10 front burners and 28 top burners. The skid system in the lower furnace area is also taken into account, whereby the entire model has been meshed block-structured with approximately 4.88 million cells.

The validation of the furnace model is based on experimental data collected during a performance test at the technical acceptance of the furnace.

For this purpose, a test block was equipped with thermocouples that recorded temperature data during the furnace run. The comparison of the simulation results with the experimental data shows that the block temperatures are overestimated by the developed furnace model between 1.34% and 3.40 %. The measured furnace chamber temperatures are overrated between 2.25% and 5.75% and can be classified as the cause of the overestimation of the block temperatures.

Since heat losses through the furnace walls and door openings were neglected with theoretically 3.91 %, it can be stated that the walking-beam furnace

References [1] Börner, K.: Energieeffiziente Industrieöfen. In: Bundesministerium für Wirtschaft und Technologie (BMWi) (2000).

[2] Raynal, L., Augier, F., Bazer-Bachi, F., et al.: CFD Applied to Process Development in the Oil and Gas Industry – A Review. In: Oil & Gas Science and Technology 71.3 (2016), p. 42.

[3] Hsieh, C.-T., Huang, M.-J., Lee, S.-T., et al.: A Numerical Study of Skid Marks on the Slabs in a WalkingBeam Type Slab Reheating Furnace.

In: Numerical Heat Transfer, Part A: Applications 57.1 (2010), pp. 1–17.

[4] Jamshed, S.: Using HPC for Computational Fluid Dynamics - A Guide to High Performance Computing for CFD Engineers. 1. edition. GB, Oxford: Academic Press, 2015.

[5] ANSYS Inc.: Fluent Theory Guide; Release 19.0. USA, Pennsylvania, 2018.

C

M

Y

CM

MY

CY

CMY

K

model built, achieves acceptable results in terms of temperature distribution in the steel blocks with consideration of the model simplifications. The development of the skid marks could be described excluding heat conduction effects and thus corresponds to literature findings. Furthermore, the parallelization on a HPC cluster with 8, 16, 32, 64 and 128 cores was investigated. It could be proven that in this case 32 cores with a solver efficiency of 117.87% represent the best ratio between computing resources and calculation time. A first optimization of11:36 the AIC2-junior145x210.ai 1 07/03/19 model should be the adaptation of the

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emissivity function of carbon steel to match the heating curves in the convective and preheating zone. Furthermore, the implementation of a modified boundary condition for the furnace walls must be considered in order to reduce the furnace chamber temperatures.

Abbreviations CFD Computational Fluid Dynamics CPU Central Processing Unit HPC High-Performance Computing RAM Random Access Memory

42

››› IRONMAKING – STEELMAKING

100 th KOCKS RSB® 5.0 for Jiangsu Yonggang Group Co., Ltd.

Friedrich KOCKS: Reducing & Sizing Blocks ensure increased Production Friedrich KOCKS supplies 100th Reducing & Sizing Block (RSB®) to China.

According to the company it is not surprising that the 100 th KOCKS RSB® will be supplied to China, since China is continously increasing the production of Special Quality Bars (SBQ). Basis for the success of the company is for sure the further development of the RSB® with the market launch of the generation 5.0.

Through the introduction of the RSB® 5.0, the level of mill availability and productivity was greatly increased by means of a new drive conMPT International 2 / 2019

cept, a dynamic and fast stand changing system and the new quick responding remote control, which can adjust the pass in milli-seconds.

Mill delays for size change or pass wear can be reduced to almost unneglectable levels. The resulting production increase justifies significant investment as a stand-alone item.

The success in China was supported by favorable economic conditions, such as higher prices for special steels. For that reason many rolling

mills switch their production from mass production (like low carbon steel and rebar) more and more to SBQ and modernize their production facilities accordingly.

Especially in the market segment of SBQ, the RSB® 5.0 shows its superiority. High engineering quality, reliability, low conversion costs in the production chain and excellent rolling results play an enormously important role in this particular field.

‹‹‹

IRONMAKING – STEELMAKING TISCO TISCO is the 4th biggest stainless steel producer worldwide and ranks among the “China 500 Most Valuable Brands”.

The producer is located in the Shanxi province and produces flat and long products for various high quality demanding industries. The new KOCKS RSB® 5.0 will be part of the modernization and upgrade of the existing stainless steel rolling mill. The RSB® 5.0 will produce various austenitic, martensitic and ferritic stainless steel, duplex steel and nickel based alloys within a dimension range of Ø 16 – 100 mm. Commissioning is scheduled for the beginning of 2020. The RSB® 5.0 is the latest milestone in reducing and sizing technology for special bar quality (SBQ) and stainless steel products and offers enhanced bar quality, improved productivity, mill availability and economy as well as a simplified and safe operation.

Weifang Special Steel Iron and Steel The Chinese special steel producer Weifang Special Steel Iron and Steel Co. Ltd.

MPT April Issue Half Horiz Metals Ad Liz.pdf 1 27/03/2019 17:06:36

has placed another order with Friedrich KOCKS GmbH & Co KG for a Reducing & Sizing Block (RSB®) in 5.0 design. This is the 2nd order from Weifang I&S to Friedrich KOCKS GmbH & Co KG within four month. Weifang I&S, is headquartered in the Province of Shandong and mainly produces carbon steel wire rod, welding wire and SBQ for the automotive industry. The KOCKS RSB® 5.0 produces various SBQ grades such as bearing and spring steel within a dimension range of Ø 18.0 – 60 mm at a maximum speed of 18 m/s. Commissioning is scheduled for mid-of 2019.

