MPT International 5/2018 (Oct)

Metallurgical Plant and Technology G 25074

5

ISSN 0935-7254

October 2018

voestalpine CC8 caster for automotive exposed steel, Danieli technology

Modern stainless steel line with advanced process control at Fuxin Special Steel

Major reconstruction prepares Bosnia and Herzegovina’s only steel plant

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EDITORIAL

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Growing trust in digital feeds into varied steel production This issue takes a close look at the modernized plant operated by Fuxin Special Steel Company in Zangzhou province, China. Fuxin’s varied stainless steel program includes sophisticated ‘duplex’ and ‘triplex’ production routes that enable the plant to flexibly produce these grades to order, efficiently and with high quality. The high tech facilities are developed and maintained in close partnership with SMS group.

Fuxin shows what is possible when automation and digitization are integrated directly into dynamic steel production, if operators are willing to take the next steps.

Powerful technologies (like SMS group’s X-Pact® systems for controlling processes remotely via a mobile phone or tablet) are underpinned by real-time data access and improvements in data storage. There is a growing trust in digitization within the industry.

Meanwhile, discussions continue as to what the industry can expect from a digital future. That was the case at the Surface Inspection Summit (SIS) in Aachen, Germany (September 28-29) attended by Danieli, Primetals, Vallourec and others. Particularly during PricewaterhouseCoopers (PwC) Strategy& Germany’s presentation, ‘Digital Disruption in the Steel Industry’, and its suggestion that steelmakers might one day employ the kinds of ecosystems already used by companies like Amazon, Uber and Tesla.

Alex Manford

Tesla’s ecosystem, for example, integrates systems, platforms and supply chains with digital solutions. At SIS, it was questioned how viable these systems can be in an industry as ‘conservative’ as steelmaking. Might there one day be an Amazon equivalent for steel buying? Could the large quantities of real-time and historical data needed to run a plant be stored in the cloud? PwC Strategy& believes these advancements are in the near future – e.g. cloud-based customer centred platforms or classification processes.

Such ideas may not be so far-fetched. A major talking point at next month’s MetalExpo’2018 in Russia is how e-commerce services have become an efficient tool to trade steel products online. And this issue of MPT reports on several projects where data is used and trusted extensively; from Siemens’ technical innovations with cloud-based systems, MindSphere, to the aforementioned advancements at Fuxin Special Steel Company.

All of these projects and discussions hint at exciting times ahead.

Alex Manford Chief Editor, MPT International

MPT International 5 / 2018

680

PROCESS CONTROL SYSTEMS

Danieli Automation automates plants through integrated systems for equipment, process and power control, handling jobs from order placement through product delivery.

Event-prediction and problem-solving operator assistance are ensured by the innovative 3Q system.

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SCRAP SHEARS AND SHREDDERS

Danieli Environment offers a full range of proprietary technologies for air pollution control, water treatment, solid waste recovery, noise reduction and energy savings.

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ENERGIRON DIRECT REDUCTION PLANTS

Through planning, complete systems integration and construction with our own heavy lifting equipment, provide our teams with full operational flexibility.

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BLAST FURNACE AND CONVERTER PROJECTS

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356

ENVIRONMENTAL PLANTS

ELECTRIC ARC FURNACES

SECONDARY METALLURGY STATIONS

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TURNKEY PLANTS SUPPLIED WORLWIDE

CASTING STRANDS FOR SLABS, BLOOMS, AND BILLETS

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SLAB, BLOOM, AND BILLET GRINDING MACHINES

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Danieli Centro Combustion and Danieli Olivotto Ferrè provide the most efficient and low consumption heating and heat treatment systems for all steel and NF metals production processes.

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HEATING AND HEAT TREATMENT SYSTEMS

Our original technology, process know-how, in-house design and manufacturing along with proprietary automation systems, environmental solutions and customer service for a competitive and sustainable steel and nonferrous metals industry.

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HOT STRIP, PLATE AND COLD MILLS

STRIP PROCESSING AND FINISHING LINES

HEAVY SECTION, RAIL, BAR AND WIREROD MILLS

DRAWING AND PEELING MACHINES

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SEAMLESS TUBE AND WELDED PIPE PLANTS

390

EXTRUSION AND FORGING PRESSES

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ALUMINIUM HOT AND COLD MILLS

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››› CONTENTS

Events 29

wire India, Tube India and Metallurgy India: a powerful metal trade fair trio

31

Metal-Expo’2018: Russia’s main forum for steel producers

Steelmaking – Metallurgy 32

Modern stainless steel process line with advanced process control at Fuxin Special Steel Co. Ltd.

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

Danieli & C. S.p.A., Buttrio (UD), Italy Contact: www.danieli.com E-mail: info@danieli.com

Fuxin, now one of the biggest flat stainless steel producers in China, has modernized it plant for flexible steel production with SMS group.

The results could steer future innovations for Industry 4.0

Company profile 36

voestalpine celebrates 350 years of steelmaking expertise in Sweden Over the centuries, Uddeholms AB (today BöhlerUddeholm AG and part of voestalpine) has become a true innovator in tool steel. Also, in Austria, voestalpine celebrates 20 years of automotive blanks production

Ironmaking – Steelmaking

Environmental protection

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52

Almamet newly provides advanced desulfurization technology Almamet has acquired the knowledge and workforce of thyssenkrupp Industrial Solutions. The new entity, Almamet Industrial Solutions, specializes in the design, construction and optimization of desulfurization facilities

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The first of 5 billion US$ worth of investments in the USA by GFG Alliance, the plant applies the Greensteel model which uses renewable energy and aims to recycle America’s growing mountain of scrap

Major reconstruction prepares Bosnia and Herzegovina’s only steel plant

Quality assurance

ArcelorMittal Zenica and Danieli Corus have completed a EUR 30 million project to rebuild blast furnace No. 4. Integrated steel production can now continue in the industrial city of Zenica for up to 20 years

54 8 CNNQWTGE EQOOKUUKQPU YQTNFoU ƂTUV ultrasonic test facility in Germany

Heat treatment 47

Liberty Steel restarts low-carbon production steelworks in South Carolina

New standards for plate cooling in heavy plate heat treatment lines SMS group has established a new technology for plate cooling in heat treatment lines, the MultiFlex-Quench®. The system has already been applied in two cutting-edge heavy-plate heat treatment lines

MPT International 5 / 2018

Vallourec and BHGE have implemented the first 2D phased-array facility of its kind in the world, enhancing the possibilities of ultrasonically testing seamless steel tubes at full production speed

Strip processing 57

Fluid solutions for the cost-effective tinplating of steels Efforts to reduce the costs and environmental impact of the tinplating of steels are necessitating expensive equipment upgrades. Quaker Chemical Corporation has a cost-effective solution for all existing lines

CONTENTS

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47

52

44

Columns 8

International industry news

66

Literature service

60

Technical innovations

67

In the next issue

61

Cartoon

67

Imprint

Advertisers’ index ABB AB AIST Association for Iron & Steel ALMAMET GmbH AMOVA GmbH BEDA-Oxygentechnik Armaturen GmbH BRAUN Maschinenfabrik GmbH BWG Bergwerk- und WalzwerkMaschinenbau GmbH Combilift Ltd. Danieli & C. Officine Meccaniche SpA F.I.M.I. S.p.A

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Fives DMS Guild International Inc. INTECO melting and casting technologies GmbH JATO-Düsenbau AG jbd Gesellschaft für Medien und Kommunikation mbH Küttner GmbH & Co. KG MICRO-EPSILON Messtechnik GmbH & Co. KG Primetals Technologies Austria GmbH Redecam Group SpA

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RHI Feuerfest GmbH 15 Saar-Metallwerke GmbH 23 TML Technik GmbH 10 TMT GmbH 39 RUDOLF UHLEN GmbH 62 VELCO GmbH 38 Ventilatorenfabrik Oelde GmbH 65 Vishay Precision Group Canada ULC (KELK) 62 WOKO Magnet- und Anlagenbau GmbH 22 Paul Wurth S.A. 19, 20 Zumbach Electronic AG 30

MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

The Americas Mexico Simec to revamp merchant bar mill. Primetals Technologies has received an order from Simec to revamp the company’s merchant bar mill in Mexicali in the Mexican State of Baja California. Primetals Technologies will be responsible for engineering the new roughing train and the new handling area, and supply the required process equipment as well as electrics and automation. The mechanical supply includes core equipment for the 60 t/h pusher-type reheating furnace and the furnace charging and discharging areas. The new six-stand roughing train will replace the existing three-high stand.

Hot commissioning is planned for the fourth quarter of 2019.

Ternium Guerrero revamps chemical energy package. MORE has revamped the chemical energy package on the 180 t electric arc furnace of Ternium Guerrero in Monterrey. The modernization project, for which MORE has already received the final acceptance certificate (FAC), included the replacement of the existing injectors with a multifunctional unit which integrates a burner and also supersonic oxygen and carbon injection.

