MPT International 6/2018 (Dec)

Metallurgical Plant and Technology G 25074

6

ISSN 0935-7254

December June 2018 2016

The Kocks 4D PantherÂŽ is designed for a 100% inline detection of surface defects (page 15)

Primetals’ transfer bar cooling system goes into operation at Tata Steel (page 38)

SMS group unveils its plans to become the leading provider in digitalization (page 28)

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EDITORIAL

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Digitalization is not a question of ‘old economy’ versus the ‘new’ It’s of no surprize that MPT International’s ‘Modernization’ issue is filled with stories of digitalization. The continual talk of Industry 4.0, automation and the Internet of Things (IoT) might seem overwhelming. Yet another point emerges strongly in this edition: there is no substitute for traditional knowledge and expertise.

One of the industry’s main purveyors of modernization is SMS group, and its recent annual press conference in Düsseldorf, Germany (pp. 28-31) underlined several key initiatives in the areas of additive manufacturing, powder production, digitalized product quality analysis and more.

To date, SMS’s most vivid realization of Industry 4.0 is the Big River Steel (BRS) plant in Arkansas, USA, otherwise known as the ‘learning steel mill’. The significant advancements in digitalization, automation and big data at BRS are clear – yet the end objective is not to replace traditional roles or expertise with technology. Rather, it is a case of humans and machines collaborating across the value chain.

Burkhard Dahmen, CEO of SMS group, had this to say when MPT talked with him at the conference (pp. 32-33): “It has nothing to do with ‘old economy’ versus specialists from the new economy.” He added: “We need new qualifications for people in addition to the ones we already have.” Mr. Dahmen should know, as SMS is already recruiting programmers and developers from the video games industry to support its digitalization projects in such areas as virtual reality (VR) and augmented reality (AR).

If modernization isn’t about ‘digitalization versus the old economy’, then how should operators aim for success? In his contribution to this issue, Digital transformation will create new ecosystems for the steel industry (pp. 34-35), Holger Stamm of PwC Strategy& writes: ‘In order to identify the best business model, the steel industry has to take their customers’ perspective and has to be prepared to fail, yet also win, through experience.’ Whatever the technologies or systems involved, the ‘customer remains King’.

Perhaps Jochen Neuer, project manager at SMS, said it best when he spoke with MPT about the group’s new digitalized manufacturing execution system (pp. 42-47): “At the end of the day, there is always a human that has to take the final decision and choose the best course for the right result.”

As 2018 draws to a close, these technologies and concepts continue to roll out at a rapid pace. Wishing you Season’s Greetings and a Happy New Year.

New technologies will enhance traditional knowledge, says Alex Manford, Chief Editor of MPT International

Alex Manford Chief Editor, MPT International

MPT International 6 / 2018

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››› CONTENTS

INTERNATIONAL INDUSTRY NEWS 16 World Steel Association says global steel demand continues to show resilience The World Steel Association (worldsteel) says global steel demand in 2018 was supported by renewed investment activities in developed economies and improvements in emerging markets. The demand should remain positive into the New Year

COMPANY PROFILE 20 Danieli presents its plans to remain ‘a step ahead’ of the market Danieli revealed its financial statement for the fiscal year ending June 2018, the group’s first to be video streamed live online. The presentations also looked towards future prospects, Industry 4.0 and the ‘new normal’ markets

COVER STORY: The Kocks 4D Panther® surface inspection system and 4D Eagle ® (right) profile measuring system currently operating at Acciaierie Valbruna S.p.a., Italy. The Kocks 4D Panther offers the capability of a 100% inline detection of surface defects with zero false positive rate, even during hot rolling.

(See the full story, page 15) Contact: www.kocks.de Email: fk@kocks.de

EVENTS 24 Additive manufacturing: the key issue for future production engineering Increasingly, the foundry and steel industries are recognizing the potential of 3D printing. In response, the trade fairs GIFA, METEC, THERMPROCESS and NEWCAST 2019 will devote a special show to the subject of additive manufacturing

STEELMAKING – MODERNIZATION 28 SMS group unveils its plans to become the leading provider in digitalization As the steel industry moves away from new construction projects towards modernization, SMS group has unveiled its key new business drivers. They include digitalization, 3D printing and the continuation of its ‘self-learning’ steel plants

34 Digital transformation will create new ecosystems for the steel industry PwC Strategy& examines how productivity gains can be made if steelmakers apply business models used by Amazon, Tesla and Uber. However, the industry must also manage digital disruptions in order to build these new models

INTERVIEW

HEAT TREATMENT

32 SMS group drives its digitalization towards best output of quality

38 Primetals’ transfer bar cooling system goes into operation at Tata Steel

MPT talked with SMS group CEO, Burkhard Dahmen, during SMS’s recent annual press conference in Düsseldorf, Germany. Topics included the group’s new growth plans and business opportunities through digitalization

MPT International 6 / 2018

Tata Steel has commissioned the system in its hot strip mill at Port Talbot, United Kingdom, to precisely control the strip temperature before it enters the finishing mill. Production has increased by around 150,000 t/year of hot strip

HOT ROLLING

ADVANCED MANUFACTURING

40 Georg supplies first roll grinding machine using CBN abrasives

42 Big River Steel, USA, implements full

digitalized production planning system

The Georg ultragrind 25 roll grinding machine put into operation, is the first to use cubic boron nitride (CBN) abrasives. It has achieved three times greater grinding throughput than the previously used machine at Salzgitter AG’s hot rolling mill

As more operators realize the importance of Industry 4.0, the new X-Pact® MES 4.0 by SMS group is a digital, modular and integrated planning and management system. It is already in use across Big River Steel’s (BRS) entire metallurgical process chain

QUALITY ASSURANCE

Columns

36 Zumbach innovates with new gauge

for comprehensive rebar measurement

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Zumbach Electronics of Switzerland, a supplier of non-contact measuring technologies for the metals industry, has introduced its newest Profilemaster® SPS 80 gauge for in-line measurement of any rebar type, in hot rolling processes

International industry news

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

Advertiser’s index SMS group GmbH 2 Danieli & C. Meccaniche SpA 4,5 ABB AB Force Measurement 18 Schade 19 Micro-Epsilon 23

AGTOS Ges. für technische Oberflächensysteme mbH 31 WOKO 33 IMS 37 BSE 39

Zumbach 41 Kiro 47 Primetals 55 Kocks 56

MPT International 6 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

Africa Nigeria Lafarge orders new grinding mill. Lafarge Africa, a group member of the global cement producer LafargeHolcim, is erecting a new coal grinding plant in its Nigerian factory in Ewekoro and has chosen Loesche to supply the grinding mill. The new mill line, a brownfield plant, handles unloading and storage, comminution, metering, drying and grinding as well as raw coal storage. Local lignite and pet coke will be used as grinding materials. The order for Loesche encompasses the engineering, supply of the core components of the mill and of the classifier, the rotary gate and the mill gearbox.

Egypt Expansion of steel production capacity. Several steel producers in Egypt have announced or started to expand their production facilities: Kandil Steel is building a new production line that will increase the capacity of the plant from 600,000 to 900,000 t/year by 2019. Al-Gioshy Steel is expanding its capacity from currently 180,000 to 420,000 t/year. Al-Ashry Steel is investing in a new plant for the production of 350,000 t/year of cold flat steel.

And El-Marakby Steel has started implementing a new rolling line at El-Marakby Steel with a production capacity of 400,000 t/year, taking total annual production of the plant to about 750,000 t.

The Americas USA Nucor Steel Arkansas places galvanizing line order. Andritz has received an order from Nucor Steel Arkansas, to supply a hot-dip galvanizing line for Nucor’s facility in Hickman, Arkansas.

The new line will have an annual capacity of approximately 455,000 t and be designed to produce high-strength steel MPT International 6 / 2018

grades, mainly for the automotive industry. Start-up is scheduled for the first half of 2021. The Andritz scope of supply and services comprises the complete hot-dip galvanizing line and, in particular, the furnace with latest annealing technology for high-strength steel grades, strip cleaning and strip transport systems, a skinpass mill, electrical and automation equipment, and commissioning of the plant.

JSW Steel orders melt shop technology. JSW Steel has selected Tenova to supply melt shop technology for its new plate and pipe facility in Baytown, Texas. The greenfield melting facility will include a Consteel® Evolution electric arc furnace (EAF), two ladle metallurgy furnaces and a twin vacuum tank degasser for the production of high quality steel slabs that will feed the new plate mill.

Tenova will also design and supply the entire melt shop material handling system for the storage and handling of fluxes and ferro-alloys as well as direct reduced and hot briquetted iron. As part of this project, Tenova will provide JSW Steel with two independent bag houses, one for the hot gasses and one for the cold gasses to comply with the low pollution limits.

Steel Dynamics increases production capacity with Fives. Steel Dynamics, Inc. has contracted the international engineering group Fives to upgrade its continuous galvanizing line (CGL) no. 2 at the Flat Roll Group Columbus Division in Mississippi, USA. The aim is to increase the production capacity of CGL no. 2 by increasing the maximum strip speed.

The basis for the increase is Fives’ specialty software, DMS OptiLine™, which simulates the complete operation of a strip processing line. The software calculates the requested characteristics of each motor of the line in order to guarantee the required line tension during operation at the targeted increased speed, as well as during line acceleration and deceleration.

Steel Dynamics to construct a new state-of-the-art EAF flat roll steel mill.

The Board of Directors at Steel Dynamics, Inc. has authorized the company to construct a new state-of-the-art EAF flat

roll steel mill in the USA. The facility is anticipated to have an annual production capacity of approximately 3 million t with the capability to produce the latest generation of advanced high strength steel products. The project will include value-added finishing lines, a galvanizing line with an annual capacity of 450,000 t, and a paint line with an annual coating capacity of 250,000 t. The product offering is anticipated to include various flat roll steel products with hot roll, cold roll, galvanized, Galvalume® and painted steel, primarily serving the energy, automotive, construction, and appliance sectors. The current investment in the mill is estimated at USD 1.7 to 1.8 billion and the facility is expected to create 600 jobs.

Chile CAP ACERO awards Primetals follow-up orders after successful replacement of converter no. 2. In October, Primetals Technologies received the order from Compania Siderurgica Huachipato S.A. (CAP ACERO) to replace the LD (BOF) converter no. 1 in its Talcahuano, Chile, works. This repeat order follows the successful startup of converter no. 2 in May 2018 that was also revamped by Primetals. CAP ACERO has also ordered the installation of Primetals Technologies’ Vaicon Stopper slag retention system on converter no. 2. It will mark the 150th implementation of this system worldwide. The Vaicon Stopper minimizes slag carry over to the ladle during converter tapping. This can significantly decrease operating costs, due to lower consumption of slag formation agents and deoxidizing materials, with a positive impact on steel quality. The modernized converter no. 1 is scheduled to come into operation in March 2020.

Asia China Shougang Jingtang orders new cold rolling mill. Andritz has received an order from Shougang Jingtang United Iron & Steel Co to supply an

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INTERNATIONAL INDUSTRY NEWS S6-high cold rolling mill with an annual capacity of 280,000 t. The new plant will be designed to process highstrength steel grades. The scope of supply includes engineering work, delivery of core mechanical components, electrical equipment, the automation system, as well as supervision of the installation and start-up of the rolling mill stand. Production of the first coil is scheduled for the first quarter of 2020.

Fives signs multi-million dollar agreements at CIIE event, China.

Fives has signed cooperation agreements worth more than USD $150 million during the recent China International Import Expo (CIIE) in Shanghai (November 5-10, 2018). The company signed deals with leading Chinese companies in the automotive, aerospace, energy and steel sectors including steelmakers Baowu Steel Group, Benxi Steel Group and Fujian Special Steel. Fives’ booth at CIIE showcased its cutting-edge and environmentally friendly technologies and digital solutions for optimized steel-processing performance. The company’s digital solutions for the steel industry enable the automation of process controls and real time quality management.

Changzhou Eastran starts up vacuum degassing plant and continuous bloom caster. A twin vacuum degassing plant (VD) and a continuous bloom caster supplied by Primetals Technologies have been brought into operation at special steel producer Changzhou Eastran. The VD plant has a capacity of 75 t. The vacuum treatment reduces the hydrogen content to less than 1.3 ppm and the nitrogen content to less than 50 ppm.

The objective is to improve the steel quality even further.

The five-strand continuous caster is designed for an annual production of 800,000 t of steel for applications in the automotive industry. It casts blooms for pipes, spring and bearing steels. In addition, a dedusting system will improve the environmental conditions onsite.

HBIS Laoting to implement autonomous stockyard management. Siemens is supplying an auton-

omous stockyard management system to be used in a new plant for HBIS Laoting Steel. The supply comprises a material tracking and management system (MAQ), an autonomous stockyard operating system (MOM) and a Simatic PCS 7 process control system as as well as industry network, consulting, engineering, project management and commissioning. Interaction between the different components will enable control of all the plant’s machines and conveying systems, with autonomous operation of all the plant’s storage and retrieval machines.

India Tata Steel places order for three processing lines. Tata Steel has awarded CMI Industry Metals a contract for two continuous galvanizing lines (CGL) and one continuous annealing line (CAL) to be installed at Tata’s new cold rolling complex at the Kalinganagar site in the Jajpur district of Orissa. The three processing lines will allow Tata Steel to produce exposed parts for the automotive industry and products for the white goods sector. All three lines are central parts of a phase two expansion to increase the steel plant’s annual production of galvanized steel by 1 million t. The material grades will range from deep-drawing steels and hot-formed and highstrength steels, to dual-phase and complex-phase steels. One of the new galvanizing lines will be designed to process aluminized coatings, and the other to apply galvannealed coatings in addition to traditional zinc coatings.

South Korea Posco to modernize wire rod and bar-in-coil mill. Pohang Iron and Steel Company (Posco) has awarded SMS group the order to modernize the wire rod mill at its Pohang works. Currently, the plant produces 540,000 t/ year of wire rod and bar-in-coils for automotive applications in a diameter range from 14 up to 42 mm, and in coils of up to 2 t. The modernization encompasses new descalers, a new cropping

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shear, a shiftable water cooling line and pouring reel machines with a walking beam conveyor, as well as cooling fans and hoods for in-line heat treatment of the coils. The project aims to expand the rolled product range to diameters of up to 55 mm and increasing the rolling speed for smaller products to 22 m/s.

Vietnam TungHo to upgrade furnaces.

TungHo has awarded Inteco the order to revamp a 100 t EAF and a LD. The plant, which belongs to the Taiwanese Tung Ho steel group, produces approximately 1 million t/year of steel. The scope of supply includes the high-current components, the mechanical upgrade, new electrical and automation systems, and new current conductive arms for the ladle furnace. In addition, Inteco will supply JetBOXesTM with burners systems, the valve stand and a package of critical spare parts. Start-up is scheduled for summer 2019.

Tenova contracted for a new Flexible Modular Furnace (FMF®) in Vietnam. Tenova, part of the Techint Group which specializes in innovative solutions for the metals and mining industries, was recently awarded a contract for a new furnace concept, the Flexible Modular Furnace (FMF), for the Pomina 3 steel plant which is part of Pomina Steel Corporation in Ba Ria, Vung Tau region, Vietnam. The 120 t Consteel® EAF at Pomina 3 (supplied

by Tenova in 2013) has been upgraded to a Tenova FMF. By adopting this new technology, the plant will be able to charge the furnace with hot metal coming from the new blast furnace.

Pomina 3 can now adopt hybrid electrical/integrated steelmaking technology that minimizes CAPEX and saves on production costs. Start-up is foreseen in early 2019.

Europe Austria voestalpine starts up mini steel mill with Inteco. Two years ago, MPT International 6 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

Inteco was awarded with the construction of a mini steel mill by voestalpine Stahl Donawitz GmbH. The steel mill with a heat size of 5 t was successfully started up in October by a team of experts from voestalpine and Inteco.

The facility is equipped with stateof-the-art plant and process control technology for the production of highest quality steels with as-cast dimensions that are identical to the ones of the bloom caster in Donawitz. Inteco’s scope of delivery included: an induction furnace, a ladle furnace, a vacuum treatment (DETEM) plant, all the necessary auxiliary equipment (e.g. ladle preheaters, tundish preheater etc) as well as a segment casting plant for bloom lengths of up to 12 m.

The mill’s finished products serve as starting material for the processing in the voestalpine mills of tubes, wires and rails.

Belgium Aperam Genk to build new cold rolling mill. Andritz is going to supply a 20-high cold rolling mill to Aperam Genk. The new mill will be of the four-column design and equipped to process stainless steel strip of grades AISI 300 and 400. In addition to engineering and manufacturing the new mill, including the electrical equipment and the automation systems, Andritz will also supervize the installation work and the start-up. Production of the first coil is scheduled for 2020.