The KOCKS 3-roll technology will allow Weifang to achieve a reliable and consistent SBQ production of premium quality with perfect surface and closest tolerances to meet the high demands of the market.

Hunan Valin Xiangtan Iron & Steel The Chinese special steel producer Hunan Valin Xiangtan Iron & Steel Co.,Ltd. has placed an order for a new Reducing & Sizing Block (RSB®)

43

370++/5 for its new greenfield special bar quality rolling mill #3. After the successful installation and operation of a KOCKS RSB® 370/5 in 2005, Xiangtan I&S also decided to install a KOCKS RSB® 5.0 of the newest generation at its new SBQ mill. The new RSB® 5.0 is designed for thermomechanical rolling and will finish most flexible all straight bar sizes of Ø 16.0 to 100.0 mm onto the cooling bed. Beside the RSB®, also the roll shop for preparation of the 3-roll stands and 3-roller guides, as well as supervision services are included in the scope of supply. The commissioning of the RSB® 5.0 is scheduled for the first quarter of 2020.

Henan Jiyuan Iron & Steel The Chinese special steel producer Henan Jiyuan Iron & Steel Co.,Ltd. has placed an order for a Reducing & Sizing Block (RSB®) 300++/4 for its new special bar quality (SBQ) rolling mill. It is the 25th block which KOCKS supplies to China and the second RSB® to Jiyuan I&S. After the successful installation and operation of >>

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combilift.com

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››› IRONMAKING – STEELMAKING

KOCKS RSB® 370/4 in 5.0 design, currently operating at Yongxing Special Stainless Steel Co., Ltd.

a KOCKS RSB® 370/4 in 2008, Jiyuan I&S also decided to install a RSB® 5.0 of the newest generation for its new SBQ mill. The new RSB® 5.0 is designed for thermomechanical rolling

and will finish most flexible all straight bar sizes of Ø 12.0 to 42.0 mm onto the cooling bed. Beside the RSB®, also the roll shop for preparation of the 3-roll stands and 3-roller

guides, as well as supervision services are included in the scope of supply.

The commissioning of the RSB® is scheduled for the second quarter of 2020.

On the way to a fully autonomous self-learning RSB® MPT International spoke with Stefan Schwarz, General Manager Sales, of Friedr. Kocks about the success of the RSB® in 5.0 design.

How does the RSB® in 5.0 design differ from its predecessors and from the products of the competition?

The Key factors of our success with our RSB® 5.0 development are quality and reliability. Our specialist worked on a new drive concept, a faster and efficient remote control and an even faster stand changing system, following exactly the dedicated needs of our customers for better economy of the Reducing and Sizing unit and for better quality of the finished product.

Intelligent engineering leads furthermore to reduced hydraulic functions of the RSB® 5.0, which ensures a safe and environmentally friendly rolling. All of our accumulated experience gained with our more than 100 RSB® references is incorporated into our ongoing development are well perceived and appreciated by the market and this gives us a distinct competitive advantage that is reflected in our success.

Why is the RSB® 5.0 particularly successful in China?

The Chinese market environment in particular has a very high demand for quality and reliability. Moreover, the market in China is extremely transparent. The networking of SBQ manufacturers in China is on a very high level and they maintain a very intensive exchange of information on different communication platforms, like WeChat. The information about the quality and reliability of our RSB® 5.0 therefore spreads

MPT International 3 / 2019

fast among fast among the Chinese special steel producer and our customers feel that they are in good hands when deciding on Kocks rolling mill equipment.

Last but not least, the RSB® 5.0 plays its strengths in the sector quality steels sector for the automotive and engineering industry. The favourable SBQ market environment in the past years, with high demand for quality steels and a high price of the finished rolled product, underpins our outstanding market position in China.

What are the next technical challenges?

Everyone is talking about Industry 4.0, and KOCKS, too, naturally faces the challenges of the visions brought to us by rolling mill operators. Our Size Control System SCS® in combination with our 4D EAGLE® measurement system has recently given a convincing answer to the market demands for autonomous rolling.

The next step would be a fully autonomous self-learning and self-adjusting RSB® fed with information from different sources of a rolling mill unit: from the furnace to the finishing facilities. Currently we are about to restructure the software landscape of our RSB®. A workflow-oriented assistance system will cover all work preparation steps around the Sizing Blocks.

Further modular software components can be combined and will cover process simulation, maintenance assistance and data acquisition. The result will be less effort in production planning and preparation, which has a direct positive influence on the return on investment.

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

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

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››› ADDITIVE MANUFACTURING

Printing ongoing, steel component coming

The term "additive manufacturing" now appears almost daily in the trade press. The principle behind this, however, is by no means clear to everyone – especially not in the manufacturing of complex steel components. So here is a brief explanation: in contrast to mechanical manufacturing processes, such as milling or turning, additive manufacturing uses a 3D printer to produce a component layer by layer.

Gas atomized metal powders form the basis for this. Deutsche Edelstahlwerke (DEW), a company in the SCHMOLZ + BICKENBACH Group, has been producing powder for build-up welding and thermal spraying for many years and is now using its expertise in this area for 3D printing.