USA Steel Dynamics to build additional galvanizing line. Steel Dynamics Inc. plans to add a third galvanizing line to its Columbus flat roll division. This investment is another step of further diversification into higher-margin products. The new galvanizing line will have an annual coating capability of 400,000 t, producing gauges between 0.33 mm and 4.06 mm, and widths between 915 and 1,830 mm. Construction is planned to take place during the next 24 months, with operations expected to begin by mid-year 2020.

MPT International 5 / 2018

Gerdau to modernize electric steel plant. Primetals Technologies has received an order from Gerdau Special Steel North America to modernize its electric steel plant in Monroe, Michigan. The project involves modernizing the existing electric arc furnace (EAF) and equipping the electric steel plant with a new twin-ladle furnace and a new material handling system.

The aim of the project is to increase the plant’s annual production capacity by 160,000 t of rolled end products. The ladle furnace and material handling system are scheduled to come into operation at the end of 2019, the modernized EAF in the middle of 2020.

Steel Dynamics orders EAF process control technology. Steel Dynamics Inc. has placed an order with Tenova for the supply of off-gas process control and water detection technologies for its Pittsboro, Indiana, EAF. Tenova will supply its hybrid extractive/laser NextGen® off-gas analysis system, iEAF® dynamic process control system and water detection technology as a fully integrated solution for the plant’s 100 t AC EAF.

Big River Steel to expand hotrolled steel capacity. Big River Steel is expanding its Leadership in Energy and Environmental Design (LEED) certified, Arkansas-based scrap recycling and steel production facility. The expansion of the Flex Mill™ will double Big River Steel’s hot-rolled steel production capacity to 3.3 million t/year.

In addition, the expansion will facilitate the company’s ability to produce even higher grades of electrical steel, demand for which is expected to increase with continued focus on energy efficiency and the increase in hybrid and electric vehicle sales. Engineering efforts are already underway with SMS group, the primary technology provider. Major construction activity will begin later this year and continue for approximately 24 months.

JW Aluminum orders roll grinding machine. Tenova has

News in brief Hoa Sen Group, Vietnam, is going to modernize two hot-dip galvanizing lines. Danieli has been chosen to supply a new furnace and air wiping equipment for the project.

Feng Hsin Steel, Taiwan, has issued the final acceptance certificate (FAC) for the new, high-speed rebar mill supplied

by Danieli. The mill produces 745,000 t/year of quality rebar in diameters from 10 to 36 mm.

MAN Energy Solutions, Germany, replaces the company’s former name, MAN Diesel & Turbo. The new branding embodies a strategic and technological transformation and the expansion of MAN Energy Solutions’ product range to include hybrid, storage and digital service technologies.

BGH Edelstahlwerke, Germany, has issued the FAC for an electric arc furnace (EAF) modernized by Primetals Technologies.

SAH CSS, South Korea, has successfullyre-commissioned a 100 t AOD converter, after installation by SMS group of an electro-hydraulic torque retainer complete with electrical equipment and automation systems.

Rashtriya Ispat Nigam Ltd. (RINL), India, has successfully commissioned a new continuous casting machine at the Visakhapatnam Steel Plant (VSP).

The caster was supplied by SMS Concast. thyssenkrupp Steel, Germany, has taken delivery of a new stretcher-leveller gear unit for its cold rolling mill in Duisburg.

The 43 t special gear unit was supplied by KWE, a specialist manufacturer from the region.

PIONEERS AT HEART

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

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

We are pioneers at heart.

contact@primetals.com

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››› INTERNATIONAL INDUSTRY NEWS

been contracted by JW Aluminum to supply a roll grinding machine for work rolls and back-up rolls, and other roll shop equipment for its Goose Creek facilities in South Carolina.

Additional equipment includes a chock changer and a chock tilter.

Asia China Fuxin orders cold rolling equipment for stainless steel production. Fuxin Special Steel has entrusted Fives with a contract for the supply of coil preparation lines and cold rolling mills for stainless steel production. Fives will design, manufacture, supply and commission two coil preparation lines and three DMS 20high cold rolling mills, each with a capacity of 110,000 t/year.

Wisdri (Xinyu) to expand cold rolling capacity. Wisdri (Xinyu) Cold Processing Engineering Co. Ltd., a joint venture between Wisdri and Xinyu Iron & Steel, have awarded Fives the order to design and supply a cold rolling mill to process non-grain oriented (NGO) silicon steel, mainly for supply to the automotive industry. The DMS 20-high cold rolling mill to be supplied by Fives will have the capacity to process 100,000 t of grade 210 NGO steel. The first coil is scheduled to be processed by the end of 2019.

Lianxin Steel to employ thermomechanical rolling process. Lianxin Steel has ordered a mill for thermomechanical rolling of rebar from SMS group for its Dafeng site. The TMbaR mill will be designed for a production of 1,000,000 t/year of rebar with diameters ranging from between 8 mm and 40 mm at a maximum rolling speed of 45 m/s. SMS group will supply all rolling mill stands for the roughing, intermediate and finishing mills, including two six-stand MEERdrive® finishing blocks, shears, water boxes as well as the double HSD® system. Additionally, the scope of supply includes the complete package of electrical and automation systems, plus supervision of erection and commissioning. The plant is scheduled to be started up by the end of 2018.

Guangxi Guixin orders electric arc furnace. Guangxi Guixin Iron & Steel Group has placed an order with Primetals Technologies to supply an EAF Quantum electric arc furnace for its Hezhou, Guangxi works. The furnace will have a tapping weight of 80 t and replaces two smaller existing arc furnaces. For the first time, an EAF Quantum arc furnace will feature the new split tapping process, which allows for continuous tapping with smaller but faster heats and significantly reduced tap-to-tap times.

Commissioning of the new furnace is scheduled for mid-2019. Primetals Technologies will supply the entire mechanical and electrical process equipment for the EAF including automated scrap yard management, charging, oxygen lancing and sand filling.

Shandong Laigang Yongfeng to expand rolling capacity. Shandong Laigang Yongfeng has ordered equipment for thermomechanical rolling of rebar from SMS group. The 1,000,000 t TMBaR mill will roll rebar in diameters ranging from between 8 mm and 32 mm. Yongfeng is also going to install two five-strand continuous casting machines supplied by SMS Concast as well as a new high-speed rolling area, including two six-stand MEERdrive® finishing blocks, cooling and equalizing lines, and a high-speed outlet. Production start is scheduled for 2019.

Yunnan Qujing to build new EAF. Tenova is going to supply a Consteel® Evolution EAF to Yunnan Qujing Iron and Steel Group Phoenix I&S Company Ltd, Yunnan Province. This contract represents the thirteenth Consteel® Evolution project in China.

Baosteel signs coal supply contract. Mechel has prolonged its coal supply agreement with Baosteel Resources, which is part of China Baowu Steel. The new agreement is valid from July 2018 to June 2019. During this time, Mechel will supply Baosteel Resources’ facilities with up to 700,000 t of premium-grade coking coal.

Henan Yaxin to build casting-rolling plant. Henan Yaxin Steel Group has placed an order with

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MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

Primetals Technologies for the supply of an Arvedi ESP (endless strip production) line. The casting-rolling facility will be part of a new steelmaking facility currently under construction in Fuding City, Fujian province. The liquid steel will be produced by two EAF Quantum electric arc furnaces ordered from Primetals Technologies earlier this year. The Arvedi ESP line will have a design capacity of 1.6 million t/year with the potential to produce 2.5 million t/year in the future. It will be capable of rolling strip to a reproducible thicknesses down to 0.8 mm. The plant is scheduled to go into operation in 2020.

JSW to build new wire rod mill.

JSW Steel Limited has signed a contract with Primetals Technologies for the supply and installation of a two-strand wire rod mill for its facilities in Toranagallu. Primetals Technologies will supply the complete wire rod mill with all mechanical and electrical equipment for two-strand production from a single stand roughing mill. Two independent rolling lines will then join at the coil handling area for further compacting and unloading. Start-up is scheduled for the end of 2019.

Pakistan Masteel upgrades reverse cold mill. Primetals Technologies has modernized a reverse cold mill at Masteel’s production site in Maanshan. The mill is the first upgrade to a Hyper Universal Crown (UC)-mill which employs smaller diameter work rolls, allowing for the production of harder and thinner materials with improved product quality. The upgraded mill now processes silicon steel grades with product thicknesses of between 0.3 and 0.65 mm in a width range of 900 to 1,280 mm.

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Tata steel starts up coke dry quenching system. Tata Steel has successfully put into operation the coke dry quenching unit for the No. 11 coke oven battery at its integrated steel plant in Jamshedpur. Paul Wurth, in a consortium with Larsen & Toubro as construction partner, provided the engineering, supply of technological equipment, training and supervision of the erection and commissioning for two new coke dry quenching systems. While the major part of the supply and the overall project management was handled by Paul Wurth, the Japan-based joint venture Paul Wurth IHI provided the key technological items and the related expertise. A second coke dry quenching system, for coke from the No. 10 coke oven battery, is scheduled to be put into operation in the second half of 2018.