Germany Deutsche Edelstahlwerke orders new walking hearth furnace. Andritz has received an order from Deutsche Edelstahlwerke Specialty Steel to supply a complete walking hearth furnace plant for the Witten facility.

The new plant will comprise two walking hearth furnaces with automatic loading and unloading device, a car bottom furnace for pre-heating sensitive material grades, and an entry and exit roller conveyor. Operated in three shifts, the plant will have an hourly processing capacity of 35 t. It will be designed for heating billets and MPT International 6 / 2018

ingots to a maximum rolling temperature of 1,320 °C. In addition to the mechanical part of the plant, the scope of supply also comprises the entire electrical, automation and visualization equipment.

Production is scheduled to start in the second quarter of 2020.

Italy Acciaieria Arvedi issues FAC for EAF. Primetals Technologies has received the final acceptance certificate from Acciaieria Arvedi S.p.A. for the new EAF installed in the Cremona steel works. The production capacity is 1.4 million t/year of crude steel. The order also included a dedusting system for primary and auxiliary dedusting and for supplementary extraction points.

This is combined with a heat recovery system which uses the thermal energy in the furnace offgases to generate steam for use in the works’ three pickling plants. The new 150 t EAF from Primetals will increase Acciaieria Arvedi’s production capacity and reduce conversion costs. The tap-to-tap time is just 36 minutes with single bucket operation. The furnace is usually charged with a mixture of 65% scrap iron, 25% pig iron and 10% hot-briquetted iron. Primetals also supplied a Level 2 process optimization system so the facility is well prepared for Industry 4.0.

Danieli supplies its 500th rolling mill to Acciaierie di Verona. The new high-speed wire rod mill of Acciaierie di Verona (part of Pittini Group) produced the first coil 19 months after the contract signature.

The timely start-up and the following hot test period of seven weeks, during which 25,000 t of finished wire rod in quality have been produced, reflects the long-term cooperation between Pittini Group and Danieli. Strict end-product size tolerances have been reached from the very beginning.

Equipped with the most advanced wire rod technologies and in full compliance with Industry 4.0 requirements, the plant produces 750,000 t/year of plain wire rod from 5.5 to 25 mm and rebar from 6 to 18 mm at rolling speed of 100 m/sec.

Russia Stoilensky to boost concentrate production capacity. NLMK has embarked on the construction of an additional beneficiation section at Stoilensky. Three new grinding lines (vertical mills) will enable the company to increase its concentrate output from 17.5 to 20 million t/year and its ore processing capacity from 37 to 42 million t by 2020.

The new beneficiation section will be integrated into a single process chain with the three sections of the beneficiation plant. Having passed the medium and fine crushing stages and the high-pressure grinding rolls, the ore will be fed into the three vertical mills for further crushing and beneficiation, before being supplied to the pelletizing plant or for being shipped to NLMK Lipetsk.

Spain Bornay places order for tube welding line. Bornay S.L. has ordered a high-frequency tube welding line from SMS group for its Alicante works. The new machine will produce round tubes with diameters from 10 to 40 mm and wall thicknesses from 0.75 to 4.5 mm, as well as squares in dimensions from 10 x 10 mm to 30 x 30 mm and rectangulars in dimensions from 20 x 10 mm to 40 x 20 mm with wall thicknesses ranging between 1 and 4 mm. Maximum production speed will be 120 m/min. Commissioning of the line is scheduled for the first quarter of 2020.

Switzerland Metalcolor to upgrade colour coating line. Aluminium coil coating specialists Metalcolor SA, located in Lavaux, has awarded CMI Industry Metals with a contract for the supply of four finish coaters to upgrade one of Metalcolor’s existing colour coating lines (CCL). The new coaters will be designed for aluminium strip up to 700 mm wide and between 0.18 and 1.50 mm thick.

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INTERNATIONAL INDUSTRY NEWS

Companies SMS group wins German Design Award 2019. SMS group has received the German Design Award 2019 in the category ‘Industry’ for its spray head component that is used to cool dies in forging presses. The judges chose SMS because its product exemplifies various aspects of additive manufacturing, which continues to open a whole range of new possibilities for the design and functional layout of components.

Every year, the German Design Council organizes the German Design Award to recognize innovative products and projects and the companies or individuals who have fabricated and designed them.

Divestment of Ruukki Construction’s business operations. As communicated earlier, SSAB has agreed to divest Ruukki Construction’s business operations in Russia (OOO Ruukki Rus) to the Russian company OAO Salavatneftemash. The transaction has received the approval of the Russian competition authorities and has now been completed. The transferred production facilities are located in Obninsk and Balabanova in the Kaluga region. The transaction excludes the right to the Ruukki brand.

value chain of ABB’s activities, including R&D, engineering, manufacturing, sales and service, as well as supply chain management and corporate functions. Constructed and equipped using the latest environmentally sound materials and systems, including ABB’s record-breaking fast-charging stations for electric vehicles, the site aims to set new standards in sustainability.

Schmolz + Bickenbach 2018 results and outlook. Schmolz + Bickenbach reports an increase in EBITDA in the third quarter of 2018. Adjusted EBITDA of EUR 41.8 million was 10.0% higher than in Q3 2017. Sales increased by 16.0% to 470,000 t, up from 405,000 t in Q3 2017, driven by Ascometal and the solid demand in most end markets and regions. Net debt increased to EUR 651 million due to the integration of Ascometal and a lower free cash flow, from EUR 626 million at the end of Q2 2018. For 2018, the company expects an adjusted EBITDA between EUR 230 million and EUR 250 million.

Pfeiffer Vacuum opens new US facility. Pfeiffer Vacuum, provider of high-tech vacuum solutions for the semiconductor, industrial, coating, analytical and R&D markets, has opened a new facility in Nashua, NH, USA, which will be the home of the North American headquarters for administration, sales, product management, marketing and customer care. In parallel, the former administration building has been converted into a Service Center of Excellence, bringing together under one roof all service activities for the major part of the Pfeiffer Vacuum product portfolio.

SSAB to increase Q&T steel production capacity. SSAB is planning a major investment in SSAB Americas’ steel mill in Mobile, Alabama, to increase the production capacity for quenched and tempered (Q&T) steels and reduce costs. The investment will eliminate production bottlenecks and increase annual Q&T capacity in Mobile to around 400,000 t from currently around 300,000 t. The project will include installation of a new, accelerated cooling system for an improved potential to increase the volumes of more advanced premium products.

Additional Q&T capacity will be created through direct quenching technology similar to that currently used at SSAB’s production facilities in Finland and Sweden. The investment will take place over a period of three years, 20192021.

ABB inaugurates an advanced innovation and manufacturing hub in China. ABB has inaugurated its new ABB Xiamen Hub in the city of Xiamen’s Torch Hi-Tech Industrial Park. The new site integrates the full

Tibnor to acquire Sanistål’s steel distribution business. SSAB’s subsidiary, Tibnor, has agreed to acquire the steel distribution business of Danish Sanistål A/S. This supports SSAB’s strategic target to strengthen its Nordic

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News in brief EVRAZ, Russia has started upgrading its Tashtagol ore mine.

The project will enhance the company’s self-sufficiency in raw materials, increasing ore production at the mine from 2.2 to 3.25 million t/year. The total investment in the project is expected to reach RUB 6.8 billion.

Aperam, Luxembourg has confirmed that the European Commission has initiated a Phase II review of Aperam S.A.’s proposed acquisition of VDM Metals Holding GmbH, Germany.

Nucor Corporation, USA is acquiring Corporacion POK, S.A. de C.V., a fully integrated precision castings company with a facility in Guadalajara, Mexico.

POK produces complex castings and precision machined products for the oil and gas, mining and sugar processing industries.

Liberty, United Kingdom (part of Sanjeev Gupta’s global GFG Alliance) has entered into a committed financing agreement with a syndicate of major international banks for the purchase of Aluminium Dunkerque, Europe’s largest aluminium smelter from Rio Tinto, United Kingdom.

ArcelorMittal, Luxembourg has reached an agreement with Liberty for the sale of its finishing lines at Dudelange (Luxembourg) and Liège (Belgium). The assets are the final part of a divestment package agreed between Arcelor Mittal and the European Commission (EC) during the EC’s investigation into the company’s acquisition of Ilva S.p.A. JSW Steel, India is to integrate the recently aquired 1.3 million t Aferpi Mill with its Indian facilities as part of the Italian steelmaker’s phased turnaround plans.

MPT International 6 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

home market position. The acquisition includes Sanistål’s modern and highly automated steel distribution centre in Taulov and three other sales offices in Denmark as well as a sales office in Latvia. Subject to the approval by the Danish competition authority, the transaction is expected to close in the second quarter of 2019.

Tibnor appointed certified partner of SSAB. SSAB has appointed Tibnor as an SSAB Laser® certified partner. To ensure greater availability, prompt deliveries and strong product expertise, SSAB has added Tibnor to the network of distribution partners for SSAB Laser in Sweden, Finland, Norway and the Baltic region.

RHI Magnesita opens new headquarters. RHI Magnesita, which a year ago was created by a merger of the Austrian company RHI and the Brazilian company Magnesita, has opened its new headquarters in Vienna. The new headquarters in the Euro Plaza in Vienna’s 12th district accommodates 460 workplaces on 7,600 square meters.

Fives joins forces with Simsa to create Fives Grinding Mexico. For more than two decades, Fives has worked with Simsa to develop its machine offer in Mexico. The companies have now joined to form a new entity, Fives Grinding Mexico, to boost the local presence of the Fives’ supply of grinding systems, predominantly for the automotive industry. Simsa is a Mexican company specializing in rebuilding machine tools mainly for automotive and aerospace. Fives Grinding Mexico will offer Mexican industrial players direct support for machine performance optimization and the modernization of full production systems. This will include the production of commodity machines to complement the process equipment already offered by Fives.

voestalpine boosts aerospace business with startup of new high-tech forge. Three major new facilities have gone into operation at MPT International 6 / 2018

voestalpine in Kapfenberg, Austria.

The highlight is a EUR 40 million forging line that, for the first time, will enable the production of materials for highly stressed, rotating aircraft turbine components.

Meanwhile, voestalpine is expanding its portfolio of steel grades for the automotive and oil and gas industry.

The run-up phases for a production facility for metal powder used in 3D printing and a state-of-the-art chemical laboratory have been completed, and work on constructing the new special steel plant is also progressing rapidly. voestalpine plans to invest around EUR 0.5 billion in technology development and digital transformation in Kapfenberg by 2021.

Partnership between Rhodes Interform and Dr. Hochstrate Maschi­nen­bau. Rhodes Interform, part of Group Rhodes, based in the UK, has embarked on a new working partnership with German manufacturer Dr. Hochstrate Maschinenbau to act as UK and Ireland distributors for its range of guillotine shears, in addition to its hydraulic folding machines that it already distributes. The Dr. Hochstrate plate shears are known for their sturdy and robust folded and welded steel construction, which makes them lighter in weight compared to conventional machines and ideally suited to the sheet metal industries.

GFC Alliance Group to buy Keystone Consolidated Industries.

GFG Alliance, led by executive chairman and metals magnate Sanjeev Gupta, is to buy the US steel company Keystone Consolidated Industries (KCI) for USD $320 million. KCI is headquartered in Texas, USA, and manufactures steel products including billet and wire rod. The purchase is the latest of GFG Alliance’s investments in North America that are planned to total USD $5 billion. It follows the successful reopening of Liberty Steel’s plant in Georgetown, South Carolina, in June.

Personalities Liberty appoints new chief executive of its UK steel division. Liberty, part of Sanjeev Gupta’s global

GFG Alliance, has appointed Cornelius Louwrens, one of the European metals industry’s most prominent figures, as chief executive of its UK steel division.

He is currently chief executive of NBH Plate, part of the international NLMK Group. Mr. Louwrens will take up his new post in February and be responsible both for the performance and sustainability of the existing Liberty Steel UK portfolio, and for leading the Group towards its target to build 5 million t of Greensteel production capacity. In addition, he will support Liberty’s global growth strategy in the steel sector.

Changes in NLMK Clabecq and NLMK Verona management.

NLMK has announced the appointment of Peter Georg Selbach as CEO of NLMK Belgium Holdings plate business, which includes two companies in Europe: NLMK Clabecq (Belgium) and NLMK Verona (Italy).

Peter Selbach is succeeding Cornelius Louwrens, who will leave the company before the end of 2018. Selbach has also joined the management board of NLMK International BV, NLMK Group’s international asset management company.

Peter Georg Selbach

NLMK appoints new CFO. Shamil Kurmashov has been appointed as NLMK Group’s new CFO. Shamil Kurmashov will be in charge of coordinating the work of financial departments across all NLMK Group companies, supporting the execution of the new

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INTERNATIONAL INDUSTRY NEWS strategic cycle and driving the efficiency of business processes in their economic and financial aspects, including the implementation of digital technologies.

ner contributes special expertise to the development of national and international sales strategies. Mr. Wagner will expand his responsibilities, both nationally and internationally, in the distribution of machines and systems that require special explanation as well as in the sales of complex machine components.

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ISRA Vision AG appoints new board member for Industry 4.0.

Dr. Jens Magenheimer has been appointed to ISRA’s executive management in order to steer the growth of its metal business. Dr. Magenheimer has been responsible for sales in the business for many years and has also played a key role in product development.

Alongside the continuous expansion of ISRA’s product portfolio, Dr. Magenheimer will ensure that the metal business unit is consistently aligned to the vision of Industry 4.0. This will include pursuing a full portfolio strategy to establish automated 2D and 3D inspection and measurement technology for the entire metal production process.

Projects in deep learning and artificial intelligence (AI) during optical inspection will follow.

Shamil Kurmashov

ABB Bulgaria introduces new Country Managing Director. Marcel van der Hoek is assigned as Country Managing Directory of Bulgaria, replacing Ekkehard Neureither who spent five years as a country leader in Bulgaria and is taking new responsibilities within ABB. In 2011, Mr. van der Hoek joined ABB Slovakia as Country Manager and led the country successfully for over six years. During his stay, ABB Slovakia expanded its business in many directions, including robotics, power, automation and services.

Uwe Wagner

SSAB appoints new manager for press and sustainability. Mia Widell has been appointed as the new manager for press and sustainability communications at SSAB. She has many years of experience in communications and journalism.

Ms. Widell will have a key role in highlighting and explaining SSAB’s activities in areas such as sustainability and innovation.

She takes up her new position at SSAB on January 15, 2019 and will report to Viktoria Karsberg, VP, Head of Corporate Identity and Group Communications.

Dr. Jens Magenheimer

With us, advertising prices are small and results are big!

New Advertising Team: Wolfgang Locker Phone +49(0) 22 03/35 84-182 wolfgang.locker@maenken.com

Marcel van der Hoek

Pallmann Maschinenfabrik GmbH & Co. KG: Uwe Wagner joins the Management Team of Pallmann, the size reduction specialist within the Siempelkamp Group, starting January 2019. His appointment follows the retirement of Hartmut Pallmann. Wag-

Katharina Flick Phone +49(0) 22 03/35 84-136 katharina.flick@maenken.com

Mia Widell MPT International 6 / 2018

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In memory of John Vallomy, inventor of the Consteel® process (1927-2018) John Vallomy, the renowned inventor and steel entrepreneur, passed away at his home in Charlotte, North Carolina, on October 3, 2018. He was aged 91. Mr. Vallomy submitted nearly 20 patents during his lifetime, yet is perhaps best known for inventing the Consteel® Continuous Melting-Preheating-Refining Electric Arc Furnace (EAF) Steelmaking Process.

First commercially installed in Charlotte in 1989, Consteel revolutionized steel production and has, ever since, been used around the world as a key technology for scrap continuous pre-heating.

Born near Point Saint Martin in the Aoeste Valley region, Italy, Mr. Vallomy would spend 57 professional years in the steel industry in technical, operational and management positions. For the first part of this ca-

Events › 14 – 17 January 2019 United Arab Emirates (UAE) Organizers: Expo Centre Sharjah www.steelfabme.com SteelFab. Now in its 15th year, SteelFab provides the latest technology and industry know-how. Last year’s event featured more than 1,000 brands and attracted close to 7,200 visitors during its four-day run. There are special focus segments dedicated to pipe and tube, welding and cutting and machinery and tools.

› 16 – 17 January 2019 Organizers: untitled exhibitions GmbH Hamburg, Germany www.automation-hamburg.com aaa – all about automation hamburg. The exhibition all about automation will include discussions about MPT International 6 / 2018

reer, he worked in continously charging direct reduced iron (DRI) to the EAF, initially at Technint group’s melt shop in Tamsa, Mexico, and then at the Dalmine Siderca steel plant in Argentina. It was during this

the requirements for automation solutions in the context of Industry 4.0.

Systems, components, software and engineering are all featured.