Within its Printdur portfolio, DEW offers a wide range of gas atomized metal powders. The company already produces more than 200 iron-, nickeland cobalt-based materials. Powder at-

Alle Bilder Copyright: Deutsche Edelstahlwerke

The amazement was great when 3D printing became known to the general public a few years ago. However, scepticism was also rife. Figures and models true to detail coming out of a printer – a revolution or a gimmick? This question has long since been answered. Nowadays, it is even possible to print complex steel components on a powder basis. However, this process requires enormous expertise and complex infrastructure.

As experts in metal powder production, Deutsche Edelstahlwerke has recognized the potential of additive manufacturing and includes customers to help with the process of prototyping. The possible applications in medicine, aviation and the automotive industry are immense.

From the product idea to material development to questions of the ideal recycling method for metal powder: additive manufacturing means a detailed planning process.

omization and the entire technology for 3D printing (including a high-quality 3D printer from EOS) are combined at DEW's Krefeld site. This also includes an in-house laboratory in which

DEW already involves interested customers in the development and prototyping stages.

MPT International 3 / 2019

all powders are tested for their chemical composition and particle size using the latest technology.

Teeth made of steel Greater design freedom and shorter process chains: these are the main reasons for customers to produce a steel component using 3D printing. The technology creates the prerequisites for the design of complex and also lightweight components with high strength values. The tool costs are also considerably lower. While conventional steel processing requires many different production steps in large halls with frequent tool changes, additive manufacturing using 3D printing ultimately requires "only" one printing room. A 3D printer usually has dimensions between two and three square meters. The metallic materials are mainly used in aerospace, medical,

The Printdur portfolio comprises a wide range of atomized metal powders based on iron, nickel or cobalt.

toolmaking industry and automotive lightweight construction. In medicine, 3D printing has already established itself for the production of dental prostheses. Automobile manufacturers, on the other hand, benefit in particular from prototype development: manufacturers can print their components themselves, which saves time and money. Additively manufactured components can be optimized for reduced weight, which is important not only for the automotive industry, but above all for aerospace industry. High strength values at a reduced weight combined with a high degree of design freedom in the construction are convincing arguments. Aircraft, for example, consume significantly less fuel and emit less carbon dioxide. The basis, however, is a high-quality powder – the production of which is a science in itself.

From powder to component For powder production, the raw materials and feed materials are first liquefied in an induction furnace and then fed to an atomizer. In a closed container, an inert gas is used to atomize a pouring stream under high pressure. The resulting particles are spherically shaped. This is the only way to ensure excellent flow behaviour which is extremely important for subsequent processing. Finally, the spherical shape improves the dosability of the powder.

The powder is also separated under inert gas, which cools down the powder without surface oxidation. In addition, the total oxygen content in the powder remains low in this way. The raw powder is then sieved, i.e. the powder required for 3D printing is separated from the oversize grain (too coarse particles) and the undersize grain (too small particles) by means of a sieve. This distinction is made at micrometre level; the grain sizes cannot be distinguished with the naked eye. The typical particle size for 3D printing is in the range of 10 to 63 Âľm. After the usable powder has reached the mixer, it can be filled into bottles.

The fact is: components are becoming increasingly complex, 3D printers more powerful and designed for larger components. This also increases the demands placed on metal powders. Since not every material is suitable for additive manufacturing, the DEW team advises on special materials from the outset with regard to the powders to be used for 3D printing. Iron-based materials can generally be divided into austenitic, precipitation-hardenable and martensitic grades. Austenitic grades, for example, generally >> have high corrosion and oxidation resistance.

MPT International 3 / 2019

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››› ADDITIVE MANUFACTURING

If applications require above-average corrosion resistance, nickel-based powders are the answer. These include materials that can withstand high temperatures and have good resistance to mineral acids such as nitric, phosphoric, sulphuric or hydrochloric acid. Good resistance to hot gas corrosion and high creep rupture strength above 600 °C are also given.

Cobalt-based materials, on the other hand, are particularly suitable for high-temperature applications and for medical products. The DEW material Printdur CoCrF75, for example, has excellent resistance to thermal shock in the heat-treated condition and is resistant to oxidizing and reducing atmospheres up to approx. 1,150 °C. These properties mean that it is preferred for high-temperature applications. In combination with certification according to DIN EN ISO 13485, the Printdur CoCrF75 is the first choice for applications in medical industry.

From the idea to the product: prototyping with the customer Deutsche Edelstahlwerke is currently looking at "additive offensive": As a known powder manufacturer, the company is pushing ahead with the next stage of development: DEW already involves interested customers in the development and prototyping stages. From the idea to the alloy design and then the finished product, the complete manufacturing process is developed together with the customer.

This also includes developing the ideal metal powder solution – away from the usual standard powder. The requirements for the components that the customer wants to pro-

Since more than 50 years!

The technology creates the prerequisites for the design of complex and also lightweight components with high strength values.

duce using 3D printing are determined during the initial discussion. These can be small quantities of spare parts or tools that the customer needs immediately on site in production without delay. Based on the requirements of the desired components, DEW engineers and technicians specify the best possible material. In addition to the classic powder steel grades, these can also be bainitic steels.

As a result of the manufacturing process, customers receive a ready-to-use powder steel with which the desired product can be manufactured in their own 3D printer. In order to ensure that all requirements are met, DEW prints out the prototype on site in Krefeld. This can then be subjected to all common load and hardness tests. Dr. Horst Hill, Head of the Special Materials Division at Deutsche Edelstahlwerke, explains: "From their own alloying idea to the printed end product – we help our customers to implement it all. We will proceed step by step: together we define the requirements, develop the material, realize the powder atomization, test and optimize the material and finally even provide support with recycling the powder. We are also extremely flexible when it comes to order quantities: we supply both small and large quantities on a ton scale."