MPT International 5 / 2018

Kamran Steel to modernize rebar mill. Kamran Steel Re-Rolling Mills has placed an order with Primetals Technologies to modernize the company’s existing rebar mill in Lahore. The project marks phase one of a threephase expansion plan. The aims of the first phase are to increase rebar production capacity from 100,000 to 150,000 t/year, increase yield, reduce energy consumption and improve rolling efficiency. Primetals Technologies’ mechanical supply will include a revamping of the reheating furnace runout roller table, to allow direct billet transfer to the new continuous roughing train. The rolling line consists of an eight-stand roughing mill and a sixstand intermediate mill. Both mills will be equipped with fifth-generation Red Ring stands. Hot commissioning is expected for the third quarter of 2019.

Philippines San Miguel Northern Cement to build new grinding plants. San Miguel Northern Cement is relying on Loesche technology for its new 5,000 t/d production line at the Sison site in the province of Pangasinan. The scope of supply includes two complete grinding plants for sub-bituminous coal. In addition to mechanical equipment, Loesche is supplying a majority of the electrical components and the automation system. Loesche will also be responsible for plant engineering, the supply of filters, blowers, etc. Delivery is scheduled for early 2019.

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››› INTERNATIONAL INDUSTRY NEWS

South Korea Daehan to upgrade bar mill. Daehan Steel has placed an order with SMS group for the modernization of its rolling mill in Sinpyeong near Busan. Currently, the mill can produce 130 t/h of rebar in diameters from 16 to 32 mm up to grade SD500. With the new equipment to be supplied by SMS group, Daehan will be able to add 13 mm rebar to the size range and produce new steel grades up to SD600. The project will comprize the replacement of the existing quenching line with a new one designed with the latest technology, including systems for precise pressure control and exact setting of the water flow rates. In addition, two dividing shears with associated pinch rolls and a bar braking system will be supplied. A high-speed delivery (HSD®) system to be integrated into the existing cooling bed will allow Daehan to feed bars onto the cooling bed via rotating channels. These are precisely synchronized with the soft bar braking unit, the cooling bed cycle movement and the bar position monitoring system.

Europe Finland Outokumpu produces thicker stainless steel slabs. Outokumpu has started up the stainless steel continuous slab caster modernized by Primetals Technologies at its production site in Tornio. The machine head of the casting plant was modified in order to enable thicker slabs to be cast at high speed. The caster was equipped with a range of modern technology packages, such as the DynaGap soft reduction system. The bending section was fitted with shims suitable for the new slab thickness of 200 mm.

Germany Waasner orders press for laminations. Motors for electric cars require highly sophisticated stacking techniques for thin laminations.

Waasner, a manufacturer of electric motor laminations, has placed an MPT International 5 / 2018

order with Schuler for the supply of a Smartline EV 3.8 press that will comply with these extremely exacting requirements. Featuring an upright opening measuring 3.8 m and a press bed with a length of 3.7 m, the press will process 0.2 mm thick sheet metal. Delivery of the press is scheduled for the second half of 2019.

Italy AST to upgrade slab caster.

Danieli Automation has been contracted by AST (Acciai Speciali Terni) to upgrade the process control system of the No. 3 slab caster. The purpose of the investment is to align the level 1 and level 2 systems as much as possible to the automation system of the No. 7 slab caster revamped by Danieli some years ago. The complete process control system will be replaced on a turnkey basis with the latest Danieli Automation 3Q suite.

Russia MMK unifies corporate information system. Magnitogorsk Iron and Steel Works (MMK) is expanding its cooperation with Oracle. In the course of the project’s implementation, MMK will update its corporate information system to the latest version of Oracle E-Business Suite R12 and expand the ERP system to other companies of the group. This unified information system includes the management of production, inventories, repairs, purchases, finances, personnel, projects, orders and sales. The launch of the pilot operation of the corporate information system is planned for April 2019.

MMK completes blast furnace reconstruction. MMK has completed the reconstruction of its blast furnace No.1 in Magnitogorsk.

The new equipment will enable the company to significantly reduce the impact on the environment.

Danieli Corus built part of the furnace with copper horizontal fridges.

Severstal places order for new coke making complex. Severstal and Paul Wurth have signed a contract for the construction of a new coke making complex at Severstal’s integrated steel works in Cherepovets.

Two stamp charged coke batteries, for which Paul Wurth provided the project documentation, will be the core parts of the new complex. Along with the coke oven batteries, Paul Wurth’s technologies and engineering solutions will be applied in the three new coke dry quenching systems, coal preparation and coke handling, as well as in the tar decanting plant.

Paul Wurth’s hardware supplies will include equipment and systems such as the coke oven doors, refractories, machines and the Sopreco® system for single oven pressure control. The two batteries will be designed for a production of 1.4 million t/year of coke.

Severstal to upgrade tandem cold mill. Severstal has contracted SMS group to modernize the exit section of the tandem cold mill “2100” at its Cherepovets plant. The main objective of the project is to enable full utilization of the maximum possible strip width of 1,850 mm. The supply scope will mainly comprize a new tension reel featuring a motor coupling of about 9 m length connected to a new electrical gear. Two coil cars running on one common rail, for the transport of the coils to the inspection station and to the coil storage facilities, will be arranged in a neighbouring shop.

Furthermore, an offline inspection station will be supplied for ergonomic and fast inspection of the finished strip. The modernization activities will take place during a scheduled downtime of 23 days. Commissioning of the revamped tandem mill is scheduled to take place by the summer of 2019.

Spain Celsa Barcelona orders taphole servicing systems. Celsa Barcelona has awarded MORE an order for two automatic EAF taphole inspection and sand filling systems. Celsa Barcelona operates two 150 t EAFs. The

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››› INTERNATIONAL INDUSTRY NEWS

eccentric bottom taphole (EBT) SAND systems, equipped with high-resolution cameras, will be installed on the equipment to inspect the EBT directly from the control desk and manage sand charging or cleaning operations remotely. The project is scheduled to be completed in the fourth quarter of 2018.

Sidenor issues FAC for upgraded bar mill. SMS group has received the FAC from Sidenor Aceros Especiales for the upgrade of its bar mill in Basauri. SMS group’s scope of supply included all process facilities, the automation system, and the entire erection and commissioning. As part of the upgrade, the existing three-high roughing stand was replaced with a six-stand continuous roughing mill with compact stands in a V-H arrangement. A new flying crop shear and two additional compact stands in an H-V arrangement were installed upstream of the current eleven-stand continuous finishing mill.

Sweden Hybrit Development places order for DRI process equipment.

Hybrit Development has selected Tenova as the supplier of selected process equipment for direct reduction ironmaking to be used in its pilot plant for fossil-free steel in Luleå. In 2016, the Hybrit Initiative was established with the aim to replace coking coal with hydrogen in order to obtain a fossil-free steelmaking process route with virtually no-carbon footprint.

Turkey Diler Demir Celik orders caster upgrade for SBQ production. Diler Demir Celik has ordered Danieli’s Fast Cast technology to upgrade its caster at the Dilovasi plant near Istanbul. The six-strand 9 m radius caster produces 130 to 180 mm square billets. The upgrading project includes the complete replacement of the equipment installed along MPT International 5 / 2018

the caster curve, specifically a compact, maintenance-free mould oscillator, an electro-hydraulic actuator for oscillation, a new Danieli Rotelec in-mould stirrer, air-mist secondary cooling, and a strand/final stirring system. The existing automation system, installed by Danieli Automation, will be updated with additional controls for the new equipment and the added quality grades. Commissioning of the caster is scheduled for first quarter 2019.

Ekinciler installs pneumatic lime injection system. Ekinciler Iron and Steel Industries, located in Iskenderun, has successfully commissioned the pneumatic lime injection technology supplied by MORE. The company supplied two sidewall injectors (combined burner/lime injector) and three dispensers for the pneumatic injection of material into the electric arc furnace, ladle furnace and ladle.

Companies ABB acquires GE Industrial Solutions. ABB has completed its acquisition of GE Industrial Solutions (GEIS), GE’s global electrification solutions business, on June 30, 2018. The transaction offers substantial value creation potential within ABB. They include growth opportunities to be leveraged from coupling ABB’s digital offering, ABB Ability™, with the extensive GEIS installed base. GEIS will be integrated into ABB’s Electrification Products (EP) division, led by EP president Tarak Mehta, as a new business unit called Electrification Products Industrial Solutions (EPIS).

Stephanie Mains, who was previously the president and CEO of the GE Industrial Solutions business, will lead the new business unit as managing director. As part of the transaction, ABB has established a long-term strategic relationship with GE to supply them with products and solutions from across the ABB portfolio. Included in the acquisition is a long-term right to use the GE brand.

Andritz takes over ASKO. International technology group Andritz has signed a contract for the acquisition of ASKO, Inc., a family-owned company headquartered in Homestead, Pennsylvania, USA. ASKO manufactures a wide range of shear knives, blades, liners, wear plates and accessories for the metals producing, processing and recycling industries. Founded in 1933, the company serves international metals production companies and delivers its products from four locations: Homestead, PA; Rock Hill, SC; South Holland, IL; and Amsterdam, Netherlands.

Argynnis acquires Solaronics.