› 22 – 24 January 2019 Mumbai, India Organizers: FICCI www.ficci.in India Steel 2019. Staged for the fourth time, the international exhibition and conference on steel industry is an industry event to meet face-toface with key individuals involved in the production and processing of iron and steel.

› 12 – 13 February 2019 Nürtingen, Germany Organizers: fairXperts GmbH & Co. KG www.wissenstransfer.events 8. Fachtagung Entgrattechnologien und Präzisionsoberflächen.

time that Mr. Vallomy developed his idea to continously charge scrap in a similar way to the EAF. He founded his own company in 1980, Intersteel Technology Inc. (ITI). ITI became part of the Technint Group of companies in 1995, during which time Mr. Vallomy proceeded to develop the sales and marketing strategy for Consteel worldwide. Today, there are 35 Consteel installations globally with eight in North America alone.

Mr. Vallomy became a citizen of the United States of America in 2009.

That same year, he was awarded the Tadeusz Sendzimir Memorial Medal by the Association for Iron and Steel Technology (AIST) in recognition of his achievements as an innovator and pioneer in modern iron and steelmaking.

‘The eighth symposium for deburring technologies and precision surfaces’ will focus on innovations and practical reports for the production of burrfree edges, fillets and solutions for increasingly complex and demanding components.

› 28 – 29 March 2019 Vienna, Austria Organizers: ASMET Wirtschaftskammer Österreich www.asmet.org ASMET Werkstofftechniktagung 2019 & 31. Härtereitagung. The Austrian Society for Metallurgy and Materials invites innovators in the fields of heat treatment processes and plants, optimized material concepts (including steels and light metals) and material testing and characterization (through new and optimized processes or applications) to submit their papers for March’s conference in Vienna.

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Kocks develops outstanding hot surface inspection system for demanding long product To meet the needs of rolling mills while maintaining a clear aim for complete surface inspection, Kocks of Germany has developed the Kocks 4D Panther®. The high-performance surface inspection system can detect the smallest defects, to the satisfaction of customers including Acciaierie Valbruna S.p.a. of Italy.

Quality requirements for hot-rolled tube, wire rod and bar have been growing constantly for a long time. Because dimensional tolerances are narrow, well-defined mechanical properties, as well as know-how related to the evolution of defects, are top priorities for steel producers.

Nevertheless, compromise is often necessary in modern rolling mill practices in order to meet these objectives and still operate economically. The major cost factor? Yield loss caused by insufficient surface quality.

Enhanced detection of defects on hot rolled product Typically, each rolling mill records common surface defects on an individual basis. Defect catalogues also publish them with descriptions of the defects’ characteristics. Whereas surface cracks can generally be traced back to the steelmaking and continuous casting process, laps and shells normally arise from the rolling process. As a result, mechanical damages (e.g. scratches) can occur at many points during the production process in a rolling mill – and easily.

Surface defects do not necessarily mean that the product has to be scrapped, however. The final application determines whether tubes, wire rods and bar products with surface defects should be disposed of. It also decides the specified limits in terms of depth, width, height and frequency.

Friedrich Kocks GmbH & Co KG, Hilden, Germany Contact: www.kocks.de Email: fk@kocks.de

But, no matter how far advancements in process technology take the evolution, defects on the final product will never be completely avoidable. Technologies for the detection of defects have always exhibited issues in terms of reliability and convenience; or, at least, that has been the case with previously available products.

Designed for a zero false positive rate The Kocks 4D Panther is designed to offer the capability of a 100% inline detection of surface defects while achieving a zero false positive rate. The optical system works with extremely high scan rates that are combined with smart and fast software algorithms. It is this combination that makes the difference when compared with previous technology. The system is fully operational upon completion of commissioning, and timeconsuming training is not required because the system is easy to use.

As opposed to the common non-destructive testing procedures in the finishing department, the 4D Panther enables defect detection already during hot rolling.

For customers like Acciaierie Valbruna S.p.a. of Italy, advantages of the new technology include 100% inline surface detection, an unattainable highest measuring frequency as well as an integrated electrical cabinet. The machine’s stainless steel housing ensures reliable long-term operation while the measuring cell is fully-sealed and resistant against scale, water and dust.

In addition, the 4D Panther causes no process water consumption and the cooling concept works with closedloop water circulation.

The Kocks 4D Panther ® is designed to offer a 100% inline detection of surface defects

Software ensures real time identification of defects Regarding software, the program works with real time identification and visualization of defects and offers 3D reconstructed surfaces to achieve a realistic view of any imperfections.

Documentation and data archiving functions are used to create a knowledge-database for the user.

Going forward, the system can provide an advanced basis on which to develop greater knowledge about the impacts on quality that originate from steelmaking and the rolling mill practice. The advantages of this can extend across operators’ processes and successful working patterns can be acquired, learned and applied.

Specialists at Kocks say that the 4D Panther will contribute towards efficiently improved product quality and help to ensure the commercial success of companies that use the new technology.

MPT International 6 / 2018

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Global steel demand will reach 1,657.9 million t in 2018, according to worldsteel

World Steel Association says global steel demand continues to show resilience The World Steel Association (worldsteel) reports that global steel demand in 2018 was supported by renewed investment activities in developed economies along with improvements in emerging markets. The demand is expected to remain positive into the New Year, growing at 1.4% globally.

The World Steel Association (worldsteel) has released its 2018 Short Range Outlook (SRO) which reports that global steel demand will reach 1,657.9 million t in 2018. This is an increase of

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

MPT International 6 / 2018

3.9%* over last year. The SRO goes on to forecast that global steel demand will grow by 1.4% to reach 1,681.2 million t in 2019.

Commenting on the outlook, Mr. Al Remeithi, Chairman of the worldsteel Economics Committee said: “In 2018, global steel demand continued to show resilience, supported by the recovery in investment activities in developed economies and the improved performance of emerging

economies. “Demand for steel is expected to remain positive into 2019, growing at 1.4% globally,” he added.

Global steel demand faces uncertainty from tensions in the global economic environment While the strong steel demand recovery seen in 2017 was carried over to 2018, risks have grown as rising trade tensions and volatile currency move-

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INTERNATIONAL INDUSTRY NEWS

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ments increase the levels of uncertainty. The normalization of monetary policies in the USA and the EU could also influence the currencies of emerging economies.

China steel demand growth is expected to decelerate in the absence of stimulus measures Steel demand in China was boosted from the mini stimulus in real estate and the strong global economy during the first half of 2018. However, continued economic rebalancing efforts and toughening environmental regulations will lead to a deceleration of steel demand towards the end of 2018 and 2019.

There are both downside and upside risks for China. The downside risks come from ongoing trade friction with the USA and a decelerating global economy. However, should the Chinese government decide to use stimulus measures to contain the potential slowdown of the Chinese economy in the face of a deteriorating economic environment, then steel demand in 2019 will be boosted.

Steel demand in the developed world remains healthy, but growth will be moderate Steel demand in developed economies is expected to increase by 1.0% in 2018 and 1.2% in 2019.

USA steel demand grew strongly in 2017. It benefited from strong consumer spending and business investment supported by tax, regulatory changes and fiscal stimulus – although growth in the construction sector moderated.

The rise in demand should slow in 2019 as automotive manufacturing and construction activities are expected to see modest growth.

f – forecast ASEAN (5): Indonesia, Malysia, Philippines, Thailand, Vietnam * See note (page 18)

Demand for steel is expected to remain positive into 2019, growing at 1.4% globally

Meanwhile, the USA’s manufacturing industry is predicted to perform well thanks to the strength of the machinery and equipment sectors.

In the EU, the broadening recovery of steel demand is expected to continue, although at a reduced pace driven mainly by domestic demand. With business confidence high, investment and construction has continued to recover while the automotive market may see slower demand growth.

Although the economic fundamentals of the EU economy remain relatively healthy, demand for steel in 2019 will show some deceleration relative to the growth seen in 2017-18. This is partly attributed to the uncertainties arising from global trade tensions.

In Japan, steel demand is expected to remain stable due to supportive factors on investment. These include record high corporate earnings, the continuation of monetary easing, demand associated with the Tokyo Olympics and

China is predicted to remain as the world’s top steel using country in 2019

the increasing need for labour-saving investments.

Demand for steel in Korea is expected to contract further in 2018. All of the country’s major steel using sectors are struggling and only a minor recovery is expected in 2019.

The developing world’s steel demand recovery continues, but faces challenges As India recovers from the twin shocks of demonetization and implementation of the goods and services tax (GST), the country’s demand for steel is expected to move back to a higher growth track.

This demand will be supported by improvements to investment and infrastructure programs. Stressed government finances and corporate debt will also weigh on the outlook.

Looking to the Association of Southeast Asian Nations (ASEAN), sluggish construction activities and stock adjustments led to a slow growth of steel demand in 2017 and 2018. Nevertheless, demand in the ASEAN region is expected to resume its growth momentum, backed by infrastructure programmes in 2019 and onwards. The risks are largely related to rising trade tensions between the US and China, currency volatilities and ongoing political instability.

In developing Asia – excluding China – steel demand is expected to increase by 5.9% and 6.8% in 2018 and 2019 respectively.

MPT International 6 / 2018

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Slow momentum and steady recoveries in the emerging and developing economies Recovery has been slow to gain momentum in the remainder of the emerging and developing economies, with rising uncertainty both in domestic and external environments. worldsteel cites structural reforms, high financial market vulnerability and possible currency pressures from tensions in the global economy as being among the main reasons.

In the Gulf Cooperation Council (GCC) countries, reforms and a stronger oil market have led to an upward momentum in steel demand but at a slow pace. The outlook for Iran has

become less favourable due to the reinstatement of sanctions by the USA. Even with the rise in oil prices, growth in steel demand in Russia is expected to show weak momentum.

Demand in Turkey is expected to contract in 2018 as a result of the currency crisis it has faced. But the government’s stabilization measures and a consequent return to competitiveness in its manufacturing sector are expected to help recovery in 2019.

In the Latin American markets, steel demand continues its second year of recovery backed by positive developments in the domestic and global economy. Steel demand in Brazil maintained a stable recovery in 2018. This

is expected to commence into 2019 as the fever and tensions surrounding its recent election subside.

Demand in Mexico has suffered because of uncertainties related to the North American Free Trade Agreement (NAFTA) negotiation and the country’s recent election. However, the appointment of new President Andrés Manuel López Obrador and the recent signing of the United States–Mexico–Canada Agreement (USMCA) should calm the jittery markets and help Mexico’s economy to recover slowly in 2019.

Overall, worldsteel expects steel demand in the emerging economies – except China – to grow by 3.2% and 3.9% in the years 2018 and 2019, respectively.

Mixed outlook for the construction and automotive markets in many countries

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MPT International 6 / 2018

In the developed economies, growth in the construction sector is likely to moderate after the strong recovery momentum seen in 2017-18. This is due to a high base and rising interest rates. On the other hand, construction activities in most developing economies will continue to grow – notably in India, ASEAN and the Middle East and North Africa (MENA). Brazil’s construction sector has not yet started to recover from its deep crisis.

The automotive markets, which have shown strong growth in the developed economies, are softening on the back of slowing demand growth, rising fuel prices and interest rates. Demand for automobiles is expected to grow at a healthy pace.

Meanwhile, the machinery sector in both the EU and USA continues to be supported by a strong business investment phase. *Note: China continued to close most of its outdated induction furnaces in 2017, which was not captured in official statistics. While nominal steel demand growth in China is expected to reach 6.0% in 2018, the dynamics of steel using sectors suggest a growth of 2.0% in real terms. Accordingly, the real global growth in 2018 is 2.1%. As reported in worldsteel’s October 2017 Short Range Outlook, this disparity comes from an underestimation of the 2017 steel use that had been supplied by the illegal induction furnaces.

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››› COMPANY PROFILE

Danieli presents its plans to remain ‘a step ahead’ of the market Danieli revealed its financial statement for the fiscal year ending June 2018 on October 23, the group’s first to be video streamed live online across five continents.

The presentations also looked towards future prospects, Industry 4.0 and the ‘new normal’ markets.

Danieli’s revenues, amounting to 2.75 billion, rose by 9% compared with last year. Its operating margins have risen by 7% over the previous year, reflecting the margin that was present in the order backlog at the beginning of 2018, and which transformed into turnover over the subsequent months.

The group’s steelmaking sector has performed strongly with almost 1.3 million t of product shipped, offsetting a decline in its plant making business. This is attributed to such factors as: restarting of the market for Federally Administered Tribal Areas (FATA); important new orders taken in Abu Dhabi and Croatia; and the start-up of an ESW Röhrenwerke GmbH tube mill in Eschweiler near Aachen, Germany, which has significantly increased the customer’s production efficiency.

The company attributes the rise in its net operating margins to the strong results of ABS (Acciaierie Bertoli Safau SpA), the group’s division dedicated to producing special long steels as used in the engine parts of cars, train wheels and earthmoving machines. Significant developments within ABS include a new Rotoforge plant in Italy equipped for innovations in heavy special bar quality (SBQ) steel production.

Danieli said the plant, along with a new Steel Centre for ABS, have enabled an expansion of the product range along with higher quality and production efficiency.

Danieli & C. S.p.A, Buttrio, Italy Contact: www.danieli.com Email: info@danieli.com

MPT International 6 / 2018

Resources, technology and innovation Giacomo Mareschi Danieli, CEO and member of the Group Executive Board and Director of Danieli, said: “We are coming from one of the longest periods of depression of the mid-recent past.

This has had consequences for our company and for the world.”

He observed that the group’s strategies had enabled it to come out even stronger than before: “We were quick to decide on the adaptation of the structure and how to run it to remain competitive. We diversified at the right time and in the right way with steel plants and FATA. We never stopped investing in resources and technology.”

Referring to the strong pressures and trends of the market, as a result of which Danieli has incurred more overhead costs than originally expected, Mr. Danieli said: “We have never denied our international nature with our production and engineering units around the world. Now, we must continually evolve to remain ‘a step ahead’ of the market.”

Highlighting flexibility and innovation as two of Danieli’s main objectives, he added: “Planning of activities and method of execution of the contract should not be confused with rigidity and bureaucracy. On the contrary, we are working to increase our responsiveness to follow the trends of individual projects in the short term and our ability to anticipate fluctuations in the market. This theme is our current mantra.”

Self-owned factories and local resources Alessandro Trivillin, CEO of Danieli, noted that more than 50% of steel is presently consumed in Asia. He said

that Danieli owning its own factories distinguishes it from competitors and this is among its strengths and strategic values. The company’s facilities in China, Thailand and India flank the European ones, said Mr. Trivillin.

“Having complete control of production allows us to guarantee high quality standards. Being physically close to the market guarantees faster delivery times, a more effective after-sales service and, consequently, an increase in the value we can give to our client base. In a nutshell, it favours the creation of long-term relationships.”

However, Mr. Trivillin also observed: “It’s OK to have self-owned factories, it is fine to be present where steel is produced and consumed. But that is not enough. We need constant tension to continuously improve our entire supply chain and internal productivity.”

During his own presentation, Mr. Danieli said that regional plants will be increasingly favoured – i.e. those that use local resources to serve the local market. “Fortunately, the technologies developed by Danieli in recent years perfectly match this new trend,” he said.

Demand for steel in the ‘new normal’ period Talking about the company’s market and clients, Mr. Danieli said that, fortunately, steel remains one of the most important materials supporting industrial development. He observed that the trend in world steel consumption is sustained by an extraordinary expansion of Chinese demand that started in the year 2000.

“We recently entered what we had already defined as the ‘new normal period’ which had previously lasted approximately 30 years. We are now

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Digi&Met, Danieli’s business unit for plant designs based on digital innovation, is among the group’s main drivers towards modernization MPT International 6 / 2018

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accustomed to the characteristic and physiological highs and lows of the market; a moment of sustained demand that, however, we are well aware follows one of the most negative periods of the last 50 years.”

Mr. Danieli highlighted several key points: ▪▪ Danieli’s plants are increasing the utilization rate that has passed on average from 71% in 2017 to 78%.

This means its customers are making profits and, hence, are investing again, ▪▪ the trend in offers confirms this, showing a constant rise in terms of both numbers and in absolute value, ▪▪ steel production increased by 4.8% in the first six months of 2018, driven mainly by the growth of China but also by a favorable global economic situation and, not least, influenced by the current trade war, ▪▪ Danieli’s current forecast for the next three years is a further production growth of around 2 to 3%.

On the subject of India’s metallurgical industry, Mr. Danieli described the country as “the eternal promise”.

“Digitalization is going to be one of the changes needed to provide a better service to customers,” said Danieli’s chairman, Gianpietro Benedetti

He said the positive trend in India’s markets in recent years gives more value to the investments by Danieli in the country, in terms of both production and customer service.