Last but not least, the subject of recycling also plays an important role, as the metal powders should not be used as often as desired without being modified. Welded powder grains or oxygen enrichment can have an additional negative influence on the processability and the printing result.

Away from the standard

CRANEFRIGOR™ – AC-unit for severe duty conditions works.

FrigorTec GmbH • info@frigortec.de • www.frigortec.com

From the product idea to material development to questions of the ideal recycling method for metal powder: additive manufacturing is a manufacturing process that is already taking effect today, but will be in even greater demand in the future. Users benefit from greater design freedom and shorter process chains – although additive manufacturing will remain an alternative to conventional steel production and component design. The choice of materials for additive manufacturing is still currently limited.

Deutsche Edelstahlwerke conducts research almost on a daily basis and will continue to expand its range of its own high-quality powder, including new alloys. The motto of the SCHMOLZ + BICKENBACH subsidiary is to move away from standard (powder) and towards process-oriented prototyping with the customer. This development promises suspense, and DEW's research work continues – under high pressure.

MPT International 3 / 2019 AZ_S+T_CRANEFRIGOR_85x128_ EN_RZ.indd 1

02.04.19 11:22

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››› ADDITIVE MANUFACTURING

Additive machines discover superalloys

Engineers must first improve the current industrial 3D printers in such a way that these machines can also process very strong and extremely heat-resistant alloys. For this, the Dresden researchers rely on their profound experience with laser powder buildup welding technologies and employ artificial intelligence (AI). They contribute their profound materials expertise to the Fraunhofer joint project "futureAM". The aim of the partners is to speed up additive manufacturing systems for metal components by a factor often and also to manage superalloys.

Fraunhofer IWS engineers have refined laser powder buildup welding over decades in order to allow more materials to be applied in additive manufacturing. In this procedure, a system feeds various filler powders into a process zone. There, a laser melts the powder and deposits it on a workpiece surface. As a result, the desired part is generated in a layer by layer process. "One of the advantages of this additive procedure is that we can adapt the process very flexibly to the requirements of highperformance materials," explains Fraunhofer IWS project administrator Michael Müller.

In this way it is also possible, for example, to print nickel-based alloys that are difficult to weld and process using traditional methods. However, this only works if the temperature, powders, feed rate and other parameters are correct. "We have to adjust all the set screws precisely," explains Michael Müller. "This is the only way we can find the right recipe." Within the framework of the Fraunhofer lighthouse project "futureAM - Next Generation Additive Manufacturing", IWS engineers are recording numerous sensor data with very high sampling rates for this purpose. However, this generates large amounts of data ("big data") MPT International 3 / 2019

Copyright: Fraunhofer IWS Dresden

Scientists at the Fraunhofer Institute for Material and Beam Technology IWS in Dresden have developed innovative methods enabling more materials to be processed in additive manufacturing than ever before. For example, additive manufacturing systems could better facilitate future aircraft engines with lower fuel consumption.

By means of laser powder build-up welding, components made of different materials can be integrally manufactured. Thus, specific materials can be placed exactly where their properties are required.

that is difficult for people to understand.

AI learns to decide Fraunhofer experts use advanced methods of "artificial intelligence" (AI) and "machine learning", which are also researched under the catchword "Big Data" in a working group led

by Prof. Karol Kozak, Head of Image Processing and Data Management at Fraunhofer IWS, to find hidden connections in these signal floods. For example, special analysis algorithms link the measured sensor values with the institute's powder database and evaluate further process parameters. Gradually, the machines learn to make their own decisions. For example, they can determine that precisely illustrate whether a slight rise in temperature in the welding process can be tolerated or whether they have to take immediate countermeasures before the entire component ends up as waste. "Industry is looking for ever more and ever different materials which are, however, often difficult to process," empha-

sizes Prof. Frank Brückner, Business Unit Manager Generation and Printing at Fraunhofer IWS.

Better aircraft engines The aircraft engines mentioned above are examples that precisely illustrate this prospect: they could work more efficiently and at higher temperatures if most materials were not already failing at temperatures of around 1200 degrees. Admittedly, there are materials that can withstand such high temperatures, but they are very cost-intensive and difficult to process using traditional methods. Additive manufacturing is intended to solve this dilemma.

Moreover, it could help to achieve a more cost-effective design: "Using laser powder buildup welding, we can feed different powders into the process zone simultaneously or successively with precisely adjustable feed rates," explains Michael Müller. Designing an entire component out of a singular material is not very effective since the component is not exposed to the same heat at all points." Preferably, the ex-

‹‹‹

51

Copyright: Fraunhofer IWS Dresden

ADDITIVE MANUFACTURING

Fraunhofer IWS Dresden has developed a process and material database which stores all details of the manufactured components. Copyright: Fraunhofer IWS Dresden

pensive, highly resistant material should only be used where it gets really hot," says Michael Müller. "In other areas, a less expensive material will be sufficient." This is precisely what can be achieved with additive manufacturing systems – once they have learned to process the required superalloy. "The next step is to combine various high-performance materials within a single component," announces project administrator Müller. In the "futureAM" joint project, the IWS and five other Fraunhofer Institutes are pooling this technology and further expertise to push additive manufacturing to a new level. By summer 2020, they want to integrate all their expertise into the additive manufacturing process chain and demonstrate it on realistic components.