Swedish Argynnis Group AB has taken over the French company Solaronics SA. Argynnis, formerly Binar AB, offers unique products and solutions relating to first responder technology, binar handling and binar industrial solutions, and heating and drying for professional customers. It develops niche companies, one of which is Ircon Drying Systems AB which specializes in industrial heating based on infrared and microwave technology.

Solaronics develops and markets infrared products and has been active for more than 50 years. It has specialized in gas-driven infrared drying combined with air technology for a wide range of industries. Argynnis can now offer an expanded range of products and services. The acquisition of Solaronics will combine gas infrared drying with Ircon’s competence in electric infrared drying.

EOS and Siemens intensify cooperation around industrial 3D printing. EOS, technology supplier in the field of industrial 3D printing of metals and polymers, and Siemens continue their close collaboration to further accelerate additive manufacturing (AM) technology and applications. The current cooperation includes the areas of software, automation and drive technology, and use of AM technology. Siemens’ control and drive components are part of a new EOS series for metal additive manufacturing, and Siemens integrates the

Fives: quality through digitalisation EYERON™, QUALITY IMPROVEMENT TOOL

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Products tracking Summary of quality events and alarms Product qualification Data mining Performance monitoring

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Products tracking: centralization of signals and measures and product history tracking Summary of quality events and alarms: sum-up of events / alarms per product and SIS data treatment Product qualification: coil grading and product reallocation Data mining: filters & segmentation and data extraction & treatment Performance monitoring: statistical process control and reports

This data is used to suggest smart solutions to metallurgical problems, resulting in increased productivity and improved quality

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functions of an EOS CAM tool into one of its AM modules. Additionally, Siemens is going to extend its Additive Manufacturing Experience Center (AMEC) in Erlangen, Germany, with an EOS system for polymer printing.

WE ARE ...

LADLE FURNACE

FIMI expands portfolio with acquisition of Selema. By taking over Selema, an Italian company specializing in processing lines for strips of nonferrous materials, Italian FIMI Group has diversified its range of products.

Selema designs processing lines such as tension-levelling and degreasing lines covering a thickness range from 10 μm to 4 mm.

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INTECO melting and casting technologies GmbH Wienerstraße 25 • 8600 Bruck a.d. Mur • Austria MPT International 5 / 2018 Tel.: +43 (0) 3862 53110-0 • Fax: +43 (0) 3862 53844 inteco.austria@inteco.at • www.inteco.at

Loesche renews ISO 9001 certification. Loesche, manufacturer of grinding plants and combined drying and grinding plants for industries such as cement, steel, mineral processing and mining, has been re-certified according to ISO 9001. Loesche was first certified in 1998. The renewal also certifies that the revised quality management of the company meets ISO 9001:2015 requirements.

Midrex achieves production milestone. In June this year, plants operating with Midrex® direct reduction technology reached a cumulative production of 1 billion t of direct reduced iron (DRI) products, according to records kept by Midrex Technologies and verified annually by World Steel Dynamics. From the startup of the first Midrex plant at the former Oregon Steel Mills in Portland, Oregon, USA in 1969, it took 38 years to produce the first 500 million t of DRI, but only 11 years to achieve the second 500 million t. By the end of 2017, Midrex plants were operating at about a 60 million t/ year rate, with sufficient capacity under construction to push the rate to about 75 million t/year by the end of 2020.

Stoilensky produces 10 million t of pellets in less than two years.

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INTERNATIONAL INDUSTRY NEWS letizing plant, NLMK group’s largest investment project, began in 2014 and was completed in November 2016. The horizontal grate induration furnace, the largest of its kind in Europe, ensures the plant’s high performance at 780 t/h of pellets produced.

The Stoilensky pelletizing plant is the first in the Russian metals and mining industry to use high-efficiency hyperbaric filters to remove fluid during the processing of ore. The concept behind the design is that of an environmentally friendly, waste-free facility in which waste charge material and captured dust are fully recycled.

NLMK expands cooperation with transformer manufacturers in India, USA and Turkey.

NLMK group has signed long-term strategic partnership agreements with leading manufacturers of components for transformers: Enpay (Turkey), KRYFS (India), National Material Company (NMC, USA). Un-

der these agreements, NLMK will regularly supply transformer steel from its production sites in Lipetsk and Yekaterinburg, Russia, and offer expanded technical support. The parties have also agreed to expand their co-operation in the field of new product development and market entry.

Novex Trading renamed NLMK Trading. Novex Trading, which supplies NLMK products to the global market, has been aligned with NLMK group’s brand and renamed NLMK Trading.

NSSMC to integrate and reorganize welded stainless steel pipe and tube business. Nippon Steel & Sumitomo Metal Corporation (NSSMC); Nisshin Steel; Nippon Steel & Sumikin Pipe (NSPC); Nippon Steel & Sumikin Stainless Steel Pipe (NSSP); and Nisshin Stainless Steel Tubing have signed a basic

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agreement to integrate and reorganize their welded stainless steel pipe and tube business. According to the agreement, the automotive stainless steel electric resistance welding (ERW) businesses conducted by NSPC, Nisshin Steel, and NSSP will be integrated into NSPC. Meanwhile, NSSP and Nisshin Stainless Steel Tubing will merge and integrate their businesses concerning manufacture and sales of tungsten inert gas (TIG) welded pipes and tubes conducted by NSSP, and TIG and laser welded pipes and tubes conducted by Nisshin Stainless Steel Tubing.

RHI Magnesita plans major investment in China. RHI Magnesita, supplier of high-grade refractory products, is going to increase investment in the strategically important Chinese market by investing more thanEUR 20 million in its dolomite plant in Chizhou, Anhui Province in China. This is part of a decisive response to address global pressures in

MPT International 5 / 2018

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the supply of raw materials to the refractory industry, and provide additional volumes to its customers worldwide rapidly. The Chizhou site includes an extensive dolomite mine and raw material production as well as facilities for the production of high-quality dolomite-based finished products.

presses and forging lines. With this acquisition, Schuler has rounded out its product portfolio in the field of forging and single-stroke presses.

Farina Presse will gain access to Schulerâ&#x20AC;&#x2122;s global distribution network and continue to operate under its own brand name.

RHI India and RHI Clasil to merge with Indian listed Orient Refractories. In order to simplify the corporate structure and consolidation of its Indian operating entities, RHI Magnesita has proposed a merger of its three Indian subsidiaries. RHI India and RHI Clasil are going to merge with Orient Refractories in pursuit of an amalgamation scheme.

On completion, RHI Magnesita will own approximately 70% in Orient Refractories which will be renamed RHI Magnesita India.

Seven Refractories and COBEX sign exclusive distribution agreement for Russia. Seven Refractories, headquartered in Slovenia, and COBEX, Germany, have signed a distribution agreement for Russia and the Commonwealth of Independent States (CIS). The announcement comes after several years of successful project cooperation. This agreement takes existing partnership between the two companies to the next level, making Seven Refractories the exclusive distributor for the entire furnace linings product portfolio of COBEX in Russia and the CIS region.

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425th anniversary of Saarstahl Neunkirchen. 2018 is an outstanding year for Saarstahl Neunkirchen. This year, the Neunkirchen steel plant celebrates its 425th anniversary and the completion of the last phase of the comprehensive revamp of its wire rod mill 32, which was the companyâ&#x20AC;&#x2122;s largest single investment since 1991.

Sandvik to divest stainless wire business. Sandvik Materials Technology has signed an agreement to divest its stainless wire business to Zapp Group, a German family-owned supplier of advanced metal products. This completes the full scope of the divestment plan for the welding and stainless wire operations, initially announced in May 2017. The deal includes the production unit in Sandviken, Sweden, and the global sales organization, along with selected trademarks and patents.

Schuler acquires Italian press manufacturer. Germany-based Schuler Group has acquired Farina Presse, an Italian manufacturer of MPT International 5 / 2018

Siemens to take over software products from OMAT. Siemens Digital Factory plans to take over products from OMAT Ltd., a Jerusalembased software solutions provider. The software solutions offered by OMAT focus on optimizing the spindle feed during machine operation. They provide a significant addition to the Siemens portfolio of machine tool control software. OMATâ&#x20AC;&#x2122;s technologies will be integrated into the software portfolio of Siemens Digital Enterprise, complementing it with process optimizing solutions in machining.

Tata Steel and thyssenkrupp sign joint venture agreements.

Tata Steel and thyssenkrupp have signed agreements to combinetheir European steel businesses in a 50/50 joint venture. This follows the signing of a Memorandum of Understanding in September 2017. The new company, thyssenkrupp Tata Steel BV, will be positioned as a leading pan-European high-quality flat steel producer strongly focused on performance, quality and technology leadership.

INTERNATIONAL INDUSTRY NEWS Wickeder Westfalenstahl completes MBO of Deutsche Nickel.

The management of Deutsche Nickel GmbH has taken over the stocks held by Wickeder Westfalenstahl in DNick Holding ltd. Deutsche Nickel will continue to focus on the production of bars and wire made of nickel and nickel-based alloys. For Wickeder Westfalenstahl, the management buyout completes an important step towards the company’s future strategic focus on special metals, microtechnology and the manufacturing of highend components.