Ongoing digital change towards Industry 4.0 Danieli’s chairman, Gianpietro Benedetti, is a key promoter of Danieli’s increased digitalization activities (including the online broadcast for its

2018 financial statement). Asked about the ongoing digital change towards Industry 4.0, he said: “Digitalization is going to be one of the changes needed to provide a better service to customers; helping them to optimize plant use, cut production costs and achieve flexibility to diversify production.”

This echoed comments made earlier

by Giacomo Mareschi Danieli about how digitalization and innovations are increasingly made for, and in collabo-

Giacomo Mareschi Danieli, CEO and Director of Danieli, said regional plants will become favoured to serve local markets MPT International 6 / 2018

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Alessandro Trivillin, CEO of Danieli, discusses the successful performance of ABS, Danieli’s division for producing special long steels

ration with, the group’s clients and partners. Whether related to products, processes, mechanics or automation, all are increasingly linked to digitalization.

“Everything must be based on a solid base of knowledge and know-how, something of which innovation is the backbone”, said Mr. Danieli.

He referred to the group’s Digi&Met ‘cross functional’ business unit which develops and implements new plant design concepts based on digital innovation; new business models; servitization (when companies develop the capabilities they need to provide services and solutions that supplement their traditional product offerings); and outcome economy principles. Also highlighted was MiDa, or the micromilldanieli, which is equipped with endless casting and rolling technology for long and flat products.

“We have concentrated the best skills of the group in this field,” said Mr. Danieli. “This product is a perfect synthesis of what Industry 4.0 technology can do in a complex process like a melting furnace. In this way, we obtain results unimaginable with the help of operators alone.

“For us, thanks to the synergy between Danieli and ABS we are ideally suited to pursuing the Industry 4.0 and customers are recognizing this.”

Minimills, ironmaking and steelmaking plants Danieli has carried out more than 40 successful start-ups during the year 2017 to 2018. Projects of particular

significance mentioned during its financial statement included: ▪▪ voestalpine Stahl, Austria. voestalpine has eight cast slabs in its Linz plant. The last was provided by Danieli and it began recently with a record start-up. From that day on, the customer (one of the most demanding in the world) has moved all of its production of automotive exposed grade onto the Danieli casting. The group said it was very proud of this project.

▪▪ Yildiz Demir Çelik, Turkey. A newcomer to the world of iron metallurgy, the customer recently completed a cold strip plant. Danieli said the relationship was built not only on technology but also trust as it introduces the customer, step by step, to the world of steel.

▪▪ Hoa Phat Steel Sheet, Vietnam.

For the first phase of the large integrated plant, the cold lines were started at the beginning of 2018.

This is the first of a long series planned with this partner.

▪▪ voestalpine Wire Technology, Austria. At the beginning of the fiscal year, VAS Donavitz launched the most modern quality wire rod plant in the world. Danieli has won many positive testimonials for the project that it describes as being one of its most advanced in the world.

▪▪ Chanchiang S.S., China. Cited as one of China’s most recent successful start-ups, the plant is equipped to produce 300,000 t/year of 20 to 40 mm bars of martensitic stainless steel.

MPT International 6 / 2018

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››› EVENTS

Photo: csi

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A Volkswagen Caddy demonstration vehicle was fitted with an extremely strong front end structure made from the 3D printed high-performance alloy, Scalmalloy. Not only heat management but also passive safety, liquid storage and other functions were integrated in the organic, load-driven design of the front module

Additive manufacturing: the key issue for future production engineering As conventional manufacturing technologies are supplemented by 3D printing, the foundry and steel industries are also recognizing its potential. For this reason, the four trade fairs GIFA, METEC, THERMPROCESS and NEWCAST 2019 (all in Düsseldorf, Germany, between June 25 to 29, 2019) will devote a special show to the subject of additive manufacturing.

A look under the bonnet of the demonstration vehicle shows the potential that industrial 3D printing has for the automotive industry: few components but with more functions and considerably less weight. The new crashproof front end structure of the old Volkswagen Caddy, which weighs 34 kg, is made from the extremely strong and tough high-performance alloy, Scalmalloy. The material was made by

GIFA, METEC, THERMPROCESS, NEWCAST 2019 Contact: www.tbwom.com Email: info@messe-duesseldorf.de

MPT International 6 / 2018

the Airbus subsidiary, APWorks, using a 3D printer supplied by the German company, EOS. This 3ipring project, carried out under the leadership of the development service provider csi, won the ‘German Innovation Award 2018’ in mid-June.

The Caddy concept indicates what is technologically possible in automotive production by using new design methods and new materials with the help of additive manufacturing.

Three-dimensional manufacturing processes – the general term used for the various additive production technologies with all the different kinds of 3D printing systems – are where the future lies. Additive manufacturing with

plastics, metals and ceramics is already an essential feature of industrial production today. Almost 40% of German companies surveyed in 2016 by the consulting firm, EY, said they already used 3D printing.

The potential in all the different fields is tremendous. For instance, 3D printing with concrete could revolutionize the construction industry. The bioprinting of living tissue is already possible, and even the printing of human organs is now the subject of serious research.

In the metal industries, 3D printing is also creating new opportunities with aluminium, steel, titanium and special materials, whether foundries and steel

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EVENTS

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mills or forging and sheet processing companies are involved.

High-tech with integrated functions: heat management as well as space and weight reduction are crucial features of the design for the innovative front end

manufacturing with wire. “What is often forgotten is that additive manufacturing cannot overcome the laws of physics either. In the final analysis, all that’s involved there, too, are processes: melting and cooling. There are limits to the speed at which this is possible,” said Dr. Geisler. In addition to this, the printed articles need to be machined into finished functional components.

Another definite disadvantage of additive manufacturing with metal is the high energy consumption involved.

Dr. Wolfram Volk, Professor of Metal Forming and Casting at the Technical University of Munich, calculates that about twice as much energy as in conventional casting is required for the laser melting of metal, from powder pro-

duction to the finished component.

Additive processes are becoming an increasingly common element of existing process chains.

The competing machine tool manufacturers, DMG Mori and Hermle, have demonstrated how additive manufacturing and machining can be combined to carry out comprehensive, hybrid processing in a single machining centre. DMG Mori supplements laser metal deposition by subsequent machining in the form of turning and milling. Meanwhile, Hermle, extends a multi-axis machining centre by a thermal spraying process. This uses its metal powder application (MPA) technology in which metal powder is applied in

Photo: Voxeljet

With 3D printers, structures are produced layer by layer on the basis of digital design data. Material is only used where it is needed. Additive technologies have strengths where conventional manufacturing processes like casting, milling or forging reach their limits. For instance, 3D printing gives designers unlimited geometric freedom.

Complex components with a bionic structure and integrated functions can be produced with varying wall thicknesses, cavities and honeycomb structures – e.g. the heavy-duty, lightweight metal, automotive structure from the 3iprint project outlined above.

The production of small batches, and even of individual components, is also economically viable with 3D printing. Die casting moulds or forming tools are not required, which quickly leads to several tens of thousands in cost savings. Individualized components, prototypes and spare parts that are rarely needed are therefore considered to be a ‘domain’ of additive manufacturing.

Nevertheless, 3D printing is not an ‘attack’ on the bastions of established production engineering. As the manufacturing expert Franz-Josef Wöstmann, from the Fraunhofer Institute IFAM in Bremen, said: “Additive manufacturing is a supplement not a substitute.”

At present, the latest 3D printing technologies reach their limits where large product quantities can be made economically with conventional manufacturing. This is primarily the case in the high-volume segment of the automotive industry. Additive manufacturing with metal is currently not productive enough for mass production in series.

Dr. Stefan Geisler, Innovation Manager at KSM Casting Group in Hildes­ heim, Germany, said: “3D printing will be increasing for premium vehicles and for a limited number of components but it will not succeed in replacing foundries.” Dr. Geisler is convinced that the quantities needed in the volume market cannot be reached even with the faster layering speeds possible – e.g. when using additive

Photo: csi

Unlimited design freedom, with some performance restrictions

A printed sand mould for a large diesel cylinder head from MAN: the mould with dimensions of 1,460 x 1,483 x 719 mm was manufactured additively in 29 hours by the binder jetting process using a sand printer MPT International 6 / 2018

››› EVENTS

layers to produce a soundly built component.

Elsewhere, Gefertec of Berlin, Germany, an expert in additive manufacturing technologies that develops new methods for the production of metallic parts, is looking to increase manufacturing speeds in the additive processing of metals.

Gefertec’s five-axis lines weld wire in layers by the electric arc (EA) process.

The workpieces produced in this way have outlines which are very close to the final shape, reducing the time and tooling operations that are required for subsequent machining.

Foundry: direct and indirect additive manufacturing processes There are several ways in which the foundry industry can benefit from additive processes. Direct additive manufacturing processes give foundries the opportunity to include individual parts, or parts needed in small quantities, in their product portfolio. Indirect processes, on the other hand, use additive technologies to produce moulds and cores out of sand as well as models out of plastic. Hybrid technologies, that involve a combination of conventional casting and additive manufacturing processes, have further potential.

To take greater advantage of the qualities of aluminium to produce lightweight structures in automotive manufacturing, aluminium producer Trimet is working on a hybrid process chain to link die casting and additive manufacturing. This approach, the ‘CastAutoGen’ project, specifically involves the incorporation of 3D printed structures in a die cast component.

Germany’s industry holds a prominent position among the producers of additive manufacturing systems. The country’s market share is about 70% with powder bed systems, according to the BDI (Federation of German Industries). Current world-leading 3D printing manufacturers include Concept Laser (metal), EOS (metal and plastic), SLM Solutions (metal) and Voxeljet.

Cost savings through the 3D printing of moulds and cores Voxeljet specializes in foundries and markets, 3D printers for the production of sand moulds and cores, and plastic models for investment casting MPT International 6 / 2018

Photo: Voxeljet

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Based on the printed sand mould, a large diesel cylinder head cast iron part in manufactured weighing more than one ton

by the lost wax process. To produce a casting requires a mould and the appropriate cores which form the cavities in the component being cast. In classic sand casting, the moulds and cores are made from quartz sand that is strengthened by a special bonding agent.

Whereas, for example, fully automatic moulding machines and automatic core shooting machines are standard features in modern foundries that mass produce car engines, it is rarely economical to use automatic equipment for prototypes and small batches. In this context, 3D printing is an increasingly common and useful alternative.

Sand moulds and cores of any complexity are manufactured with a computer aided design (CAD) dataset via a layering process. Toolless manufacturing of this kind provides high flexibility with regards to numbers, design and versions. It permits the production, in exactly reproducible quality, of complex moulds and cores with practically any geometry.

Voxeljet has reported cost savings of up to 75% in the 3D printing of moulds and cores made from sand for small batches.

Opportunities for die casting companies Die casting with reusable moulds made from tool steel also benefits from 3D printing.

“Additive manufacturing is creating tremendous opportunities for die casting companies,” said Dr. Ioannis Ioannides, CEO of the die casting machine manufacturer Oskar Frech to the magazine Giesserei. Dr. Ioannides is also Board Chairman of the VDMA foundry machine trade association

and a member of the board of the VDMA additive manufacturing task force. Specifically, Frech uses 3D printing to produce a complex key component for its low-sprue Flick Gocke Schaumburg (FGS) tool technology that economizes on recycled material (e.g. aluminium or magnesium).

The mould plays a key role in the die casting process. It’s important that the castings solidify as quickly as possible.

The process time for a component can be shortened by faster cooling, while the quality of the casting is improved at the same time, too. This depends on adequate heat removal in the casting mould which is achieved traditionally via cooling holes. However, due to process constraints, there are limits to how close to the shaping surface the cooling holes can be produced.

Additive manufacturing can help here, because cooling close to the surface is possible even in critical areas of the mould due to the tremendous amount of design freedom.

Steel industry: numerous opportunities with 3D printing The situation in the hot forming of steel plate is not much different than in die casting. Cooling close to the surface increases productivity and quality here, too. Additive manufacturing has therefore been a standard process in the tool production operations of German car manufacturers for a long time now.

Steel companies are discovering additive manufacturing as an additional area of operation to an increasing extent. The Austrian technology and steel company voestalpine, for example, chose Düsseldorf to be its corporate centre of excellence for metal additive manufacturing two years ago.

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EVENTS

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Initial results have been achieved.

Together with the development service provider, Edag, and Simufact, the specialist for simulation software, the Austrian company has developed a lightweight bonnet hinge with integrated pedestrian protection that is produced by additive manufacturing.

The biggest open die forging company in Southern Germany, Rosswag Engineering of Pfinztal, is demonstrating the ‘best of both worlds’. Rosswag manufactures new products by linking the two manufacturing processes of forging and selective laser melting of steel powder. The production of a heavy-duty, forged workpiece with appropriate grain flow is followed by additive manufacturing via a 3D printer to supplement the complex structures.

For instance, in the case of an impeller with additively manufactured vane structures, channels were incorporated to influence flow characteristics.

Significant reductions in the weight of dynamically moving components The most recent member of the additive manufacturing club is SMS group, the specialist for metallurgical machine and plant manufacturing.

The group has installed a new pilot plant for metal powder production in Mönchengladbach, Germany, at which it has several projects. On the one hand, SMS not only aims to produce high-purity metal powder for additive manufacturing on behalf of customers, but also to develop and test new materials.

The company can apply decades of experience with the atomization of iron powder or sintering, extensive metallurgical know-how and wideranging expertise in thermal process engineering. As a plant manufacturer, SMS intends to supply the rapidly growing market for metal materials for additive manufacturing processes by marketing powder atomization equipment. Last, but not least, the group’s in-house metal powder production facilities are a link in the company’s additive manufacturing process chain.

SMS group is already additively manufacturing spraying nozzles for swaging presses. These are produced either from plastic or from metal in accordance with the customer’s needs.

Additive manufacturing processes are using new design methods and new materials

Spraying nozzles remove scale from dies, cool the surface, apply lubricants and dry the dies. Whereas the original spraying nozzle was a solid and heavy component, very light and compact spraying nozzles can be produced by 3D printing that are customized precisely to meet the requirements of individual dies.

The company reports that use of the 3D spraying nozzles leads to a reduction in cycle time, as well as to an extension of tool service life in the swaging process. Other projects have shown promise, too: ▪▪ a conformal design with integrated nozzles is an outstanding feature of a new roller cooling pipe for wire rolling mills. Using alumide, a combination of aluminium and plastic powder, the structure is easier and more cost-effective to produce than conventional components, ▪▪ in the steel converter field, it has been possible to reduce the size of the Siemag Injection System (SIS) injectors used for molten steel by 60% while they can be produced from a single part instead of eight parts,

▪▪ pipe welding machines from SMS group can also produce pipe diameters of 14 inches or less in future thanks to printed parts. Smaller but more efficient lubricating rings for the expander tools are possible in a hybrid structure, produced with a combination of additive and conventional manufacturing.

Special additive manufacturing show at GMTN 2019 Further to these developments, Messe Düsseldorf is supplementing its metallurgical trade fairs GIFA, METEC, THERMPROCESS and NEWCAST (which are being held from June 25 to 29, 2019) by a special additive manufacturing show.

Exhibitors from all over the world will be presenting new developments about additive processes on the GIFA site. Other participants are software companies that will be highlighting solutions from 3D visualization and modelling to data processing, as well as metal powder suppliers and producers of machines, equipment and processes for additive processing and subsequent machining.

MPT International 6 / 2018

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››› STEELMAKING – MODERNIZATION

SMS group unveils its plans to become the leading provider in digitalization

The annual press conference of SMS group was held at the offices of SMS digital GmbH in Düsseldorf, Germany on October 10, 2018. The company announced four strategic growth areas as its most important drivers and said it will pursue a strong focus on foreign growth markets.

SMS’s four so-called “central offensives” are: ▪▪ digitalization with a view to creating growth, ▪▪ new business models (including those made possible by digitalization), ▪▪ expanding the group’s services business to generate around one third of all business volume, ▪▪ a number of “promising projects” that the company calls New Horizon.

While the boom years were marked by major new construction projects, modernization projects are now the main focus of our business,” Burkhard Dahmen, Chairman of the Management Board for SMS group, told the conference’s press and attendees.

“After some difficult years, the situation of steel producers has improved.

Steel prices have risen significantly and the profits of many of our customers are developing accordingly.

However, it must also be noted that there is still a global overcapacity in steel production; around 30% of capacities are currently not being used.

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

MPT International 6 / 2018

Picture: SMS group

As the steel industry moves away from new construction projects towards modernization, SMS group unveiled its key new business drivers at the company’s recent press conference in Düsseldorf, Germany. They include digitalization, 3D printing and ‘self-learning’ steel plants.

The Management Board at SMS group’s conference: Burkhard Dahmen, CEO (centre); to his right is Torsten Heising, Chief Financial Officer; to Mr. Dahmen’s left is Katja Windt, Chief Digital Officer and Guido Kleinschmidt, Chief Technology Officer

This is equivalent to about 15 times the capacity of the German steel industry.”