Additive manufacturing (AM) is regarded as a key technology for "Industry 4.0". It is designed to combine the advantages of mass production and manufacturing and even to generate individual parts ("batch size 1") economically on an industrial scale. AM machines can also freely create highly complex components that cannot be produced using conventional milling and turning machines.

These machines use principles similar to those used by 3D printers in the creative and DIY scene: The desired component is designed on the computer; subsequently this model is fed into the system, whereupon a heating module or laser heats a plastic. From this material melt, the system generates the designed part layer by layer.

Compared to 3D printers for private use, AM systems are far more efficient. They can, for example, process metals and ceramics as well as plastics, usually use laser technology and work with extreme precision and more complex CAD models.

In November 2017, the Fraunhofer lighthouse project futureAM was launched with the aim of accelerating additive manufacturing of metal components by at least a factor of ten. The focus is on a holistic view of digital and physical added value from incoming order to the finished metal 3D printing component. The central goal is a leap into a new technology generation of additive manufacturing. Five other Fraunhofer institutes are participating in this project under the leadership of the Fraunhofer ILT: IWS, IWU, IAPT, IGD and IFAM.

MPT International 3 / 2019

››› DIGITALISATION Copyright: SMS group (blast furnaces No. 1,2,3 at Hyundai Steel, South Korea).

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Benchmarking study forecasts significant market changes In the course of ongoing digitalization, the construction of large-scale plants is facing significant market changes for which companies have to prepare intensively. This is the core result of a new broad-based benchmark study by the VDMA Large Industrial Plant Manufacturers’ Group (AGAB) and PwC Capital Projects & Infrastructure.

Data-driven services

Skills for the digital age

The study examined the state of digitalization in international large-scale plant engineering and the market requirements in 2025. The German companies were compared both with traditional and with new, more digitally driven competitors worldwide; their market position was benchmarked and possible fields of action were identified.

Based on a quantitative survey of more than 40 plant manufacturers and numerous interviews with international industry experts, the study shows that the technology-oriented business models ("technology enabled"), which dominate the market today with a share of around 60 percent, will lose considerably in importance by 2025. By contrast, digital, data-driven services ("open digital") will more than triple their market share by 2025.

"In this changing environment, skills

Large-scale plant construction companies have to adapt quickly to the changing market situation and the new customer requirements. Based on a digital reference model, the study has identified 18 specific capabilities for large-scale plant construction that are necessary to fully exploit the market potential in 2025. These include, for example, knowledge of change management and agile project management methods, the promotion of business incubators and the development of intelligent logistics concepts which help to optimize construction site processes.

MPT International 3 / 2019

Dr. Hannes Storch, member of the management board of Outotec GmbH & Co. KG and deputy spokesman of AGAB

such as agility and flexibility are becoming increasingly important," explained Dr. Hannes Storch, member of the management board of Outotec GmbH & Co. KG and deputy spokesman of AGAB, on the occasion of the publication of the study in Frankfurt.

Transparent processes "The analysis shows that German large-scale plant manufacturers have already achieved remarkable successes in building up the required capabilities and are clearly ahead of their compet-

DIGITALISATION itors in some areas," explained Christian Elsholz, plant engineering expert at PwC and project director of the study. This is particularly the case with the further development of cyber security and virtual reality, which 94 percent of German plant constructors regard as crucial future capabilities.

"Against the backdrop of radical technological upheavals and rapidly changing customer requirements, however, it is important that companies continue to push ahead with their digital transformation," said Elsholz.

"Transparency of processes and close cooperation with partners within the value chain, particularly within the framework of integrated platforms, are becoming key success factors."

Intense competition The market for large-scale plants will change dramatically.

In contrast to international competition, German large-scale plant constructors rely predominantly on the development of internal skills in connection with digitalization. Only to a small extent they do purchase external

Guide to digital success In conclusion, it can be said that the large-scale plant construction industry sees digitalization increasingly as an opportunity to become more efficient and to optimally meet customer requirements. It also became clear that considerable investments are still required in order to meet the expected changes in the market by 2025. "There are no general solutions for this. However, the study provides a guideline that each company can use individually to define the key steps to digital success," summarizes AGAB spokesman Storch.

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MPT International 3 / 2019

54

››› DIGITALISATION

“Service covers the entire life span” Large-scale plant constructors use digitalization to give themselves a competitive edge.

They seek to increase their scope of services, shorten their product development times and lower their costs. In an interview with MPT International, the Chief Executive Officer of thyssenkrupp Industrial Solutions Marcel Fasswald talks about current opportunities and challenges and about what large companies can learn from startups.

Copyright: thyssenkrupp Industrial Solutions.

What opportunities does digitalization offer the large-scale plant construction industry?

Marcel Fasswald: The use of digital technology in the large-scale plant construction industry is a crucial factor when wanting to increase process efficiency and the benefits that the provided services offer the customer.

There is a lot of potential here, especially in the engineering sector, on the construction site and for the services offered. At the same time, the time-tomarket period, which is the time it takes from developing a product until its release onto the market, shortens.

This becomes particularly apparent when looking at the engineering aspect: This is where the foundation for the digital cycle is laid. So in order to meet the demands of a digital life cycle, simple engineering has to become a form of multi-disciplinary systems engineering, which overall is faster, more cost-efficient and more flexible.

In order to achieve this, IT-based business process management and "big data" will have considerably more influence on the work done in the engineering sector.

The use of drones offers new possibilities.