Midrex and ChemTreat enter alliance on water treatment services. Midrex Technologies and ChemTreat have entered into a strategic agreement to offer integrated process water treatment services to Midrex® direct reduction ironmaking plants worldwide. ChemTreat has collaborated with Midrex for over a decade.

NSCI starts commercial production. Nippon Steel & Sumikin Cold Heading Wire Indiana (NSCI), established in 2016 as a joint venture company for cold heading and forging by Nippon Steel & Sumitomo Metal Corporation (NSSMC), has recently started its commercial production. The new plant has an annual production capacity of 36,000 t and is capable of manufacturing steel wires with a maximum diameter of 40 mm.

Sanyo Special Steel acquires Ovako. As part of the next step to integrate Ovako into Nippon Steel & Sumitomo Metal Corporation (NSSMC), Ovako will be acquired by Sanyo Special Steel. NSSMC, which is today the largest shareholder of Sanyo Special Steel, will, in conjunction with the acquisition, increase its shares and make Sanyo Special Steel a subsidiary. This will enable an even stronger cooperation between

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23

Ovako, NSSMC and Sanyo Special Steel with ambitions to strengthen their special steel offering to the global market.

Schenck Process acquires Process Components. Schenck Process has taken over Process Components Ltd (PCL) and its subsidiaries. PCL is UK-based designer and manufacturer of powder processing and handling equipment. The acquisition adds key process steps in the areas of mixing, milling and classification to Schenck’s portfolio.

SSAB sells Ruukki Construction’s business operations in Russia. SSAB has agreed to divest Ruukki Construction’s business operations in Russia to the open joint stock company Salavatneftemash. The transaction excludes the right to the Ruukki brand.

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

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MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

Ruukki Construction’s business operations in Russia largely consist of building frame and envelope structures.

Republic Steel prepares for increased market demand. Republic Steel, USA, provider of special bar quality (SBQ) steel, has prepared for increased market demand as a result of the recently imposed steel tariffs.

Republic invested in melt shop facilities and human resources to increase average production capacity at its Canton facility from 40,000 to 75,000 t/month, and at its Lackawanna, NY, site from 40,000 to 60,000 t/month.

Additionally, Republic anticipates restarting the 9”/10” rolling mill at its Lorain, Ohio, plant followed by the EAF as orders dictate.

Tenova launches R&D projects.

In partnership with leading European players of the industry, Tenova has launched three cooperative R&D projects supported by public funding.

BigData@MA stands for Big Data application in Manufacturing and aims to develop a specific Big Data application framework as a tool to give online support in decision-making. This two-year project is co-financed by the European Commission, the Lombardy Region and the Belgian Walloon Region.

CyberMan4.0, an approach for intelligent data-driven maintenance in the rolling area, and ECOSLAG, eco-friendly steelmaking slag solidification with energy recovery to produce a high quality slag product for sustainable recycling, are two projects co-financed by the European Commission Research & Innovation Fund for Coal and Steel.

tenure. Most recently Evans was director of technical/marketing services.

New general director of NLMK Engineering. Maxim Tevs has been appointed as general director of NLMK Engineering. In his new role, Maxim Tevs will focus on boosting the efficiency and quality of engineering activities, promoting the use of advanced design technologies and developing the NLMK Engineering talent pool.

delivering the final steps of the merger between RHI and Magnesita. Since July, Lisa Fuchs has been responsible for the global group’s media relations as communications manager together with Christian Paulmichl.

Schoeller Werk appoints new production manager. Herbert Frank is the new manager of production, maintenance and tool management at Germany-based Schoeller Werk,

Maxim Tevs

Herbert Frank

New CFO at RHI Magnesita.

Octavio Pereira Lopes, CFO and executive director of RHI Magnesita, has announced he will leave the company by the end of 2018 and return to Brazil. RHI Magnesita has nominated Ian Botha, currently CFO of Anglo American Platinum, as its new CFO and finance director for appointment in the 2019 annual general meeting. Octavio Lopes will, until his departure, focus on

specialists in longitudinally welded stainless steel tubes. Herbert Frank is responsible for 21 production shops with more than 300 plant systems, furnaces and machines, and 740 employees.

Ian Botha

Christina Båge-Friborg

SSAB appoints head of sustainability. Christina Båge-Friborg is to become head of sustainability at SSAB

Personalities Electralloy assigns new vice president sales. Michael Evans has assumed the duties of vice president of sales for Electralloy, replacing Wayne Weaver who has retired after 50 years of service. Evans has been with Electralloy since 1999, holding various positions with the company during his MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

and a member of the company’s group executive committee. She has previously held a number of leading positions in the sustainability field, most recently as head of sustainable business at Sandvik AB.

Schmolz + Bickenbach to elect new board chairman. The chairman of the board of directors of Schmolz + Bickenbach, Edwin Eichler, will not stand for re-election to the board of directors at the next annual general meeting. Edwin Eichler has been chairman of the board since 2013 and would now like to turn to other projects.

New head of SSAB Special Steels. Johnny Sjöström has been appointed the new head of SSAB Special Steels. He will take up the position by April 1, 2019, succeeding

Events ›

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

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

›

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

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

Johnny Sjöström

Per Olof Stark, who is going to retire in 2019. Johnny Sjöström joins SSAB from Uddeholm, where he has been CEO since 2014.

TimkenSteel appoints additional independent director.

The board of directors of TimkenSteel Corporation has appointed Marvin Riley, chief operating officer of EnPro Industries, as a new independent director. Eleven directors now serve on the TimkenSteel board.

MPT International 5 / 2018

›

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

Alacero-59. The Latin American Steel Conference will bring together the high-ranking representatives of the continent’s steel sector. The conference will be staged together with ExpoAlacero, the industry exhibition that brings together the most important companies of the steel value chain.

›

13-16 November 2018 Moscow, Russia Metal-Expo’2018 http://www.metal-expo.ru/en

Metal-Expo. The 24th International Industrial Exhibition in Moscow is expected to attract more than 500 exhibitors. The attendees from 35 countries will include leading ferrous and non-ferrous producers, as well as heavy-engineering and metalworking companies.

›

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

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

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

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

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

Clean Tech. Now in its fourth year, the European Conference on Clean Technologies in the steel industry will provide a forum for researchers and steel manufacturers to review recent developments in clean technology, energy efficiency and CO2 reduction, material efficiency and product life cycles.

INTERNATIONAL INDUSTRY NEWS

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MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS 22 – 24 January 2019 Mumbai, India Organizers: FICCI www.ficci.in

India Steel 2019. The 4th International Exhibition and Conference is a joint initiative taken by the Ministry of Steel, Government of India and Federation of Indian Chambers of Commerce and Industry (FICCI) providing a platform to all key decision makers from the steel and related industries to interact with, and explore new business avenues.

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

Made in Steel 2019. Southern Europe’s biggest conference and exhibition dedicated to the steel industry.

Besides a showcase, it is a culture hub which, through conventions, forums and round tables, hopes to further competitive collaboration and the exchange of information, two vital ingredients for business growth.

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ICASP-5 and CSSCR-5. This is the fifth year for both the International Conference on Advances in Solidification Processes (ICASP-5) and the International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR-5). Both events cover all aspects of solidification related research and applications. Experts from both academic research and engineering applications gather to discuss their knowledge, new scientific achievements, the common challenges and future developments.

›

— Millmate Thickness Gauging systems Gapless gauging for aluminium strip

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

MPT International 5 / 2018

17 – 21 June 2019 Salzburg, Austria Organizers: MINES ParisTech CEMEF http://www.icasp5-csscr5.org

24 – 28 June 2019 Düsseldorf, Germany Organizers: Steel Institute VDEh www.METEC-ESTAD2019.com

ESTAD 2019. The European Steel Technology and Application Days (ESTAD) 2019 will take place for the fourth time. The long lasting alliance between the METEC international trade fair for metallurgy and this accompanying conference makes this event the quintessential meeting point for the world’s leading steel experts.

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25 – 29 June 2019 Düsseldorf, Germany Organizers: Messe Düsseldorf www.METEC.com

METEC 2019. The tenth international metallurgical trade fair will be staged together with the trade fairs GIFA, THERMPROCESS and NEWCAST. Exhibits will include plant and equipment for iron, steel or non-ferrous metal production, and equipment for metallurgical plants, rolling mills and steel mills.

INTERNATIONAL INDUSTRY NEWS

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wire India, Tube India and Metallurgy India: a powerful metal trade fair trio The â&#x20AC;&#x2DC;powerhouse trioâ&#x20AC;&#x2122; of exhibitions for the countryâ&#x20AC;&#x2122;s thriving manufacturing sector expects to attract more than 12,000 international trade visitors in Bombay over three days to view the latest technologies, services, machines and equipment.

For the seventh time, the Indian subcontinent will see the trade fair trio wire India, Tube India and Metallurgy India at the Bombay Convention & Exhibition Centre (BCEC), located in the Western Suburbs of Northern Mumbai, between November 27 to 29. As with previous years, the three fairs are held concurrently and organized by Messe DĂźsseldorf together with Messe DĂźsseldorf India.