Mr. Dahmen commented that SMS group’s share of major new projects has declined noticeably in terms of order intake. On the other hand, service and modernization orders are becoming increasingly important. Therefore, the nature of the group’s business has changed significantly to focus on these demands.

“We are systematically pressing ahead with our realignment to maintain our leading position in the rapidly changing market,” said Mr. Dahmen.

“Customers need higher cost efficiency and an improved energy balance. SMS not only provides them with the hardware, but also with the automation, advice and on-site support they need.”

The steel industry is adjusting to the ‘new normal’ markets SMS group confirmed the financial targets in its core business and said it has achieved important successes in its

structural and cultural transformation programme. The group’s order volume for new projects and products in 2018 will be slightly higher than last year.

“We are fully on track. Our clear target is an operating result of 7% in 2021, with an order intake of 3.2 billion EUR,” said Mr. Dahmen.

After years of significant growth – driven primarily by the expansion of the steel industry in China – the last few years have been characterized by stagnating project volumes. SMS group said it was pleased its project volume has recently increased noticeably again, but it does not expect the world market to experience sustainable growth.

“Metallurgical plant construction is a cyclical business,” Mr. Dahmen told the conference. “Overall, our industry will gradually adjust to this ‘new normal’ over the next two to three years and we are also adjusting to the new market level.”

Mr. Dahmen highlighted how such factors as urbanization, green energy,

‹‹‹

connectivity or mobility are impacting the industry. He said that SMS group not only responds to the trends, but actively drives them forward with innovative products, processes and business models. The impact of sanctions on Iran or Russia and the uncertainty over Brexit were given as prominent examples when referring to geopolitical developments that affect the group’s business.

“We are keeping a close eye on the developments around protectionism and trade restrictions,” Mr. Dahmen said. “SMS is a strong representative of free trade, even if sometimes we benefit from market developments such as those currently happening in the USA.” He said the group is turning its attention to opportunities in foreign growth regions, adapting its local product portfolio and providing local customer support. Mr. Dahmen also cited the initial successes of the ‘Task Force 2021’ transformation programme. This comprises more than 600 individual measures to improve all of SMS group’s cost categories and internal processes, while also enabling higher investments in new areas and business fields.

Digital products and the Learning Steel Mill SMS has confirmed its intentions to expand further into digitalization with a view to create growth opportunities through new business models.

Prof. Dr.-Ing. Katja Windt, Chief Digital Officer for SMS group, and a member of its managing board since the beginning of 2018, explained the role of digitalization within the company’s “four central offensives”.

Ms. Windt told the conference: “SMS is already the leading supplier of metallurgical plant engineering in its industry. This also applies to digitalization. It is my goal to sustainably expand this leading position together with my colleagues.”

SMS group has nearly 200 different digital products in use today. The majority of these are already being used successfully on the market, while others are still in development.

Products mentioned at the conference included: ▪▪ PQA® (Product Quality Analyzer), a software-based solution which monitors, documents and safe-

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Picture: SMS group

STEELMAKING – MODERNIZATION

SMS group regards the ‘Learning Steel Mill’ as the most vivid example of its idea of digitalization, or Industry 4.0

guards process and product quality from the start of the steelmaking process chain through to the surface-finish or coated strip, ▪▪ Manufacturing Execution System (MES), an integrated, modular solution for planning and controlling the entire metallurgical process chain and all production facilities, ▪▪ The X-Pact® Energy Advisor, offers automatic evaluation of the current energetic situation of the plant by connecting energy and production data to significant key performance indicators (KPIs). It supports the targeted reduction of energy costs, ▪▪ Smart Alarm, using data from the automation system (therefore requiring no additional hardware), the system issues alarms, documents solutions for specific alarms and displays statistics with analyses to illustrate alarm trends.

Ms. Windt revealed that various divisions and subsidiaries throughout SMS group are working on a large number of digitalization products and initiatives.

“The most vivid example of our idea of digitalization, or Industry 4.0, is the ‘Learning Steel Mill’. I joined SMS to roll out this concept of the Learning Steel Mill on a large scale and to expand digital products into a core component of our portfolio,” she said.

Predictive quality assessment and larger data volumes Big River Steel (BRS) in Osceola, Arkansas, USA, remains the best-known implementation of the Learning Steel Mill concept. SMS group supplied all the plant and equipment for BRS, including the mechanical equipment as well as electrical and automation systems.

MPT International 6 / 2018

››› STEELMAKING – MODERNIZATION

Ms. Windt said, “The objective of the Learning Steel Mill is for a plant to independently optimize and control itself based on human know-how, physical correlations and complex mathematical models which are evaluated in real time. This improves key performance parameters such as product quality, throughput time, delivery on schedule and output.”

Ongoing developments at BRS confirm the growing importance of predictive quality assessment and of processing increasingly large data volumes. Ms. Windt explained that thousands of sensors are installed at critical points throughout the plant’s production process to make them “Industry 4.0 able”. The system currently generates about three terabytes (TB) of data per month. This is analyzed using artificial intelligence (AI) and pattern recognition algorithms that SMS group has developed in-house, and that can also be used for predictive applications.

The result of this neural network is a prediction of the various parameters of product quality, throughput time and on schedule delivery. Based on these predictions, relevant steps in the production process can be adjusted manually or automatically to guarantee that the plant’s objectives are achieved.

Going forward, SMS group plans to transfer the Learning Steel Mill concept across the entire process chain and other industries.

Katja Windt mentioned SMS group’s many years of combined expertise in the fields of plant engineering, steel production, electrics and automation: “As well as its openness to new business models, methods such as Big Data and AI are unique to SMS. Like no other company, we have everything it takes to be the leading provider in the field of digitalization.”

Young digital talent joins the steel industry The evolution of SMS group’s digitalization approach includes building up an extensive network of internal specialists and internal suppliers. In particular, the group is positioning itself “as a central contact point for young digital talent” to gain employees from outside the field of metals, such as from the data engineering sector.

This includes the company’s attendance MPT International 6 / 2018

Picture: SMS group

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SMS group has built and commissioned its own pilot plant to provide metal powder for metal 3D printing

at gamescom, the conference for video game developers which in August drew 370,000 visitors from 114 countries to Cologne, Germany.

The company said it has since received several applications from programmers and 3D designers, of which the first have already signalled their intent to transfer their skills from the virtual games world to augmented realities (AR) in plant engineering.

Upstairs from the press conference at SMS Digital’s offices, various examples of virtual reality (VR) applications were displayed on tablet devices.

Modernization can support performance-based models Sat beside Katja Windt was Guido Kleinschmidt, Chief Technology Officer for SMS group. He explained how SMS’s services business integrates into the group’s digitalization initiatives and is getting nearer to the target of generating around one third of the group’s business volume. Mr. Kleinschmidt said a modernization approach can help to satisfy customers’ increasing appreciation of performance-based models.

SMS group already has a number of performance-based contracts where it is no longer paid for the hardware or services it supplies and instead shares the jointly-agreed financial success, be it output increase or cost reduction.

This includes more leasing-like models, such as Software as a Service

(SaaS) or Equipment as a Service (EaaS) that are being very well received by the market and increasingly implemented by the group.

“Digitalization is a core component of our technological innovations, regardless of whether these are systems or services,” said Mr. Kleinschmidt.

“We will increase the share of sales generated by our service activities to around one third. Our long-standing customer relationships, coupled with our full-liner understanding of the entire value chain and the latest technological innovations, enable us to be increasingly integrated into our customers’ plants and processes.”

Expanding to industries outside of metals Mr. Kleinschmidt went on to explain SMS group’s New Horizon initiatives that are geared towards contributing SMS’s metallurgical know-how to other industries outside of metals. This includes using the group’s access to metallurgical companies to establish new products. Innovations that SMS group is currently launching onto the market include: Metal powder for 3D printing.

3D printing will boom over the coming years, and SMS group is ready to handle high growth rates. For areas where metal powder is needed for metal 3D printing and requires

STEELMAKING – MODERNIZATION

ILTEC coolant. The new, non-explosive coolant is designed to eliminate risks associated with the cooling of furnace units. Many metallurgical plants are water-cooled, therefore an explosion occurs if liquid metal comes into contact with water. In the event of leaks, there is a danger to the systems and particularly to employees. ILTEC is designed to extend the service life of

the units and presents a “completely new vision of metallurgical processes,” said Mr. Kleinschmidt. The technology is demonstrably safe, having already been used several times in the steel and non-ferrous metal industries.

UrbanGold: precious metal recycling to create value and protect the environment. Mr. Kleinschmidt commented that more than 40 million t of electronic scrap is collected every year. “It is therefore not surprising that this scrap has become an important source for extracting metals as raw materials. Professional recycling not only makes sense from an ecological point of view, it also offers economic incentives,” he said.

In 2017, Aurus of Moscow, Russia, which operates in the areas of construction and ferrous and non-ferrous products, placed an order with SMS group for the delivery of an UrbanGold Compact plant. The technology enables high-quality metals such as gold, silver, platinum, nickel and copper to be economically recycled. Mr. Kleinschmidt said that, with this technolo-

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gy, 98% of these metals can be recovered and converted into pure metal products.

The plant will process approximately 6,000 t of printed circuit boards every year to produce high-purity copper, nickel, gold, silver and platinum.

Further plants are already being discussed between SMS group and the customer.

Upcoming projects and investments Mr. Dahmen concluded the conference with some project examples highlighting SMS group’s close partnership working with its customers.

The company put the world‘s largest forging press into operation for its North American customer, Weber Metals, in October.

Böhler, a subsidiary of voestalpine, has commissioned the group to build the world‘s most modern stainless steel plant in Austria.

SMS group has also commissioned the world‘s largest ring rolling mill for its Chinese customer, Shandong Iraeta Heavy Industry (SIHI).

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specific properties, especially with regards to size and structure, SMS group has built and commissioned its own pilot plant. The facility will produce high-purity metal powder on an industrial scale for additive manufacturing applications.

“Our aim is not to produce powder, but to sell the powder production plant,” said Mr. Kleinschmidt. “In doing so, we are consciously positioning ourselves at the beginning of the value chain.” He noted that various processes are competing for the purpose of metallic 3D printing. “In principle, we don‘t care which one will prevail because powder is needed for every process.”

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MPT International 6 / 2018

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SMS group drives its digitalization towards best output of quality During the recent SMS annual press conference in Düsseldorf, Germany (October 10), MPT talked with SMS group CEO, Burkhard Dahmen, about the company’s exploration of growth opportunities and new business models through digitalization. › MPT: As SMS group’s latest strategies lean so heavily towards modernization, how do you think the steel industry will evolve over the next 10 years?

Burkhard Dahmen: The next 10 years in the steel industry will be mainly determined by special applications, by modernization for new steels, high strength steel and other grades. We may also see the influence of regional necessity, of the supply and demand ratio and some additional capacities.

But, in general, I think there is no room for additional capacity – hence why we have an almost 30% overcapacity of steel in the industry.

If you take the example of China, there will be a relocation from inner cities because of fine dust emissions and pollution, and relocation projects to the outside. With any relocation of a complete steel plant there will, of course, be the necessity for some equipment to be newly built. But this will be on a much lower scale than it used to be. There will not be the large number of greenfield facilities like we were used to seeing in the ‘90s and early 2000s. › MPT: SMS attended Cologne’s gamescom developer conference to recruit programmers and 3D designers from outside the metals industry. Are we seeing a change in skillsets and the workforce?

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

MPT International 6 / 2018

Burkhard Dahmen, SMS group CEO (right), spoke with MPT at SMS digital GmbH’s offices in Düsseldorf, Germany

“We need new qualifications for people in addition to the ones we already have… It has nothing to do with ‘old economy’ versus specialists from the new economy.”

Burkhard Dahmen: SMS group is coming traditionally from mechanical manufacturing. Then we broadened to a plant engineering company, and then came the period of focusing on electrics and automation in order to operate and control our mechanical equipment. This is the basis of the next level of digitalization.

In automation, we are picking up important data with sensors to which we then apply data algorithms and analytics, and so forth. We are utilizing these to get a conclusion, predictive analysis into the future, condition monitoring and such. So, this is the logical development and the next step to come.

But we do need different qualifications for the workforce. Of course, there will still be people who draft but this

is no longer done with a whiteboard.

Drafting has long been done with computer aided design (CAD) and, the next time, it will come together with simulation or programming skills – of the complete individual components of plant; or to have anti-corrosion testing; or to have electronic manuals ready for the installation assistants.

The erection people onsite will be able to see directly into their goggles: ‘OK, what is the next piece that I need to install?’ How to screw it, how to position it and all of the figures.

Digitalization is internal but also external to the customer and the plant, so SMS group has two paths that we are following. We therefore need new qualifications for people in addition to the ones we already have, and some of those are coming from different back-

STEELMAKING – MODERNIZATION grounds. It has nothing to do with ‘old economy’ versus specialists from the new economy.

The gamescom conference is a good example because we approached these people informally. I mean, they were gamers. They were sitting for hours per day in front of a computer playing or adapting games – which is visualization; which is software programming; and thinking in new ways to optimize an existing game. So those are exactly the qualifications we need. › MPT: Has SMS group faced ‘conservatism’ within the steel industry when promoting your modernization objectives?

Burkhard Dahmen: Well, first of all, a conservative industry is not in itself bad, because they are risk averse.

Before they take a risk, they will analyze it and want to understand what the risk is. I think that is not a bad habit. However, we are finding that steel producers – our customers – are behaving differently in their flexibility to adapt to new ways of software and tools.

Some customers are maybe a bit more attracted to digitalization; more open, like the Americans or even the Russians. The Chinese are interested but they want to see it in operation somewhere else – ‘seeing is believing’ – so they are not the first movers. In Western Europe, customers are more reluctant to start using data – especially operations data. They might buy the software but then want to do the programming, utilizing or feeding the software with the data and you don’t have any access. Some cooks are ready to publish the recipe and others not!

Burkhard Dahmen: Absolutely. I mean, what is the advantage of Big River Steel for SMS group? For us, BRS was a pure greenfield facility. We have supplied almost every screw, every bolt, every piece of machinery into that plant within a short period of time.

Simultaneously, because it’s greenfield, it is covering all the different processes from steelmaking to continuous casting, hot rolling, cold rolling, pickling, galvanizing, annealing and whatever. We delivered it not only mechanically, but also the automation and service. We have the complete set-up already in our database and then, based on that, we can put the digitalization and analytics on top.

So, Big River Steel was like a laboratory condition, a unique opportunity.

And it is the unique masterpiece, based upon which we can, and will, go further.

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› MPT: We’ve talked about where you feel the steel industry will go over the next 10 years – what will SMS group’s goals be during this time?

Burkhard Dahmen: You know, our industry has had the stigma that we are supposed to be the ‘old economy’. This is a dreadful term because steel is the material for the future. Steel is never the same – not last year, 10 years ago or in 10 years’ time. There will be new steel grades, new applications, new demands and new adaptations for the usage of steel. It’s not an ‘old economy’, it is a challenging economy with continuous development and changes to come.

SMS group will further develop its technical competence to provide customers with better solutions for

“Steel is the material for the future. It is never the same.

Not last year, 10 years ago or in 10 years’ time.”

It is a question of culture, I would say – maybe also habits. Utilization can never be done by a supplier, or by a software company, only. It is a joint effort between operator and technology provider.

stable operations and for best output of quality in an ecological, economical way. This involves not only mechanics and automation, but also digital applications. We will still be the leading partner for our customers.

› MPT: Is leading by example the best way to overcome these ‘cultural barriers’?

› MPT: Thank you for speaking with us, Mr. Dahmen. Enjoy the rest of the conference.

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MPT International 15.08.13 6 / 2018 10:03

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››› STEELMAKING – MODERNIZATION

Digital transformation will create new ecosystems for the steel industry

Source: PwC Strategy&

PwC Strategy& examines how productivity gains can be made if steelmakers apply business models from Amazon, Tesla and Uber. While it is possible to create an outlook on the integrated value chain for steels, the industry must also manage digital disruptions in order to build these models.

It is predicted that the digitization of metals production and the metals value chain could lead to a productivity revolution

The global steel industry is the critical backbone of the industrialized value chain. As an essential base material for significant sectors, such as automotive and aerospace, steel is a centerpiece of innovation and economic growth.

However, despite steel’s importance for the industry today, uncertainty seems to be the only certainty.

Through significant efforts, the sector has recovered from the aftermath of the last decade’s recession when the number of new construction virtual and agile production projects worldwide decreased significantly, and investments in infrastructure and machinery plummeted.