MPT International 3 / 2019

Marcel Fasswald, Chief Executive Officer of thyssenkrupp Industrial Solutions

The construction site will also benefit from digitalization. Parts of its management will be automated and scheduled deadlines are more likely to be met. Digital data makes the building condition safer and more transparent.

It also forms the basis for creating digital twins.

What is the present situation regarding digitalization?

Marcel Fasswald: Today plant constructors are much more prepared for the challenges of digitalization than they were just two years ago. This can be said about the entire industry as well as about my company thyssenkrupp Industrial Solutions. Even when we’re facing considerably stronger competition from companies from other sectors, we, as a large-scale plant constructor, have a clear advantage: We combine digital competence with years of engineering and process expertise. We digitalize our engineers’ knowledge and by means of, for example, machine learning, we make it available to our customers. At thyssenkrupp Industrial Solutions we call this “digitalized expertise“. Examples of new products and services this development creates can mostly be found in the areas of sensor-supported, intelligent automation and prediction-based process optimization.

What digital services can plant constructors offer their customers?

Marcel Fasswald: Service strategies are closely connected with digitalization. First successes with digital services in plant construction could already be achieved. For example, thyssenkrupp Industrial Solutions is now able to present customers with a variety of digital, value-added solutions. It’s important that we offer our services for the entire life span of a plant and beyond the limits of single components. Let me give you three examples: Nowadays, we use drones for several tasks. They inspect the plants’ operations and monitor various work processes and performance scopes. When building a plant, they are used for documentation purposes by creating 3D models. This allows us to very quickly locate and react to possible deviations from the plan.

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DIGITALISATION

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A second example: By using intelligent measurement technology and sensor systems, we can accurately record machine data. The data continuously updates the so-called “digital twin”, which consists of a 3D model of the plant, a process simulation and the as-built data. This allows for prescriptive maintenance and repair based on the actual condition of the plant. These are important requirements for reducing costs and possible outage times for the customer as well as for significantly increasing production volume.

Last but not least, I want to mention the use of radar sensors for plant automation. One area of application is that of conveyor belts and bucket-wheel excavators. Here we can accurately measure the distance and the orientation of single components. Deviations, some of which might very well be relevant to safety, are recorded and reported in real time and can immediately be stopped. thyssenkrupp Industrial Solutions has the know-how to collect, process and analyze data. With this data as our basis, we’re able to suggest suitable courses of action to our clients. This data is an important prerequisite for sustainable maintenance and for an effective and needs-oriented usage model.

How can working with startups help with digitalization and what can large-scale plant constructors learn from startups?

Marcel Fasswald: thyssenkrupp wants to work with startups. To this end, we have created the platform “Beyond Conventions” in cooperation with several other companies. This platform is designed to encourage startups to help find digital solutions for specific challenges our industries can face. We don’t want to travel the world to see what others are doing. We’re doing it differently. We’re letting inspirations come to us. Because that’s where we need them - startups with smart teams willing to offer digital solutions for specific problems.

Working with startups has another positive effect. These joint projects can loosen tight corporate structures and self-imposed restrictions.

On top of that, thyssenkrupp has created its own accelerator program called #tkGarage for innovative ideas that transcend the current core business. We’ve already been able to develop many exciting concepts and business ideas.

Where do you see the biggest challenges?

Marcel Fasswald: Nowadays the importance of new business models is being clearly recognized; the same goes for the danger posed by competitors from outside the industry also entering the market. The realization that already-existing processes and structures have to be adapted to suit the business models of today has become widely accepted. The digitalization of the large-scale construction industry also plays a crucial role in the development of the service range. There is enormous potential for the constructors as well as for the operators of large plants. thyssenkrupp Industrial Solutions accommodates these developments by having its own business entity called “service”, which combines the know-how of all aspects of plant construction and relentlessly works on developing new digital solutions.

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MPT International 3 / 2019

››› CLIMATE PROTECTION

Copyright: ABB

56

ABB presents a state-of-the-art CO2-neutral and energy self-sufficient factory of the future at its Lüdenscheid location.

Going Green

To permanently reduce CO2 emissions, ArcelorMittal has developed a lowemissions technology strategy, which targets not only the use of alternative feedstocks and the conversion of CO2 emissions, but also the direct avoidance of carbon (Carbon Direct Avoidance, or CDA).

This year, the Group intends to launch a new project in the ArcelorMittal plant in Hamburg to use hydrogen on an industrial scale for the direct reduction of iron ore in the steel production process for the first time. A pilot plant is to be built in the coming years.

Hydrogen-based process The Hamburg plant already has one of the most efficient production processes of the ArcelorMittal Group due to MPT International 3 / 2019

Copyright: Salzgitter AG, Carsten Brand.

Steel producers and plant builders are investing in new methods and technologies to reduce CO2 emissions and save energy. In this article we look at three examples of ArelorMittal, Salzgitter and ABB.

Salzgitter AG and Tenova sign the Memorandum of Understanding (from left): Dr. Volker Hille, Corporate Technology Salzgitter AG; Dr. Markus Dorndorf, Product Manager Melt Shops Tenova; Ulrich Grethe, member of Salzgitter AG’s Management Board; Paolo Argenta, Executive Vice-President Upstream Tenova; Christian Schrade, Managing Director of Tenova Metals Deutschland GmbH; Dr. Alexander Redenius, Head of Division Salzgitter Mannesmann Forschung GmbH.