Following a strongly increased attendance over the previous years, organizers expect to see more than 12,000 visitors in Bombay during the three trade fair days. Around 400 exhibitors from 25 countries will represent the latest technologies and services from various segments of the wire and cable industry, the production and processing of tube and pipe, and metallurgy.

Regarded as a â&#x20AC;&#x2DC;powerhouse trioâ&#x20AC;&#x2122; of exhibitions, wire India, Tube India and Metallurgy India have come to represent the countryâ&#x20AC;&#x2122;s thriving manufacturing sector.

India has set itself an ambitious target to increase the contribution of its manufacturing output to 25% of gross domestic product (GDP) by 2025, up from the current 16%. Meanwhile, the flagship â&#x20AC;&#x2DC;Make in Indiaâ&#x20AC;&#x2122; campaign â&#x20AC;&#x201C; initiated by the Prime Minister of India, Mr. Narendra Modi, in September 2014 â&#x20AC;&#x201C; continues in its aims to bring global recognition to Indiaâ&#x20AC;&#x2122;s economy, and place it on the world map as a manufacturing hub.

wire India, Tube India and Metallurgy +PFKC KP /WODCK +PFKC s 0QXGODGT %QPVCEV YYY YKTG KPFKC EQO

The three exhibitions, wire India, Tube India and Metallurgy India, are proving crucial as India continues to establish itself as a manufacturing hub on the world stage

wire India: with Indiaâ&#x20AC;&#x2122;s Ć&#x201A;TUV nFGFKECVGF \QPGo HQT HCUVGPGTU wire India is the largest exhibition for Indiaâ&#x20AC;&#x2122;s wire and cable industry, in terms of both participants and visitors. More than two-thirds of exhibitors are expected to showcase products at this yearâ&#x20AC;&#x2122;s event. These will include machinery and equipment for wire making and finishing, forming technology, spring making and strand machines.

Other products on display are tools and auxiliaries for process engineering; measuring and control technologies; all types of wires (rolled wire, bare wire, and special wires); cable; and sheet metal. Springs, polymers, optical fibre and welded wire mesh will be among wire India 2018â&#x20AC;&#x2122;s new product segments.

This yearâ&#x20AC;&#x2122;s wire India is also the first to welcome exhibitors from the area of fastener technology to its dedicated â&#x20AC;&#x2DC;Fastener Special Zoneâ&#x20AC;&#x2122;. wire India is already one of

the worldâ&#x20AC;&#x2122;s leading trade fairs for fasteners, and its organizers have introduced the dedicated show as a response to growing interest within the industry. According to market analysis (by technavio), Indiaâ&#x20AC;&#x2122;s wire and cable market is expected to grow steadily over the next four years and post a compound annual growth rate (CAGR) of almost 6% by the year 2020.

This growth should be driven by increasing demand from Indiaâ&#x20AC;&#x2122;s power, telecommunication and real estate sectors.

Tube India: expanding VQYCTFU VJG CWVQOQVKXG UGEVQT Now in its eighth year, Tube Indiaâ&#x20AC;&#x2122;s main focus is on visitors from the iron, steel and non-ferrous metal industries, along with machinery manufacturers and equipment suppliers. This yearâ&#x20AC;&#x2122;s event seeks to expand beyond drawing visitors MPT International 5 / 2018

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››› INTERNATIONAL INDUSTRY NEWS

from the tube and pipe industry and also target automotive component manufacturers.

India’s automotive sector is expected to contribute in excess of 12% of the country’s GDP over the next decade, and comprise more than 40% of its manufacturing sector. This is partly due to the Government of India and Indian Automotive Industry’s joint Automotive Mission Plan 20162026 (AMP 2026). The plan aims to promote the country’s vehicles, auto components and tractor industries as the “main engine” of its manufacturing sector, in combination with the Make in India campaign.

Exhibits at Tube India will range from tube and pipe manufacturing to pipe finishing and pipe processing. That includes: raw materials; pipes and pipe ccessories; pipe trade; pipe-production machinery; second-hand machinery; tools for process engineering; auxiliaries; and measuring, control and testing technologies.

The event’s Technical Conference is jointly Organized by the International Tube Association (ITA) and Messe Düsseldorf India. This year, it will examine ‘Digital Technologies in Tube and Pipe Manufacturing’.

There will also be special country pavillions for manufacturers from Germany and China.

Metallurgy India: the entire OGVCNNWTIKECN KPFWUVT[ India boasts of one of the largest metallurgical industries in the world, due to its massive iron ore deposits and the presence of several iron and steel plants and factories.

The country’s iron and steel industry is now is more than a century old, dating back to when TATA Steel set up the first integrated steel plant in the city of Jamshedpur in 1907. India is today the fourth largest crude steel producer after China, Japan and the USA. The steel sector itself contributes towards nearly 2% of the coun-

try’s GDP and employs more than 600,000 people.

This year’s Metallurgy India promises to showcase the entire metallurgical industry. The exhibition is intended primarly for iron, steel and non-ferrous metals with a focus on machine supply for metallurgical works; the supply of raw and auxiliary materials; and process materials.

This year promises an array of electrical and automation equipment with popular segments for construction and energy, and will address the strong demand in India’s automotive sector. Exhibitors include key players and decision makers in metallurgical technology, processes, material handling and services.

Alongside the many exhibtors from India and neighbouring countries will be companies from Italy, Austria, the USA, China and Germany, all present to showcase their latest technologies and product launches.

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

MPT International 5 / 2018

INTERNATIONAL INDUSTRY NEWS

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Metal-Expoâ&#x20AC;&#x2122;2018: Russiaâ&#x20AC;&#x2122;s main forum for steel producers Informally called â&#x20AC;&#x2DC;Autumn Metal Weekâ&#x20AC;&#x2122; in Moscow, the last Metal-Expo attracted nearly 30,000 visitors from more than 60 countries. This year promises to be even more successful in drawing ferrous and non-ferrous producers, as well as heavy-engineering and metalworking companies, from around the world.

More than 550 companies from 35 world countries will exhibit at Metal-Expoâ&#x20AC;&#x2122;2018, the yearly International Industrial Exhibition, between November 13 to 16 at the VDNKh exhibition centre in Moscow, Russia. The event showcases industry products relating to minerals, metals and ores.

The 24th Metal-Expo is endorsed by the Russian Engineering Union and METALLURGMASH, The International Union of Metallurgical Equipment Producers. According to the eventâ&#x20AC;&#x2122;s organizers, the whole range of ferrous and non-ferrous products will be on display with the most state-of-the-art equipment and innovative solutions.

Metal-Expoâ&#x20AC;&#x2122;2018 will bring together leading steel and tube producers; hardware product manufacturers; non-ferrous producers, manufacturers of high-conversion products; suppliers of steel products and processors; and metal builders; along with oil and gas suppliers; and heavy engineers.

In addition, more than 30,000 industry professionals are expected to attend the event. Metal-Expoâ&#x20AC;&#x2122;s targeted audience includes steel product consumers and traders from such areas as construction, heavy engineering, fuel and power, transportation and logistics.

European and Asian engineering and steel companies will join leading Russian ferrous and non-ferrous producers and engineering companies on the 27,000 m 2 exhibition floor. A number of these have

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SMS Group, Danieli, Severstal and SSAB will be among the 550 exhibitors at Metal-Expoâ&#x20AC;&#x2122;2018 in Moscow, Russia (Picture: Metal-Expo)

already successfully implemented large scale projects in 2018 â&#x20AC;&#x201C; e.g. modernizing facilities, mastering new kinds of products, and contributing towards increased competitiveness in the domestic and global markets.

Among those displaying their latest engineering solutions will be SMS Group, Ficep, Metalforme, Danieli, EZTM, Ural Engineering Center, Weber CoMechanics, VI-MENS, NKMZ, KAMI, Nord Drives, Energomashspetsstal, CFHI, Sinosteel, WISDRI, Reltec, Zlatoust, Litmashpribor and Engineering Works.

' EQOOGTEG UGTXKEGU VQ VTCFG UVGGN RTQFWEVU QPNKPG Among the talking points at Metal-Expoâ&#x20AC;&#x2122;2018 will be how the latest digital solutions can help increase competitiveness, while also reducing risks and costs.

Discussions will include how data tools and solutions enable steel companies to manage certain processes more efficiently â&#x20AC;&#x201C; e.g. industrial safety, human resources and financial flows. There will be talks

on how e-commerce services have become an efficient tool for trading steel products online.

/CLQT UVGGN UWRRNKGTU HQT VJG EQPUVTWEVKQP KPFWUVT[ More than 40 conferences, roundtables, seminars and presentations will be held over the four days.

MetallurgMashâ&#x20AC;&#x2122;2018 is among the smaller exhibitions within the main event, where leading steel industry equipment manufacturers exhibit their solutions. Meanwhile, MetallTranslogistikâ&#x20AC;&#x2122;2018 focuses on the most pressing issues of logistics in mining and metallurgy.