Author: Holger Stamm, PwC Strategy& (Germany) GmbH, Düsseldorf, Germany Contact: www.strategyand.pwc.com Email: holger.stamm@ strategyand.de.pwc.com

MPT International 6 / 2018

In addition to managing volatile demand, companies have had to contend with increasingly stringent environmental regulations, volatility in raw materials and steel prices, and greater competition from producers in developing economies such as China.

If that were not challenging enough, in times of increasing protectionism in the USA with planned tariffs on steel imports, the global steel market is bracing itself for disruption.

Beyond the macroeconomic forces, the steel industry faces a raft of external challenges such as CO2, eMobility, lightweight design, new qualities and demanding customers. Companies are being compelled to transform their operations to satisfy calls for: ▪▪ ever stronger and more durable steel, ▪▪ a more diversified and specialized portfolio of products and grades, ▪▪ shorter innovation cycles that ▪▪ enable enhanced flexibility in mill capacity and prioritize reliable

delivery and service to downstream partners or customers.

Digital business models for flexible steelmaking These disruptions will catalyze the digital revolution in the steel industry.

In past years, the steel industry has successfully implemented first digital solutions and use cases, such as data analytics, to control the furnace or introduce predictive maintenance solutions in rolling mills. The challenge now is to further develop the digital strategy and convert these use cases into digital business models.

The results of a survey of CEOs by PwC Strategy& in 2017 indicate that, in metals, CEOs expect nothing more than a burst of growth. In their estimate, digital business models could lead to a 2.9% growth per annum in revenue and offer a significant potential of 3.6% per annum in cost reductions and performance improvements.

STEELMAKING – MODERNIZATION Combining existing use cases, digitization of the steel value chain could lead to a productivity revolution in steelmaking. Productivity could be increased with an end-to-end approach from supplier to customer by using (as examples) data integration, track and trace solutions, sensors for steelmaking and casting, flexible steel processing and additive manufacturing. The integrated steel value chain delivers significant performance improvements and cost reductions and is a prerequisite for digital business models.

New networks from supplier to customer

Source: PwC Strategy&

Digital business models can be split into dimensions covering the digital product portfolio, digital service offerings and digital go-to-market. A digital product portfolio means the digitization of the ‘physical’ product with value-add through new and improved product characteristics (e.g. quality information about the coil). This provides new options for the steel producer to engage with customers around the physical product.

To create a digital service offering, steel companies need to expand their existing product portfolio with new digital services; e.g. in product development, design and quality management. A digital go-to-market approach transforms the customer interface and customer experience. This could lead to increased performance through higher customer integration, as well as personalized customer communication and sales approaches.

In the future, these new steel business models will have a significant impact on the integrated steel value chain, and will lead to virtual and agile production networks from supplier to customer.

As key drivers of these networks, steel companies will play a crucial role in building up digital ecosystems. Endto-end integration creates transparency across the whole network based on real-time data exchanges with partners. The further development of digital products, services and a new customer experiences based on these digital platforms is leading to a new ecosystem for steel.

Three digital models for the future Looking forward to the year 2025, the integrated steel value chain and the role of the steel industry could be described by three models: Supplier in a digital ecosystem.

Applying the business model of the big internet platforms like Amazon to the steel industry will create an ecosystem that consolidates and centralizes sales, distribution and planning for various steel producers.

Digital system supplier. The application of the Tesla business model to the steel industry will increase integration into the customer industry, supporting the customer with design, development, production planning and component production.

Digital network supplier. Using the Uber business model in the steel industry will create a virtual and digital network of partnerships in production, development, and sales.

A steel company can combine ele­ ments of these three models depending on their product and customer segments.

For example, a higher-grades steel producer for the automotive industry could act as a digital system supplier.

It will have close integration into the value creation of its customers, providing a platform for tool producers, steel

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producers and car construction. This platform will allow for integrated part and process design with the full transparency of the value chain.

For the original equipment manufacturer (OEM), this has significant benefits: reducing waste (ramp up parts), quality costs and lead times. As a result, the steel company can extend forward integration up to production of pre-finished parts.

Our proprietary analysis shows that getting this whole digital process right can increase margins on a ton of steel by as much as 16% by reducing quality costs and increasing efficiency.

Conclusions The steel industry has to manage the digital transformation and digitization of the integrated value chain. A guiding principle for this transformation is that each steel company has to start with the big picture regarding its role in the value chain and the relevant digital business models for its segments.

In order to identify the best business model, the steel industry has to take their customers’ perspective and has to be prepared to fail, yet also win, through experience.

The best way to create and develop new business models is to collaborate with partners – e.g. customers, other suppliers and technology companies.

Finally, digital may be a buzzword or notably hyped now. Nevertheless, it needs to be anchored in the DNA of the steel industry, as well as in the governance and culture of each steel company.

The steel sector is embarking on a digital journey. However, companies should take a minute to think about the route, their luggage and their fellow travellers.

Cases with significant digitization optimization potential and high attractiveness for all players in the network MPT International 6 / 2018

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››› QUALITY ASSURANCE

Zumbach innovates with new gauge for comprehensive rebar measurement Zumbach Electronics of Switzerland, a supplier of non-contact measuring technologies for the metal and steel industry, has introduced its newest Profilemaster® SPS 80 gauge for in-line measurement of any rebar type.

Sophisticated capabilities allow the measurement of rebar products in hot rolling processes.

It’s through a commitment to extensive research and development activities that Zumbach Electronics of Orpund, Switzerland, has grown into a pioneer of on-line measurement.

Areas to which the company has turned its attention include the measuring of rebar in the rolling mill; specifically, the issue of effective quality assurance without having limitations in terms of rolling speed.

Because many rolling mills produce rebar in more than one strand, Zumbach has designed its Profilemaster®, a range of gauges for in-line measurement of any rebar type, to handle up to three strands simultaneously with one single gauge. Every individual strand is measured and related statistics can then be generated.

The system is designed to be solid and reliable based on Zumbach’s experience of supplying measuring systems into the metal and steel market.

Advantages for the customer include producing rebar with higher quality and higher efficiency.

In-line complex profile, measurement and monitoring The Profilemaster is developed from a core set of proprietary mega pixel camera/laser modules and software technologies. The application capabilities of these technologies have been adapted to serve specific measurement, monitoring and surface flaw detection

Zumbach Electronic AG Contact: www.zumbach.com Email: sales@zumbach.com

MPT International 6 / 2018

requirements. This includes for extruded plastic and rubber tubes, hoses, profiles, wire and cable, wood, plastic composites, steel rod, bar, profiles and more.

The Profilemaster range consists of various models.

A number of gauges are available depending on the customer application and product dimensions.

These comprise models for small precision profiles starting from a dimension of 0.5 mm (.02 inches), cold formed tubes and profiles as well as medium size products, hot or cold, up to dimensions of 600 mm (23.6 inches).

The systems are available with four up to eight laser/camera modules which continuously measure the cross section of the moving profile. A powerful PC-based processor combines the captured line images of the individual cameras to yield a momentary cross-section of the profile. All relevant dimensions such as width, height, angle and radius or other geometric quantities are computed to characterize the full cross-sectional picture. The product can be monitored during the production through an operator-friendly graphic display of this data.

In addition, the nominal values for the profile can be directly imported

from computer aided design (CAD) files to enable an easy and problem free configuration of the device. A key advantage is that changes in speed and twist within normal limits have no influence on the measurement precision.

Detecting process problems at an early stage Zumbach’s top priority is its customer relationships. These are maintained through a local presence in combination with proven high-quality products, services, personal consulting and support. Advantages of the Profilemas-

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ter SPS 80 gauge for the customer include that it: ▪▪ gives rebar measurement irrelevant to the rolling speed, ▪▪ provides 100% inspection in real time, ▪▪ reduces start-up times, ▪▪ increases the repeatability and precision of the end product, ▪▪ makes post production measurements irrelevant, ▪▪ provides reliable operation in harsh conditions and product temperatures of up to 1200° C, ▪▪ improves process control and reduces scrap and production costs, ▪▪ saves raw material and post processing costs.

The system is designed to be Industry 4.0 ready which includes detecting process problems at an early stage. The Profilemaster SPS 80 integrates into the network or high-level systems through OPC Unified Architecture (UA), the unified machine to machine communication protocol for industrial automation. Meanwhile, all production data can be logged for the quality control department.

The Profilemaster® SPS 80 is designed to measure the rebar in the rolling mill without having limitations in terms of rolling speed.

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IMS Messsysteme GmbH | Dieselstraße 55 | 42579 Heiligenhaus | Deutschland Tel.: +49 2056 975-0, Fax: -140 | info@ims-gmbh.de | www.ims-gmbh.de

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››› HEAT TREATMENT

Primetals’ transfer bar cooling system goes into operation at Tata Steel

In February 2018, a transfer bar cooling system supplied by Primetals Technologies was commissioned and brought into industrial operation in June 2018 in the hot strip mill of Tata Steel’s Port Talbot integrated steel plant located in South Wales, United Kingdom. The order to install the transfer bar cooling system was awarded to Primetals Technologies in April 2017.

The purpose of the cooling system, installed after the roughing mill, is the precise control of the strip temperature before it enters the finishing mill, without having to slow down the roughing mill. This has resulted in an increase of production capacity by approximately 150,000 t/year of hot strip.

The system is based on Primetals Technologies’ Power Cooling technology. The Power Cooling technology not only comprises a sophisticated and complete E&A (electrics and automation) and mechanics solution, its intellectual property is protected with more than one dozen patents. The solution encompasses Level 1 (L1) and Level 2 (L2) automation, pump and water management control as well as special design of the headers.

Equipped for a large variety of steel grades Tata Steel Port Talbot’s hot strip mill has a nominal capacity of about 3.4 million t/year of steel. The Port Talbot site is an integrated blast furnace based steel complex which produces slabs,

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

MPT International 6 / 2018

Picture source: Primetals Technologies

Tata Steel has commissioned the system in the hot strip mill of its integrated steel plant.

It precisely controls the strip temperature before it enters the finishing mill, without having to slow down the roughing mill. The production capacity has increased by around 150,000 t/year of hot strip.

The transfer bar cooling system from Primetals installed at Tata Steel’s hot strip mill

hot rolled, cold rolled and galvanized coils.

The transfer bar cooling system, installed after the roughing mill exit table, employs a total of 18 spray headers in its initial configuration, nine top and nine bottom headers, and may be extended with additional headers at a later time. The total length of the transfer bar cooling system is approximately 10 m. In order to cope with a large variety of steel grades and process requirements, especially the minimum surface temperature of the bar during cooling, the flow rates of the Power Cooling headers are adjustable over a wide range so that a higher or a lower cooling intensity are also achievable as required for each individual product. Each header is flowcontrolled by a separate ball segment valve.

Improving the single components of the cooling technology In addition to the transfer bar cooling system itself, Primetals Technologies’

scope of supply encompassed the affected roller table including motors, drives and transformers, an overhead tank, a booster pump station and a cross-spray pump station.

L1 and L2 automation, as well as the interface to the existing hot strip mill automation system, was also provided.

The transfer bar cooling technology was tested for the first time at voestalpine Stahl in Linz, Austria, in 2003.

The first industrial installation was thereafter set up at Thyssenkrupp Bruckhausen, Germany in 2013.

Since early 2018, a cooling line test facility has been in operation at the Primetals premises, also located in Linz.

This allows Primetals to continuously improve the single components of its unique cooling technology.

Complete pairs of cooling headers, but also single headers, valves or nozzles, are assessed in the testing facility.

The facility is open to customer visits.

BSE Consulting & Qualification

Learning from one of the World’s leading MiniMills!

The operational excellence of Badische Stahlwerke (BSW) – the mini-mill of the Badische Group – is the result of continuous investment and application of the ”Badische Philosophy“: skilled, motivated personnel provided with appropriate tools and assigned clear responsibility within a lean organisation.

For more than 30 years now, Badische Stahl-Engineering (BSE) has been successfully implementing this special mini-mill culture to various steel plants and rolling mills all over the world – with comprehensive know-how contracts, classic seminars as well as individual training and consulting services.

Contact us – we can help you to optimise YOUR productivity and efficiency by smart adaptation of selected methods and proven technologies.

Badische Stahl-Engineering GmbH Robert-Koch-Straße 13 D-77694 Kehl/Germany Phone (+49) 78 51/8 77- 0 Fax (+49) 78 51/877-133 eMail info@bse-kehl.de www.bse-kehl.de BSE America 1811 Sardis Road North, Suite 210 Charlotte, N.C. 28270 USA Phone (704) 553-1582

40

››› HOT ROLLING

Georg supplies first roll grinding machine using cubic boron nitride (CBN) abrasives

Picture source: Heinrich Georg Maschinenfabrik

The Georg ultragrind 25 roll grinding machine has been put into operation at Salzgitter AG’s hot rolling mill and is the first to use CBN abrasives. As well as achieving three times greater grinding throughput than the previously used machine, it dramatically cuts set-up, testing and idle times.

By using cubic boron nitride (CBN) abrasive tools, the roll grinding machine reduces grinding times by more than 50%

While in the automotive industry and other sectors cubic boron nitride (CBN) abrasives have become well established, in roll grinding shops for hot rolling mills there is still some way to go. In the roll shops, performance features like high wear resistance and short grinding times matter more than the surface quality.

Roll grinding machines of the Georg ultragrind series perform machining and measuring within one sequence without having to reclamp the workpiece. This design concept provides a

Author: Thomas Kleb, Heinrich Georg GmbH Maschinenfabrik, Kreuztal, Germany Contact: www.georg.com Email: thomas.kleb@georg.com

MPT International 6 / 2018

significant reduction in machining times and higher efficiency compared with conventional machines.

With the introduction of CBN abrasives, the company has introduced a new innovation to the marketplace. It is the first time that CBN abrasive tools have been used in roll shops of hot wide strip mills in the steel industry. These tools are demonstrably superior to other abrasives in that they are able to machine even rolls of high-strength materials with the highest precision and efficiency – e.g. high-speed steel (HSS) grades featuring a hardness between 83 and 87 Shores C.

Significant potential for improvement in roll grinding efficiency The new machine at Salzgitter AG, which passed all acceptance tests in

June 2018, can grind HSS work rolls with diameters of up to 1,000 mm and weights of up to 25,000 kg in a fully automatic process. Both conventional and CBN abrasives may be used.

Michael Kotzian, Manager of the roll shop in the hot rolling mill at Salzgitter, expects a significant potential for improvement in roll grinding efficiency from the CBN technology: “We know that with the investment in the Georg roll grinding machine we are pioneers in the steel industry. The results of the acceptance tests are convincing proof that the technology works. In a next step, we will work with Georg and the abrasives manufacturers to sophisticate the process and advance the technology with a focus on further improving economic efficiency.”

A major decrease in machining times can be attributed alone to the higher

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Picture source: Heinrich Georg Maschinenfabrik

HOT ROLLING

The probe measures the surface of the roll over the complete barrel length

grinding throughput achieved by CBN-based abrasive tools. With the new machine average grinding times have been reduced by more than 30%.

Considering also the time saved through the possibility to perform the measurements and crack testing online, roll grinding now takes more than 50% less time. The grinding of HSS rolls with conventional abrasive tools takes 40 to 45 minutes on aver-

age. The new machine needs only 20 minutes.

This performance improvement is largely attributable to the performance of the Georg measuring system. Both the shape and eccentricity of the rolls are measured automatically during grinding. Also roughness measurements, crack testing and demagnetizing have been integrated into the system and are performed automatically.

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By bringing together CBN-based grinding, measuring performed during grinding and a computer numerical control (CNC) system adapted to the use of CBN abrasives, Georg machines also achieve higher grinding precision and a much higher surface quality than conventional systems.

Cost savings through real time measuring results Dr. Wieland Klein, head of Georg’s Machine Tool Division, explained the advantages of having to clamp the work piece only once for three operations – grinding, measuring and crack testing: “The availability of real time measuring results guarantees that no more material than absolutely necessary is removed. This means shorter grinding times, longer roll life times and cost savings in general.”

Aside from the use of CBN abrasives, a further advantage of the Georg ultragrind 25 is that it can machine the rolls complete with chocks, including all types of pinch rolls. This eliminates the frequent and inefficient removal of chocks that, previously, was necessary prior to grind rolling.

Measures rebar like never before regardless to the rolling speed High-tech light section measurement...

MPT International 6 / 2018

42

››› ADVANCED MANUFACTURING

Big River Steel, USA, implements full digitalized production planning system

Steel production poses many challenges that must be successfully overcome.

Operators are required to provide the flexible customization of products while also maintaining consistently high levels of quality. Lead times should be kept to a minimum with the utmost delivery punctuality levels. And the use of resources should be optimized with reduced stock, with achieving maximum yield to ensure profitability. At the same time, end customers’ requirements are increasing – e.g. for special properties and ‘tailor made products’ – while lot sizes tend to become smaller and smaller.

The steel industry is becoming more aware of how digital transformation can help make these processes faster, more personalized and more efficient.