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the use of natural gas in a direct reduction plant (DRI). The aim of the new hydrogen-based process is to be able to produce steel with the lowest CO2 emissions. The project costs amount to around 65 million euros. In addition, a cooperation agreement with the University of Freiberg is planned to test the procedure in the coming years at the Hamburg plant premises. The hydrogen-based reduction of iron ore will initially take place on a demonstration scale with an annual production of 100,000 tonnes.

"Our Hamburg site offers optimum conditions for this innovative project: an electric arc furnace with DRI system and iron ore pellets stockyard as well as decades of know-how in this area.

The use of hydrogen as a reducing agent shall now be tested in a new shaft furnace," comments Frank Schulz, CEO of ArcelorMittal Germany.

Pressure swing adsorption In the process, the separation of H2 with a purity of more than 95 percent from the top gas of the existing plant should be achieved by so-called pressure swing adsorption. The process is

57

Copyright: Salzgitter AG

CLIMATE PROTECTION

SALCOS® graphic, demonstrating how the integration of a direct reduction reactor into the existing steelworks can help to lower CO2 emissions.

first tested with grey hydrogen (generated at gas separation) to allow for economical operation. In the future, the plant should also be able to run on green hydrogen (generated from renewable sources) when it is available in sufficient quantities.

With the Hamburg hydrogen project, ArcelorMittal is advancing pioneering technology for direct CO2 avoidance as one of several potential pathways for low-emissions steelmaking. The Group is already investing

more than 250 million euros in various carbon emissions reduction technologies, for example in Ghent where waste carbon gases will be used for the production of alternative fuels or in chemical products. Likewise, methods are tested in which biocoal from waste wood is used instead of coking coal as a reducing agent in the blast furnace.

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MPT International 3 / 2019

››› CLIMATE PROTECTION

steel production: Tenova – a company of the Techint Group specialized in solutions for the metals and mining industries – and Salzgitter AG – one of Europe’s leading steel and technology groups – declared officially a mutual cooperation for the realization of SALCOS® (SAlzgitter Low CO2 Steelmaking) by signing a Memorandum of Understanding (MoU).

SALCOS® is a revolutionary concept for a significantly CO2-reduced steel production, commonly developed by the two companies. The aim is to undergo a stepwise transformation process of the integrated steel making route, moving from carbon-intensive steel production based on Blast-Furnaces towards a Direct Reduction and Electric Arc Furnace route, including the flexible incremental utilization of hydrogen. This concept is capable of reducing CO2 emissions up to 95% with respect to the entire steel production route.

Reduction Technology The cooperation aims at jointly applying for public funding of the SALCOS® project. In this context, Tenova will provide the ENERGIRON-ZR-direct reduction technology, the innovative HYL Direct Reduction Technology with integrated CO2 absorption system, jointly developed by Tenova and Danieli.

“Over the last years, Tenova has been heavily investing to develop technologies able to significantly reduce energy consumption and the environmental footprint of steel production.

Copyright: ArcelorMittal

58

The direct reduction plant of ArcelorMittal in Hamburg.

Hydrogen plays a pivotal role in this revolution, and the SALCOS® concept could represent an important milestone in our industry”, said Paolo Argenta, Tenova Executive Vice-President Upstream. “We are currently involved in a further study, GrInHy2.0, with Salzgitter AG and Sunfire GmbH, which has received the support of Hydrogen Europe and the European Commission. This should lead to another step toward the first full-scale initiative to move from coal to hydrogen in the steel production.”

Ulrich Grethe, member of Salzgitter AG’s Group Management Board: “The agreement with Tenova is another important step in the implementation of the SALCOS® project. With this, we affirm our offer to politics and society to realize a low CO2 steel production in the

near future. Thus, SALCOS® is securing the future viability of the Salzgitter steel location and the jobs here.”

ABB: CO2-neutral manufacturing site ABB has an extensive portfolio of eco-efficient solutions and services that can help decouple economic growth from environmental impacts.

In fact, over half of ABB's worldwide revenues are generated by technologies that combat the causes of climate change. The company’s goal is to increase this contribution from 57 percent in 2018 to 60 percent by 2020.

The company’s commitment to combatting climate change includes limiting the environmental impact of its own operations. ABB’s current target for climate action is to reduce its

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Sustainable energy transition

Integrated solution

At its site in Lüdenscheid, Germany, ABB shows how a sustainable energy transition can succeed with digital energy management. After a two-year design and construction phase, as part of its “Mission to Zero” project, ABB has opened its first CO2-neutral and energy self-sufficient production site in the world, with the commissioning of a solar power plant at a factory of its subsidiary Busch-Jaeger. ABB technology will generate enough power from the solar plant to cover, on sunny days, 100 percent of the factory’s power requirements. The flagship site will save about 630 tonnes of CO2 a year.

The full energy cycle of the factory has been created with ABB's energy-efficient components so that the entire system can run with significantly less power. A large part of the energy that is needed is created with a sustainable solar power plant and an extremely energy-efficient cogeneration plant.

Measuring 3,500 square meters and installed over the car parks on the company premises, the photovoltaic system will deliver around 1,100 MWh of climate-neutral solar power a year – approximately the annual requirement of 3,360 private households. In combination with a cogeneration plant, which operates with double the energy efficiency of a coal-fired power plant, around 14 percent more energy can be generated than is needed at the site. The surplus power is fed into the public grid, contributing to the region’s power supply with sustainably produced energy. To cover peaks in demand, additional green energy is sourced from MVV Energie AG, which

“The photovoltaic system is part of an integrated solution that covers all aspects of energy production and distribution, making it possible to generate enough power to cover on sunny days 100 percent of its power requirements,” says Tarak Mehta, President of the Electrification business at ABB. “With this state-of-the-art site, we demonstrate the advantages of creating a system in which all components are digitally networked and controllable. This intelligent ecosystem enhances energy efficiency, sustainability and resource conservation, enabling a genuine zero emission future for industry and beyond.”