The construction industry is one of the major consumers of steel products in Russia and, every year, manufacturers ramp up their production for MetallStroyForumâ&#x20AC;&#x2122;2018, Metal-Expoâ&#x20AC;&#x2122;2018â&#x20AC;&#x2122;s dedicated construction segment. The forum brings together producers and end-users of construction steels. MMK, Mechel, Severstal, SSAB, Metallinvest and Energomash-BZEM will be among the steel producers and service centres exhibiting their new dedicated steel products.

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş STEELMAKING â&#x20AC;&#x201C; METALLURGY

Modern stainless steel process line with advanced process control at Fuxin Special Steel Co. Ltd. )X[LQ LQ WKH 3HRSOHĹ&#x2019;V 5HSXEOLF RI &KLQD LV QRZ RQH RI WKH FRXQWU\Ĺ&#x2019;V ELJJHVW Ć&#x192; DW VWDLQOHVV VWHHO SURGXFHUV $V ZHOO DV OHDGLQJ GHYHORSPHQWV LQ Ć&#x192; H[LEOH VWHHO SURGXFWLRQ with its duplex and triplex technologies, Fuxinâ&#x20AC;&#x2122;s modernized new plant â&#x20AC;&#x201C; developed and maintained with SMS group â&#x20AC;&#x201C; could steer future innovations for Industry 4.0.

Fuxin Special Steel Company employs around 1,400 people at its steel plant located in Zhagzhouâ&#x20AC;&#x2122;s Longchi industrial area (Picture: SMS group)

Driven by stainless steel production technologies and market demand, the compound annual growth rate (CAGR) of stainless crude steel production has risen by 5.3% every decade, on average, during the last 60 years. In comparison, the CAGR of ordinary steel rose by only 2.9% during the same period.

Meanwhile, China has become the primary force in consuming the worldâ&#x20AC;&#x2122;s stainless steel resource surplus, and gradually the worldâ&#x20AC;&#x2122;s main market for stainless steel. Based on economic analysis, the countryâ&#x20AC;&#x2122;s stainless steel production capacity surplus exceed-

Fuxin Special Steel Company Limited, Taiwan Contact: www.fjfss.com Dr. habil. Jan Reichel, SMS group, Germany Contact: www.sms-group.com E-mail: jan.reichel@sms-group.com

MPT International 5 / 2018

ed roughly 20% by 2010. Taking into account the capacity of planned new projects, this will exceed 30% according to Chinaâ&#x20AC;&#x2122;s latest national Five Year Plan (2016 to 2020) of social and economic development initiatives.

It is against the backdrop of these developments that, since 2014, Fuxin Special Steel Company, Taiwan, has become one of the biggest flat stainless steel producers in China and the world. A member of Formosa Heavy Industries Corporation, the company produces 0.72 million t/year and employs around 1,400 people at its steel plant located in Zhagzhouâ&#x20AC;&#x2122;s Longchi industrial area, a designated investment zone for Taiwanese businesses in Fujian Province, China.

A total of 1.3 billion US$ has been invested in the plant which occupies a total land area of 88 hectares, close to the East China Sea. The location is ideal for lowering costs related to transport, the supply of raw materials and delivery of final products. The facili-

tyâ&#x20AC;&#x2122;s high tech equipment and technologies are maintained and further developed in cooperation with SMS group GmbH.

Modern facilities for varied steel production In August 2012, Fuxin awarded the contract for setting up its complete, state-of-the-art stainless steel plant to SMS Siemag AG, now known as SMS group. The projectâ&#x20AC;&#x2122;s scope included engineering, supply and supervision of the plantâ&#x20AC;&#x2122;s erection and start-up, all conducted under the full responsibility and general management of SMS. The Fuxin steel plantâ&#x20AC;&#x2122;s modern facilities include an electric arc furnace (EAF), an argon oxygen decarburization (AOD) converter, a ladle furnace (â&#x20AC;&#x2DC;LF1â&#x20AC;&#x2122;) and a continuous casting machine (CCM) with environmental facilities for gas cleaning and energy recovery. Liquid steel production completes the plantâ&#x20AC;&#x2122;s hot rolling, hot an-

STEELMAKING – METALLURGY

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33

The technological variants of Fuxin Special Steel operate in three ways, with two variations of its duplex process line plus the triplex process line

duction heat.

Today, it manufactures high-performance steels for all flat-product applications. In accordance with the Five Year Plan, the plant’s proNew data streams in Fuxin’s production system duction is focused on ultra-pure nealing and pickling line. The plant’s ferritic stainless steels, austenitic steel equipment was extended in 2016 with grades containing high nitrogen and an additional ladle furnace (‘LF2’) super austenitic corrosion resistant and vacuum oxygen decarburization stainless steels. Its range presently in(VOD) plant. With its highly flexible cludes the austenitic steel grades AISI and structured equipment and pro- 304, 304L, 316 and 316L and the ferriduction line, the plant can adapt its tic grades AISI 409, 409L, AISI 410, 420 production directly to suit current and 430. market requests while also maintainA steel plant’s ability to produce ing a high level of variability in the different grades economically without steel grades it produces. loss of quality is, of course, determined by its complete integrated production line. Different variations of technoloProcess routes: duplex and gy have been tested and applied withtriplex technology in the plant. These changes were in reThe development of Fuxin’s produc- sponse to unstable market situations, tion programme was developed with or to make production readjustments an awareness that today’s steel produc- to suit customers’ changing demands. ers face greater demands on producThe plant’s process routes apply intion flexibility than in the past. This novative technology concepts on the can entail quick changes to the scope basis of scrap and take into account of the main steel grades – e.g. austenit- the specific local conditions of the ic, ferritic, martensitic or duplex stain- steel plant. The routes work in two less steels – or changes in the supply typical configurations: duplex and to suit different customer orders. Ex- triplex technology. Each is achieved ternal factors include higher restric- through numerous technological comtions on the chemistry and mechan- binations of the installed equipment – ical properties of stainless steels, or specifically: the EAF, LF1 and LF2, price fluctuations in the internation- AOD and VOD. al and domestic markets.

The converter charge in Fuxin’s duFuxin reached full production ca- plex and triplex process lines contains pacity 11 months after the first pro- approximately 85-90% metal. The re-

maining amount comes from alloy additions, mainly solid ferrochrome and ferronickel.

The AOD process in the duplex technology allows the cost-effective production of steel grades with final standard carbon contents of more than, or equal to, 0.03%.

Steel grades with lower carbon requirement are produced by the triplex technology. In these cases, the AOD process is finished at a carbon content in the range of 0.25-0.1%. This corresponds to the thermodynamic equilibrium through a high chromium content (1018%), a temperature of approximately 1,700°C and atmospheric pressure. Final refining of the AOD metal takes place in the stainless steel vacuum oxygen decarburization (SS-VOD) plant.

The triplex process is characterized by high efficiency and economy. This is due to several factors, including: the use of inert gas (nitrogen/argon); the longer refractory lifecycle due to shorter treatment times; reduced energy consumption and also short treatment times because of reduced decarburization in the AOD. The greater economy is also due to the low price of the raw materials (high-carbon alloys) from which Fuxin’s steels are produced.

From the scrap yard to the electric arc furnace (EAF) The Fuxin plant is equipped with an alternating current (AC) EAF which supplies both the duplex and triMPT International 5 / 2018

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››› STEELMAKING – METALLURGY tion grade. Particular care is taken in respect of the dust and noise accompanying the process operations. The capacity of the filter is more than 1,500,000 m3 (stp)/h. Dust is collected directly on the furnace, in the canopy hood, and at all various chutes of the alloying system.

Each collecting line is independent so as to avoid any adverse effects on gas collection.

QR-code: links to www.sms-group.com

A decisive factor in the TGƂPKPI RTQEGUU

The Fuxin plant is equipped with an alternating current (AC) EAF which supplies both the duplex and triplex technologies (Picture: SMS group)

plex technologies. The final moltenmetal weight requires the charging of two to three buckets. Different tapping weights are accomplished by applying the different technologies – e.g. a tapped weight of 140 t corresponds to the triplex and 160 t to the duplex technology.

Scrap is supplied to the mill from the yard by a transfer car. The scrap yard is located adjacently to the melt shop, where scrap buckets are prepared by cranes which communicate wirelessly with the weighing system and process computer.

From the scrap yard, large amounts of alloys and fluxes are introduced directly into the furnace via an automatic charging system. Fourteen bins supply this process in total, with alloys and fluxes for the required steel grades and trimming purposes. At this stage, the highly sophisticated L2 EAF process model, in combination with L1, supports the metallurgical and economical optimization of the scrap and alloys. This process takes into consideration the current producMPT International 5 / 2018

Steel refining in the AOD converter is an important link in the chain of interrelated production steps which comprise the manufacturing and further processing of steel.

The installed AOD-L converter at Fuxin is a complex system. It includes an oxygen top lance, submerged blowing tuyeres, material bins and hoppers, as well as an exchange vessel system. A total of 22 bins, eight weighing and two charging hoppers supply the process with alloys and fluxes for the required steel grades and trimming.