For SMS group, the world’s largest supplier in metallurgical plant construction, Manufacturing Execution Systems (MESs) are a particular focus.

The company sees MESs as being one of the most attractive fields of application with a high potential for improvement through digitalization.

Already, MESs are helping operators to master today’s industry challenges.

This includes evolving facilities into a ‘smart steel plant’ or ‘learning factory’.

Integrating digital while managing growing data volumes A key principle of digitalization is that it integrates fully into the production

Authors: Wilfried Runde and Franck Adjogble, SMS group Contact: www.sms-group.com/ x-pact-mes-4-0 Email: wilfried.runde@sms-group.com

MPT International 6 / 2018

Picture: SMS group

As more plant operators realize the need for change towards an Industry 4.0 environment, the new X-Pact® MES 4.0 by SMS group is designed to play a vital role.

The digital, modular and integrated planning and management system can be used across the entire metallurgical process chain.

Practical solutions of the warehouse management system

process. To this end, a large number of set-up values are created for the various process steps to optimize the product. Added to this are many different measured values and information signals. Generally, around 15,000 signals are available in a modern compact strip production (CSP®) plant.

It is easy to become confused when analyzing this quantity of information, especially as there may be 500 or more temperature values (measured, calculated, surface and average) from the heat, through to the casting and rolling process, right up to cooling. Knowing the origin of the signals and the way they were created is of vital importance when analyzing them, and a crucial factor for long-term production optimization. Against this backdrop of advancing digitalization in all areas of steel production, SMS has developed

the X-Pact® MES 4.0. The integrated, modular planning and management system is designed to offer plant owners economic advantages in terms of the productivity of their plant and equipment. It can be used in all production facilities across the metallurgical process chain including in meltshops, casting plants, flat rolling mills, tube and pipe mills, strip processing lines and more.

The X-Pact MES 4.0 has a large range of customizable functions for the whole variety of plant and equipment, and links with the automation systems of all units in the plant. The system obtains status information as well as production and process data.

SMS has designed the system to be clearly structured and future-proof and offer plant owners economic advantages in terms of the productivity

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ADVANCED MANUFACTURING

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of their plant and equipment. This includes for greenfield and challenging brownfield projects.

Big River Steel: the first self-learning steel plant The possibilities of digitalization are already in evidence at Big River Steel (BRS) in Osceola, Arkansas, USA. Covering a site of 567 hectares, BRS is North America’s most modern steelworks as well as being SMS group’s first self-learning steel plant project.

The facility is designed for an annual production capacity of 1.6 million t in its first stage of construction and utilizes a CSP® plant in its thin slab production route [1]. As an integrated systems supplier, SMS provided all the plant and equipment, including process know-how for the steel complex, and supported BRS throughout the commissioning.

Katja Windt, chief digital officer (CDO) for SMS group, spoke about BRS at the company’s recent annual press conference in Düsseldorf, Germany, on September 10: “The most vivid example of our idea of digitalization, or Industry 4.0, is the learning steel mill. For a learning steel mill, the objective is to independently optimize and control itself based on human know-how, physical correlations and complex mathematical models that are evaluated in real time.” She added: “This improves key performance parameters such as product quality, throughput time, delivery on schedule and output.”

Successful implementation of the X-Pact MES 4.0 system The X-Pact MES 4.0 has been integral to the realization of the learning steel mill concept at BRS. It is of note that SMS group also develops its own cutting edge software architecture. In the case of the X-Pact MES 4.0, this is designed to be modular and expandable while also addressing certain key issues, such as how: ▪▪ growing product individualization can be achieved while ensuring consistently high quality, ▪▪ production lead times can be minimized while guaranteeing timely delivery, ▪▪ resources can be used most efficiently while inventories are reduced.

Key facts and figures on the self-learning steel plant at Big River Steel in Osceola, Arkansas, USA

BRS has been able to develop metallurgical strategies centrally and apply them to various plants and machines. With the X-Pact MES 4.0, the plant has been able to build a sustainable platform that can be scaled for the integration of other innovative modules in connection with Industry 4.0. Because new modules are added easily, the system’s performance can be enhanced for every new solution. Some of the system’s key modules are as follows: Planning. The planning modules form the centerpiece of the X-Pact MES 4.0. They generate technical orders based on customer specifications and set up optimized capacity plans, time schedules and production sequences.

A highlight of the system is its dynamic rescheduling capability which automatically responds to any disruptions

in the production process that may impact on planning schedules. The system relieves the operators in the control room of this critical task. The planning module is also significantly influenced by new data-driven models from ongoing development activities.

Support and Optimization. These modules bring together additional factors that are vital for efficient planning processes – e.g. the plant condition, product quality and energy consumption. The idea is to achieve a situation where all production equipment and plant units along the entire process chain are vertically networked in the most effective way. Additionally, the Support and Optimization modules solve the central administration and maintenance of master and production data.

Integrated product quality analysis with the PQA® in the X-Pact® MES 4.0 at BRS MPT International 6 / 2018

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››› ADVANCED MANUFACTURING

Warehouse Management. This module keeps track of inventories and stored products along the whole production line. The quality of stored items can be documented swiftly and efficiently on a smartphone with the integrated barcode scanning feature.

Supply and Dispatch. These modules provide the basis for a horizontally connected process chain that is geared towards Industry 4.0. The chain integrates both suppliers and customers throughout the entire production process. It facilitates material supplies and requests for equipment at shorter notice, speeds up the dispatch of products, and achieves significant cost savings from these effects. Customers also obtain specific information about the progress of their production orders.

Integrated flexible chemical analysis in the X-Pact MES 4.0, case 1 and case 2

Reporting. This is where the cycle ends. A series of state-of-the-art, webbased Business Intelligence (BI) tools provide reporting functions and speed up decision-making processes. The wide range of options on offer cover various information types: conventional reports; the display of key production parameters on smartphones; and interactive analyses of production data. This way, data becomes a valuable source of information to further improve the efficiency of planning and production processes.

Basis. The Basis modules provide a general overview of all the production processes and, at the same time, guarantee maximum data security and

data protection. Because the data can be made available across various locations via a dedicated Enterprise Cloud, the X-Pact MES 4.0 supports plant operators all the way from order intake to the dispatch of the product.

Together, these modules have a high potential for plant-wide real time material tracking, flexible production planning and continuous performance optimization support. With the X-Pact MES 4.0, BRS is achieving strategic key performance indicators (KPIs) like short lead-times, delivery reliability, maximum yields, high plant utilization and a competitive cost focus.

Crucially, the systems have proven integral to the flexible customization

Integrated warehouse management system in the X-Pact MES 4.0 at BRS MPT International 5 / 2018

of products while also maintaining consistently high levels of quality. Said Mark Bula, BRS’s chief commercial officer, when interviewed by MPT International in December, 2017: “There are some niche positions in the market and there is new technology that makes it even more cost efficient to manufacture the products for these niches [2].”

Overcoming scepticism within the industry There is still always room for improvement where process optimization is concerned. This is why data-controlled models, in particular, are gaining increased importance in the industry – e.g. with seamless vertical and horizontal connectivity or optimization algo­rithms.

These factors help to enhance the flexibility of production planning without adversely impacting on operational productivity or stability.

However, technological know-how in the field of metallurgy remains a crucial factor. Indeed, it is today more important than ever that such specialist knowledge is easily and intuitively integrated into dynamically growing MES functions. After all, dynamic changes in market demands – such as those triggered by the Internet of Things (IoT) – require considerably shorter cycles of automated modernization as the industry heads towards Industry 4.0. On the human level, the

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ADVANCED MANUFACTURING rising volumes of data and new means of exchanging information will result in closer collaboration between integrated system suppliers of plants and automation systems, like SMS group, and plant owners and operators.

At the same time, there is a need to overcome scepticism about digitalization within the industry.

“That is the key question,” Jochen Neuer, project manager for X-Pact MES 4.0 system at BRS, told MPT International at the recent SMS annual press conference. “In the steel industry, there is always the worry that jobs are in danger. Instead, we make customers aware of the benefits of digitalization; for example, your productivity will increase. Digitalization can make the customer’s life easier because they are using semi-automatic functions – especially with production planning, process stability or big order changes.

“In these instances, where production planning plays a major role, we can say to the customer: ‘If something happens to your process then you can select from three semi-automated functions: option A, B or C. Each is based on artificial intelligence (AI) or rules, select which one you’d like to do.’ At the end of the day, there is always a human that has to take the final decision and choose the best course for the right result.”

Combining process steps with more efficient data SMS group’s electrical and automation systems were applied in all process stages at BRS from steelmaking down

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Two examples of the various solutions jointly implemented by BRS and SMS group PQA® (Product Quality Analyzer) The PQA system collects and evaluates quality data and quality-related process parameters for all products in BRS’s whole process chain, from steelmaking to the finished product.

The parameters include measured values and results, and also complex criteria applied for quality analyses.

Starting from quality order dressing (where customers’ requirements are translated into detailed product quality targets, including tolerance values) the X-Pact® MES 4.0 also determines the sampling required to keep yield losses to a minimum.

A ‘make to order’ philosophy is therefore promoted while the plant’s performance is also taken into account; e.g. a ‘flexible target analysis’ for steel grades from individual heats.

to the strip-processing plant. The X-Pact MES 4.0 immediately took over the production planning and control.

It ensured that the steelmaking complex started right on schedule in December 2016, and afterwards achieved a steep run-up curve in hot strip production. Rather than being an ‘end in itself’, the tool is designed to increase productivity and profitability, enhance product flexibility and reduce the outfall operation of all installed production facilities.

Flexible chemical target analysis This function of the X-Pact MES 4.0 is used in the SMS group production planning system for the EAF, LMF, RH degasser, and to minimize transition bars in the caster for huge advantages in terms of yield and increased production. For example, if six orders (thin slabs/strip) are all part of the same heat, then the minimum and maximum values for the chemical elements must suit all orders.

The target analysis of the heat is calculated while taking all single targets and limits into account. Or, if the target values are calculated for each heat, but the first target is too high for the second heat, then the closest limit value for the second heat can instead be used for the first. The number of transition slabs has been reduced from 5% to 2% which, according to BRS, saves them several millions of dollars every year.

Mr. Neuer says that horizontally connected process chains are key to realizing these advantages: “I believe that operators lose 3, 4 or 5% of their productivity as a result of the clear separation between different processes.

This is because you do not have any holistic approach in such situations.

“Much more efficient data is also a change of mindset in the steel industry – how to get connected to the process, how to fetch and share the data, ensure that it is correct, delivered on time and so on. This transparency is a very important point. But, very often, such data sharing is not desired within companies. The Big River plant definitely sets an example because they are open to new approaches that you hardly see in many other companies. This enables a lot of new improvements and to combine process steps that used to be separate.”

Picture: SMS group

How BRS’s operator teams use the system

Intelligent reporting with X-Pact Business Intelligence

For BRS, combined process steps allow the centralized management of best practices. The plant can develop metallurgical strategies centrally and then apply them to various plants and machines. BRS is using the X-Pact MES MPT International 6 / 2018

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››› ADVANCED MANUFACTURING

4.0 company-wide to actively control production processes and achieve set objectives. From the end user’s perspective, the system is highly utilizable for a variety of different user groups. A total of between three and four terabytes (TB) of data are collected and processed in the system, each month, for the purposes of optimization. All of these processes require optimal planning, especially as a team of just 450 employees is responsible for the preparation and execution of the entire BRS plant. Of these, 150 members of staff cover a wide range of user roles with the MES system every day including quality, technology, production, and material requirements planning.

The BRS team has a total of more than 100 different dialogs at its disposal.

Here, the Warehouse Management system is crucial and used by 110 members of staff on a daily basis. The module controls the material flow for around 3,700 strips in the strip warehouse every day. There is also the Business Intelligence (BI) reporting platform, a critical central function for fast decision-making processes and intelligent analysis of all information in the MES database. New reports are

SMS group’s approach to the self-learning steel plant

added daily – in fact, a production planner at BRS spends an average of 80 hours a month using the BI application.

Meanwhile, the PQA® (Product Quality Analyzer) has already managed to achieve transparency in terms of the rate of complaints concerning material quality. BRS says that, with the PQA, virtually no reworking of defective materials is now required.

Because of the dynamic interaction between all of the applications supplied

Sharing enormous data volumes with all operating teams, in real time X-Pact® MES 4.0’s core features also include the X-Pact Business Intelligence (BI) application with interactive analysis options and an extensive, advanced web reporting system. This provides a clearly structured and comprehensive dashboard visualization of the production processes and use of associated inputs, in addition to processing the information to the desired level of detail.

For SMS, the challenge was to channel the enormous amount of detailed data into relevant information packages at one central point for intuitive analysis and strategy development. With the BI application, relevant data from a variety of different sources – tables, databases, web data, plant control systems, automation systems and so on – can be easily consolidated and retrieved using a standard web browser in the plant network.

Data available on the reporting platform react to every click by the operator and

MPT International 6 / 2018

are re-calculated based on the parameters selected. An intelligent search is used to find keywords across the whole data model. To avoid the time-consuming process of creating reports using complex SQL (structured query language, the standard for searching databases) scripts, the operator can create customized reports with a simple drag and drop function.

Centrally-controlled key performance indicators (KPIs) can be made available to all operating teams at the same time.

The data dashboards enable close monitoring and tracking of target parameters. As well as creating conventional, web-based reports, the BI module can be used to scrutinize the connections between data. For BRS, this interactive evaluation of data is the key to improvement opportunities, economic competence and quick decision-making. The resulting business processes can then promote long-term cost reductions.

by SMS group, data can be connected easily to ensure transparency across the whole process chain. BRS says that it has 100% faith in the functionality of the X-Pact MES 4.0 system.

Intelligent real time production planning SMS group predicts that, in the learning steel mill of the future, today’s generally centralized and inflexible long-term production planning will be replaced by real time, self-optimizing production planning.

Jochen Neuer says planning that would otherwise be taken one stage at a time is achieved more holistically at BRS: “You can avoid certain losses if, overall, your processes are geared for an increase. But you can only achieve this if you combine two, three or four process steps into one plan.”

In terms of real time capabilities, the X-Pact MES 4.0 reviews current planning whenever a change takes place – e.g. a new order, altered maintenance plan or quality deviation. The system applies defined key performance indicators while searching for a better planning result. Because the system uses real time data, it takes fact-based views on product quality, the plant’s condition and a structural production planning model. Overall, the system can dynamically optimize production planning in respect of four KPIs: ▪▪ output, ▪▪ delivery performance, ▪▪ product in stock, ▪▪ cost-efficiency.

These objectives are being further explored in a research and development

‹‹‹

ADVANCED MANUFACTURING project launched by SMS group in cooperation with Jacobs University of Bremen, Germany. With a focus on intelligent production planning, the project will cover such aspects as dynamic reactions to specific production situations, the use of AI, and the autonomous learning of automation systems.

The findings and dynamic planning and optimization processes developed during this project will then be integrated into the real world automation environment at BRS. The project’s objectives include: ▪▪ that improved adherence to production schedules and increased yield, thanks to reduced downgrading and scrap will have positive effects on the economic efficiency of BRS’s production facilities, ▪▪ using learning machines and pattern recognition techniques to predict the schedule compliance of orders,

▪▪ the development of a planning module based on AI and the X-Pact MES 4.0 Performance Enrichment Analysis. This module will be used to detect relationships between production parameters and performance indicators based on historic production data.

For example, it is intended that these capabilities will be used to perform scalable and self-learning order analyses. They can also be used to generate plans which take order schedules into account.

Humans and machines collaborating across the value chain

47

processes and business models. SMS says that the system is, “more of an evolution than a revolution.”

By evolving ever more towards an Industry 4.0 environment, BRS can better meet the challenges of flexible production planning (e.g. changing or smaller lot sizes) through largelyautonomous steel production. Its dynamic production processes can adjust to optimum parameters in real time and, crucially, involve the interconnection and collaboration of humans and machines across the entire value chain.

References [1] Big River Steel’s flat steel complex on

A main conclusion that can be drawn from the use of the X-Pact MES 4.0 system is that SMS group’s solution not only tackles the subject of digitalization technologically. It also regards the impact of digitalization on a company’s internal processes, existing

its way to become a learning steel mill.

MPT International, 6/2017 (December), 42-44 [2] Big River Steel’s learning steel mill to take steel production to the next level. MPT International, 6/2017 (December), 46-49

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48

››› TECHNICAL INNOVATIONS

New software for laser beam melting (LBM) reduces times and costs ADVANCED SOFTWARE Additive Works of Bremen, Germany, a leading provider of highly usable solutions for additive manufacturing and laser beam melting (LBM) technology, has introduced a new release of its Amphyon software. Amphyon is the company’s simulation-driven process software developed for use with powder bed-based, laser beam melting additive manufacturing processes. It makes sure that critical values are not exceeded, and that the desired shape of the part will be achieved.