The technical centerpiece of the entire system in Lüdenscheid is the scalable energy management system OPTIMAX® from the ABB Ability™ Energy Management Suite. ABB Ability™ is the company’s innovative offering of digital solutions and services across all business areas that bring new levels of flexibility, efficiency and performance. The OPTIMAX® digital solution provides a continuous and transparent view of energy consumption. It allows real-time monitoring and optimization of energy use, as well as the integration of distributed generation and flexible consumption and storage, and operates largely autonomously.

This learning system calculates the optimum energy flow on the basis of predictive data and compensates for deviations in real time, helping companies to reduce energy costs and emissions.

Copyright: ArcelorMittal

own GHG emissions by 40 percent by 2020 from a 2013 baseline.

ArcelorMittal is dedicated to reduce CO2 emissions. This picture shows the plant in Mexico.

Digitally interconnected Aside from the energy management system and the photovoltaic system with inverters, the entire system at the factory brings together other ABB technologies that are digitally interconnected. For example, a battery energy storage system (BESS) with an output of 200 kW and a capacity of 275 kWh is responsible for energy storage. In addition, ABB charging points, where staff and visitors can charge their electric vehicles free of charge, provide for an additional improvement in the regional eco-balance. This single-source energy management solution is rounded off by smart switchgear for energy distribution.

MPT International 3 / 2019

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››› TECHNICAL INNOVATIONS

Gunning Manipulators THE HOT GUNNING REPAIR OF AGGREGATES (converter, ladle, EAF, RH-snorkels etc.) is a cost saving alternative to the shut-down and renewal of the complete lining. This process increases the service life of a furnace considerably and it further results in savings of re-heating energy. Due to the quick repair, the number of circulating aggregates, e.g. ladles, can be reduced, too. Moreover, the accident risk is reduced. However, melt shops are not identical. VELCO offers a customized solution for each aggregate, being a fix installation, crane-moved or mobile unit.

The market introduction of VELCO’s MobiGUN manipulator found a lot of interest because this gunning manipulator offers several advantages compared with a fix-installed one.

The latest start-up of a MobiGUN was at an Indian steel plant where several EAFs on same furnace floor. MobiGUN offers an electro-mechanic gunning head which is diesel driven from a telescopic handler with hydraulic boom. MobiGUN

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TECHNICAL INNOVATIONS

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New high-performance spectrometer HITACHI HIGH-TECH ANALYTICAL SCIENCE, a Hitachi High-Technologies Corporation (TSE: 8036) wholly owned subsidiary engaged in the manufacture and sales of analysis and measuring instruments, has launched an advanced line of handheld laser induced breakdown spectroscopy (LIBS) analysers, known as Vulcan+. The range sees updates to the existing Smart and Expert models, whilst a new Optimum+ model is added to the product line. The whole range maintains Vulcan’s market leading analytical capability.

The new Vulcan Optimum+ model has been optimised for analysing aluminium alloys. It features a new high-performance spectrometer, enabling the measurement of lithium in aluminium alloys and it’s also capable of measuring boron-aluminium alloys. Boron and lithium are both

elements that cannot be measured with any handheld X-ray Fluorescence (XRF) analyser. The Vulcan Optimum+ is an ideal tool for identifying modern aerospace alloys in manufacturing and scrapyards.

The calibrations for the updated Vulcan Smart+ and Expert+ models have been revised and extended based on feedback from customers. “We’ve also added new elements and optimised performance. Customers will continue to benefit from unparallel speed and ease of use they’ve come accustomed to with the Vulcan. Our Vulcan+ range of analysers will continue to enable users to identify metal alloys in just one second, delivering productivity gains in both manufacturing QA/QC and scrapyards.”

The Vulcan+ range will continue to benefit from advanced reporting direct from the instrument as well as the ExTOPE Connect mobile phone app and cloud connectivity for data transfer and storage. With the cloud service, users will have real-time access to results anytime, anywhere.

Mikko Järvikivi, Head of Product Management, said: “Delivering best in class analytical capability, the Vulcan is known for its speed, ease of use and robustness. We continue to invest in developing our LIBS product range, working together with customers to manufacture market leading instruments.”

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MPT International 3 / 2019

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››› IN THE NEXT ISSUE...

EVENTS GIFA, METEC, THERMPROCESS and NEWCAST 2019: the hotspot for international foundry and metallurgy technology Düsseldorf once again becomes the capital of the international steel industry. What are the latest trends?

What are the solutions for climate protection? Which innovative products help to improve processes?

How can digitalization be used in a smart way? We compile the most important answers in a follow-up report.

Steelmaking – Metallurgy Innovative Bearing Solutions for very High-Speed Rolling Mill Auxiliary Equipment The focus of this article, written by Timken Europe, is on the rolling mill auxiliary equipment operated under high and very high speed conditions in conjunction with the heavy loads.

Innovations Special machines from Austria Alpine Metal Tech GmbH from Regau, Austria, develops special machines for the metallurgical and automotive industries. An interview with CEO Dr. Christian Preslmayr.

This preview may be subject to change.

Metallurgical Plant and Technology

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