The software helps engineers to generate ‘first time right’ support structures which are essential for a high-quality print in additive manufacturing. The new version is equipped with a support module that now automatically generates and optimizes these structures.

The module also automatically creates the support geo­ metry to help ensure a stable process and minimized post-processing effort.

An adaptive mesh graphic created with Amphyon simulation-driven process software

Additive Works intends for its new version of Amphyon to pave the way for a simulation driven workflow that not only saves material but also reduces the required calculation time and development costs.

Additional enhancements to the software include adaptive meshing so that users can perform calculations of larger and more complex components. This can lead to significant time savings when developing models for laser beam melting additive manufacturing. In addition, users of the 2018 version will now be able to export layers. They can now benefit from an enhanced workflow which integrates the support module with an improved connectivity to machines.

Contact: www.additive.works

A step towards digitalization in gear manufacturing SPECIAL EQUIPMENT Klingelnberg, a leading manufacturer in the gear industry located in Zurich, Switzerland, has introduced its latest innovation: the Höfler Speed Viper 300 cylindrical gear generating grinding machine which uses Koenig Automation technology for high production grinding and largescale components.

The new Speed Viper generation is designed for high productivity and robustness in grinding processes. In this regard, it fulfils all of the requirements that are needed in modern large-scale production: short set-up times, minimum cycle times, innovative software solutions and digital process control in a closed loop system.

The Speed Viper platform is optimally designed for the Industry 4.0 manufacturing environment. This most recent development makes it possible to connect cylindrical gear machines directly to the measuring devices.

The technology is already being used successfully in bevel gear manufacturing. For Klingelnberg, the transferral of its own closed loop concept to the world of cylindrical gears represents a systematic step towards digitalization in gear manufacturing. Due to a wide variety of associated applications and software, Klingelnberg is implementing central production control using its digitalized production system. This will standardize rating results on different machines and even in MPT International 6 / 2018

Höfler Speed Viper 300 cylindrical gear generating grinding machine

different plants. Depending on the model, Speed Viper is designed for maximum workpiece diameters of 80, 180, and 300 mm. These match the standard component sizes of the automotive and commercial vehicle sectors and their suppliers, for whom the Speed Viper is mainly intended. They also perfectly meet the stringent productivity requirements of this industry. The series is ideal for cylindrical gears in industrial transmissions and for robotic applications.

Contact: www.klingelnberg.com

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TECHNICAL INNOVATIONS

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Automatic tool changing press brake with 50% more capacity SPECIAL EQUIPMENT LVD of Belgium, which offers a range of integrated products for the global sheet metalworking market, has launched its ToolCell XT, the latest generation of its ToolCell automatic tool changing press brake. The new machine has an extended capacity to hold 50% more tooling than the original design, and can perform tool changes quickly and precisely following an optimized tool change path.

ToolCell XT is designed to efficiently bend small batch, high mix parts with high accuracy and minimal changeover time. The larger tool capacity offers the flexibility to handle a wider range of bending jobs, including complex layouts. An automated tooling setup improves the efficiency of bending operations and eliminates time-consuming manual adjustments.

With its extended tooling capacity, ToolCell XT can handle varying material types, organize tooling by material type, and easily switch between stainless steel and mild steel applications. The extended integrated storage holds a maximum of 17,280 mm (+/- 17.2 m) punches and a maximum of 40,320 mm (+/- 40.32 m) dies. Extra toolboxes are integrated on both sides of the machine.

Because it is critical to avoid costly test bends in small batch production, like all ToolCell press brakes, the ToolCell XT is equipped with the LVD Easy-Form® Laser (EFL) in-process adaptive bending technology. The EFL guarantees the desired angle from the first bending operation.

The system consists of two laser cameras linked with an intelligent bending database in a Touch-B control. As the

The ToolCell XT can perform tool changes quickly and precisely

bending sequence of the press brake is initiated, the measuring device transmits the digital information in real time to the CNC control which subsequently adjusts the depth to obtain the correct angle. The bending process is not interrupted and no production time is lost.

The control is linked to a central CADMAN® database where all production-relevant data is stored. After importing a 3D CAD part, CADMAN-B (bending) software automatically calculates bend allowances and determines the optimal bend sequence, gauge positions and tool setups based upon CADMAN’s expert algorithms.

ToolCell XT is offered in a 135 t/4 m configuration, with other sizes to follow.

Contact: www.lvdgroup.com

SSAB and Kemppi create digital solution to speed up the welding process SPECIAL SOFTWARE Collecting welding documentation is time-consuming. Documents have to be collected from different source systems, and documenting the welding process is done manually.

To streamline base material information handling in welding production, the Nordic and US based steel company, SSAB, and the Finnish welding digitalization pioneer, Kemppi, have successfully integrated SSAB’s SmartSteel and Kemppi’s WeldEye cloud-based platforms. WeldEye, Kemppi’s welding management software, is designed to make the process smoother by collecting welding parameters digitally from workstations, even by adjusting the welding equipment according to digital welding procedure specifications (dWPS).

To automate the process one step further, SSAB now offers their SmartSteel data through an application programming interface (API) to be used in the process. The company calls SSAB SmartSteel “the digital identity of steel”. It

stores all of the information related to the steel from its manufacturing to delivery, processing, use and recycling.

Launched in May 2018, SmartSteel 1.0 introduced the possibility to scan steel and have easy access to its material certificate. Now, through the API, base material information and material certificates can be sent to welding equipment automatically. This makes it possible to reduce manual work, adjust the equipment faster, increase arc-on time and reduce the repair rate. It also provides for automatic documentation of the welding process.

Following the successful pilot, SSAB customers that are already using Kemppi’s WeldEye software can get automatic material information from the SmartSteel cloud. New partners are also welcome to contact SSAB in order to start developing new services around SmartSteel.

Contact: www.ssab.com MPT International 6 / 2018

50

››› TECHNICAL INNOVATIONS

Thermal imagers for the automotive industry PROCESS INSPECTION Fluke Process Instruments has launched a new thermal camera, ThermoView TV40, which integrates both an infrared and a visible-light camera. Designed for a fixed installation, it enables the continuous monitoring of processes and products.

Operators can define various areas of interest with discrete tolerances, alarms, and trending. By scanning moving blanks and press parts at a 150 Hz frequency, the linescanners generate thermal images which provide information on temperature uniformity, part integrity (thickness variations, overlapping material), furnace performance, die wear and cooling cycle performance. The imager provides a ±1% accuracy compliant with CQI-9 HTSA. Thermal imagers for automatic process control

Contact: www.flukeprocessinstruments.com

Automated surface inspection for the entire production chain QUALITY ASSURANCE Well-known global companies in the automotive industry such as Daimler, BMW and Honda rely on high-tech solutions from Micro-Epsilon in the field of automated surface control. The company’s reflectCONTROL and surfaceCONTROL robotic inspection systems are designed for easy, fast and reliable quality inspection of surfaces.

The robot-supported reflectCONTROL Automotive system uses deflectometry, or the automatic analysis of reflections, to detect defects on shiny surfaces. The system can be flexibly adapted to different vehicle shapes and is integrated into the processing line. Micro-Epsilon also provides experienced advice and guidance when it comes to instal-

lations in greenfield and brownfield plants. reflectCONTROL can provide resolutions in the range of 0.1 mm. This enables the detection of almost all defects in the base paint and top coat in a three-dimensional form and position on the bodywork surface.

Meanwhile, the surfaceCONTROL robotic inspection system from INB Vision, a subsidiary of Micro-Epsilon, relies on 3D sensors to detect mat surfaces quickly and reliably in three dimensions. Aside from the automotive industry, these applications are used in aviation, domestic appliances and entertainment devices.

The new sensors operate on the basis of fringe projection and are available for measurement areas of 290 x 210 mm² to 570 x 430 mm². The sensors typically detect a surface within 0.5 s per measurement area. The achievable, lateral resolution is between 0.25 mm for the smallest area and 0.5 mm for the largest one. Therefore, surface deviations from 5 µm in height can be detected reliably.

The depth of the measurement area of between 150 mm and 300 mm also enables the reliable detection of zones with a strong curvature.

Using planning software based on CAD data, larger test objects are separated into several measuring positions that are approached one after another. The system is designed in such a way that several robots can operate in one cell on the same test object, so inspection times can be adapted to suit the production cycle.

Both systems, surfaceCONTROL and reflectCONTROL Automotive, cover the automated surface inspection process of the entire production chain in vehicle build, from the press plant and the chassis manufacture to electrophoretic deposition (EPD) coating and painting.

Micro-Epsilon’s reflectCONTROL is robot-supported for reliable and flexible quality inspection of surfaces MPT International 6 / 2018

Contact: www.micro-epsilon.com

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TECHNICAL INNOVATIONS

51

Skoda reduces energy consumption by 10% with laser precision MEASURING INSTRUMENTS StrikoWestofen, part of the Norican Group and a world leading provider of technology for the formation and enhancement of metallic parts, has helped Skoda Auto reduce energy consumption by 10% at its manufacturing plant in Mladá Boleslav, Czech Republic.

Skoda opted to have its four 15-year-old StrikoMelter shaft melting furnaces relined and retrofitted for greater levels of performance and efficiency. Supplied by StrikoWestofen, the StrikoMelter special burner technology combines preheating, heating and melting in one furnace shaft.

A melting shaft that is full at all times will achieve optimum energy consumption. This is because hot waste gases from the melting process are used to preheat the melting material in the StrikoMelter furnaces’ EtaMax shaft prior to the actual melting process.

To deliver this benefit for Skoda, StrikoWestofen refitted the EtaMax filling shafts of its 15-year-old StrikoMelter with laser technology. A laser beam scans the filling area of the melting shaft and permanently monitors the filling level.

When there is no melting material left in the upper part of the shaft, the filling process is initiated automatically.

According to StrikoWestofen, the continuous filling of the shaft, made possible by the integrated laser scanner, has increased the energy efficiency to the point where it is pos-

Laser technology permanently monitors the StrikoMelter furnace shaft

sible to reduce gas consumption by around 10% per system.

The one-off purchase costs of the retrofit are usually recovered after only a few months.

StrikoWestofen says the laser scanner is one of its most frequently sold modernization options, and therefore one of its bestsellers.

Contact: www.strikowestofen.com

Combined cut-to-length/EPS line for dry pickled plate ANNEALING AND PICKLING Users of large plate – such as construction and agriculture equipment or rail, car, tank and vessel manufacturers among others – desire a dry, scalefree product because it simplifies paint preparation, keeps their shops cleaner and eliminates blasting operations.

However, such a product has proven difficult to source.

Few acid pickling lines run material over 0.5 inch (12.5 mm) thick, and few cut-to-length (CTL) processors can transform coils of 0.5 to 1 inch (12.5 mm to 25 mm) material into sheets.

In response to this, The Material Works, Ltd. (TMW), flat rolled metals toll processing and supply chain experts based in St. Louis, Missouri, USA, have unveiled a new application of Eco Pickled Surface (EPS) technology which can produce ‘stay flat’ pickled dry plate up to 1 inch (25 mm) thick.

Rather than perform two separate operations on plate, TMW has devised a way to combine the pickling

and CTL operations into a single processing line. The technology integrates a smaller EPS Version 6 ‘mini-cell’ into a heavy gauge Stretcher Leveling or Temper Pass CTL line.

This creates an efficient and compact CTL line that can produce the ‘stay flat’, dry and rust-resistant plate.

A patent on this application of EPS technology has been applied for and it will soon be offered for sale to steel producers and processors.

Contact: www.thematerialworks.com

TMW has combined pickling and cut-to-length operations into a single processing line MPT International 6 / 2018

52

››› TECHNICAL INNOVATIONS

New steel grade makes connecting rods lighter and stronger INNOVATIVE STEELS Ascometal has developed a new variant of their steel grade Splitasco HC, which the company has successfully marketed for many years as an efficient way of optimizing standard C70 connecting rods. The new steel grade, Splitasco XS, developed in cooperation with a connecting rod manufacturer, features enhanced mechanical properties. Since connecting rods are subjected to extreme loads, it is crucial that they feature a high fatigue strength and can withstand maximum pressure loads without plastic deformation. Compared to standard materials, like C70 used for connecting rods, the compressive yield strength has been improved by 110% and the fatigue strength by more than 60%. As Splitasco XS is a bainitic steel grade, components made of this material obtain these superior mechanical properties without quenching, ruling out any risk of deformation. Since Ascometal has also optimized the chemical composition of the steel grade, a totally bainitic microstructure is achieved with high cooling rates. As a consequence, Splitasco XS is a reliable steel grade whatever the cooling rate after forging.

Splitasco XS is suitable for all connecting rod sizes. Machinability is good and there is no risk of deformation. With the new steel grade, it is possible to produce connecting rods of lighter weight. Ascometal is a company of the Schmolz + Bickenbach Group.

Since connecting rods are subjected to extreme stress, high fatigue strength is crucial

Modernization doesn’t always run so smoothly MPT International 6 / 2018

Contact: www.ascometal.com

LITERATURE SERVICE

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3D inspection of slabs and heavy plate 12 pages, English As a manufacturer of surface inspection systems, IMS Messsysteme GmbH of Heiligenhaus, Germany, supplies both 3D systems for high-resolution capture of topographical data for slab inspection and also 2D systems for hot and cold rolling applications. This in-depth brochure examines how, with its combined 3D and 2D surface inspection solution for slabs, also directly after casting, IMS has closed one of the last gaps in optical surface inspection.

Contact: www.ims-gmbh.de · Email: info@ims-gmbh.de

Spray technology for steel mills 75 pages, English Spraying Systems Co. of Wheaton, Illinois, USA, are experts in spray technology for steel mills.

This detailed magazine brings together process diagrams, product specifications and technical references and datasheets. These explain the capabilities of Spraying System Co.’s nozzles, headers and systems which are specially-designed for such applications as fabrication and testing, continuous casting, hot and cold rolling mills and more.

Contact: www.spray.com · Email: info@spray.com

The world of furnace technology 24 pages, English LOI Thermoprocess GmbH of Essen, Germany, part of Tenova Metals Group, specializes in reheating and heat treatment plants for high performance materials. This brochure offers a comprehensive overview of the company’s know-how, services and components related to furnace technology. Topics include the reheating of long and flat products and forgings, quenching and tempering lines for heavy plate and the company’s product portfolio.

Contact: www.tenova.com · Email: LOI@tenova.com

Electric temperature measuring sensors 7 pages, English Herth elektrische Temperaturgeber GmbH of Werne, Germany, supplies thermocouples, resistance thermometers and accessories. Beginning with the company’s origins in 1978, Herth offers a short and concise overview and specifications of its planning, engineering and production of electric temperature measuring sensors. The company outlines its long-standing relationships with large, well-known companies and strong delivery capabilities.

Contact: www.herth.de · Email: info@herth.de

Software for advanced quality assurance 8 pages, English QuinLogic is headquartered in Aachen, Germany, and part of SMS Group. Presented in a friendly and entertaining style, this brochure walks the reader through the company’s advanced quality assurance systems. These include the Quality Execution System (QES), of which the challenges, algorithms and successes are explained with factoids and customer statements. The testimonials include Gallatin Steel, NLMK and USS-POSCO. Contact: www.quinlogic.com · Email: info@quinlogic.de MPT International 6 / 2018

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››› IN THE NEXT ISSUE...

IRONMAKING Tata Steel technology could save half the amount of CO2 released during steelmaking Tata Steel has been carrying out long-term testing of its HIsarna plant in IJmuiden, the Netherlands. HIsarna is a completely new technology for producing iron consisting of a reactor in which iron ore is injected at the top.

The company says its has exceeded expectations in sustainable steel production.

COLD ROLLING First reverse cold mill worldwide upgraded to a Hyper UC-mill by Primetals Technologies A reverse cold mill (RCM) modernized by Primetals, at the cold rolling plant of China’s Magang (Group) Holding Co (Masteel), is the world’s first to upgrade to a Hyper Universal Crown (UC)-mill. Hyper UC-mills use smaller diameter work rolls for the production of harder and thinner materials with improved product quality.

QUALITY ASSURANCE 3D surface inspection for highest quality in metal production ISRA Vision Parsytec of Darmstadt, Germany, has developed a new system that enables 100% 3D surface inspection and measurement from the first production step. Quality defects and costs in the subsequent production process can be prevented, as a result.

This preview may be subject to change.

Metallurgical Plant and Technology

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Experience matters. We believe imagination matters too. Curious minds question everything to find groundbreaking solutions. There is still so much to discover. So many great opportunities.

We love the heat and we love the cold. We love the glow and we love the dust. We love the quantum leaps and the small steps. We love to innovate and we love to be challenged. We love metals and we will change the way you produce it.

We are pioneers at heart.

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