Thanks to the modern vessel exchange technique, it is possible to replace a spent converter in approximately 50 minutes. The change-vessel design works by lifting the vessel out of the trunnion ring and replacing it by another freshly lined vessel in an off-converter rebricking area.

In addition, mechanical improvements in the tilting system reduce converter vibrations by up to 70%.

A decisive factor in the refining process is the oxygen blowing lance.

The lance is exposed to extreme stressing in the reaction space as oxygen exits at the lance tip nozzles at high velocity. This causes splashes and changes the vessel as well as the nozzle tip geometry. A consequence of these stresses is that lance changing becomes a necessity, a process which can take around four hours.

The top lance usually works up to an oxygen-inert gas ratio of 1:1.

After the top-lance has been swung out, refining is continued by submerged tuyeres. The AOD-L converter is equipped with nine tuyeres which are protected all the time by shroud gas. A waste gas analyzer system significantly supports this for optimal process control.

Extremely clean steel with optimal properties The SS-VOD features a powerful vacuum system and strong bottom stirring through three porous plugs. This ensures excellent refining, as well as mixing of the metal. Depending on the chemical composition and temperature of the metal bath, the final carbon and nitrogen contents – especially of ferritic steel grades – can be reduced to 25 ppm carbon and to less than 30 ppm nitrogen.

Thanks to the extremely high vacuum pump power – which allows producing a vacuum below 0.5 mbar, and intensive metal stirring at a power of more than 1.300 W/t steel at approximately 10 dm3(STP)/t – Fuxin can produce extremely clean steel with optimal properties suitable for direct casting, within a reasonably short vacuum time.

The SS-VOD plant works as the third link in the triplex technology. With duplex technology the plant’s function is reduced to supplying the right temperature and chemistry adjustments of the metal refined in the AOD-L converter.

Fully automated process planning systems SMS group worked closely with Fuxin to design and apply an integrated automation system across all of the components in its production line. The system is organized into the three basic process control system Levels 1, 2 and 3 which are fully integrated into the production planning system.

For the EAF, the automated process model is semi-static so that charge material, electrical energy and current processes are calculated and updated depending on events that occur during operation. Its measurements include: temperature; sample-taking with corresponding chemical analysis; electrical

STEELMAKING – METALLURGY energy input; consumptions of oxygen; and iron (Fe) and silicon (Si) injections to the furnace via a lance manipulator.

For the AOD control station, a highly sophisticated supervisory control and data acquisition tool was chosen. The system incorporates unique dynamic and metallurgical models that control the process during the complete treatment, combined with a supervisory system that focuses on a single application. The system is uniquely designed to be very easy to handle by operators and metallurgists. With ‘Auto Mode’, users can manually introduce controlled data sets. ‘Computer’ or ‘Dynamic Mode’ fully automate the process through data relating to technological predictions, material handling, process gas control, temperature and sample readings and, finally, the end of the treatment.

The system relies on process data archiving with current data log-files, and systems that facilitate quick communications between Levels 1, 2 and 3 as well as a laboratory. Troubleshooting and communication delay times can be solved within an extremely short time through an intelligent human machine interface (HMI) system. A key advantage is that disturbances in production and equipment operation can be avoided on time.

Meanwhile, an off-line process simulation runs parallel to the on-line system.

This simulation combines all the current system data and makes it possible to directly analyze a just-finished heat or its simulation, as well as any requested grade coming into the treatment. The user visualizes this process divided into several screens which show the current metallurgical and mechanical signals, as well as selected information from a database and production archive.

For Fuxin, the automation system brings many important benefits: ▪ the reliable achievement of low final carbon levels, ▪ optimal utilization of process gases, ▪ minimized chromium losses, minimizing of silicon and slag former consumption, ▪ accurate charge calculation as well as reduced charge to tap time.

Using predictive data to plan treatments in advance By using predictive data, the Fuxin plant’s integrated automation system can calculate the treatment strat-

egy in advance. The data covers the overall process: beginning with temperature and analysis of the steel before the treatment starts, and ending with completion of the process. Calculations based on these predictions control the sequence of the treatment steps, verify the target course of the analysis and temperature, and also determine the treatment time.

Because all of Fuxin’s units are equipped with waste gas analyzers and waste gas flow meters, the process models can be used at all treatment stages to reproduce on-line metallurgical and thermo-dynamical conditions and calculate new set-points.

‹‹‹

35

standing of Industry 4.0. To this end, the operator’s plans include synchronizing the data relating to all of its equipment components: maintenance; metallurgical; digital and graphical visualizations and statistical analysis. This synchronization will be designed to make the plant management easier and faster.

Fuxin’s current project concerns include the complex system of the EAF, LF2, AOD-L and VOD. Here, the operator is considering a further system extension that would involve the LF1 and CCM. It is certain that data will play a crucial role in developments at Fuxin Special Steel Company. At present, the company regards its horizontal data

Table illustrating an overview of Fuxin’s triplex technology. The process is EJCTCEVGTK\GF D[ JKIJ GHƂEKGPE[ CPF GEQPQO[

Data will play a crucial role in future developments To meet the greater demands today’s steel producers face with regards to production flexibility, Fuxin and SMS group plan further developments of the technologies at Zhagzhou. They will include improvements to the plant’s data flow to build more on its advanced process management systems. Fuxin’s next stage for investment is a strong combined equipment system designed to correspond with the latest requirements of modern plant managing and product quality.

For Fuxin, its future interests are not only in technical equipment but also – and especially – the adaptation of its process controls to suit the available digital solutions. In other words, a true under-

stream as being the leading channel for optimal decision making concerning its duplex or triplex technology.

This also applies to the plant’s pre-metal preparation on the prime side of the process line – e.g. in the EAF and LF2. The kernel of this data system is integral to Fuxin’s refinery, the AOD converter and the VOD plant. Its capabilities – which include helping to define the identity process model structure and similar metallurgical relations – are crucial for both easing and clarifying the parameters, practices and maintenance of the plant’s production processes.

Fuxin will continue to explore new ways to produce quality steels flexibly and economically through the use of advanced process control systems.

MPT International 5 / 2018

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››› COMPANY PROFILE

voestalpine celebrates 350 years of steelmaking expertise in Sweden Over three-and-a-half centuries, Hagfors, Sweden, has become synonymous with innovations in steelmaking thanks to the advancement of Uddeholms AB (today BöhlerUddeholm AG and part of voestalpine) into a global player in tool steel. Meanwhile, in Linz, Austria, voestalpine also celebrates 20 years of automotive blanks production.

Founded in 1668 as a family-run iron mill in Hagfors, southern Sweden, today Uddeholms AB is a global market leader in the production of special steels for toolmaking. In 1991, Uddeholms AB and Austrian-based special steel manufacturer Böhler combined to form Böhler-Uddeholm AG which was subsequently listed on the Vienna Stock Exchange. The group was taken over by voestalpine in 2007 and is now part of the Group’s High Performance Metals Division.

“With its know-how in developing and manufacturing high-tech steels, and its global customer network, Uddeholms AB has played a significant role in making our Group more specialized and international over the past decade,” said Wolfgang Eder, Chairman of the Management Board of voestalpine AG. With sales sites and partners in over 90 countries, the company supplies the global automotive, mechanical engineering, and consumer goods industries with sophisticated steel grades from Hagfors. Uddeholms AB has a workforce of 900 employees at its headquarters and generated revenue of EUR 305 million in the past business year.

Over the past ten years, more than EUR 130 million has been invested at the site.

Leadership in high-tech steels

Johnny Sjöström, Managing Director Uddelhoms AB; Mikael Damberg, Minister for Enterprise and Innovation; Franz Rotter, Member of the Management Board of voestalpine AG and Head of the High Performance Metals Division (Picture: voestalpine)

ing capacity and precision are in demand. For example, in punching and forming tools used in the manufacture of automotive body parts, and in special forms for the production of smartphones and computer displays. The average export rate is 94% with more than half of the products headed for markets outside Europe. The company operates its own research laboratory with around 50 employees working to strengthen its standing as an innovation leader. As a result, Uddeholms AB owns more than 300 patents.

High-tech steels from Uddeholms AB are used wherever extreme load-bear-

voestalpine AG, Linz, Austria Contact: www.voestalpine.com E-mail: peter.felsbach@voestalpine.com

MPT International 5 / 2018

Investment focus on additive manufacturing and environmental technology Over the past ten years, voestalpine has invested more than EUR 130 million in continually upgrading technol-

ogy at the Hagfors site, with a record sum of EUR 24 million invested in the business year 2017/18 alone.

As part of its Group-wide activities in additive manufacturing, the current focus at Uddeholms AB lies in expanding metal powder capacities. In addition to the existing pilot plant, a large unit for the production of extremely fine powder – the pre-material for additive manufacturing (3D printing) – will go into operation this autumn. Other investment projects include six new, fully digital heat treatment facilities and enhancements to remelting furnaces in order to produce even higher steel grades in the future.

There is also consistent investment in environmental protection. Thanks to a new, large-scale de-dusting facility, Uddeholms AB has succeeded in re-

COMPANY PROFILE

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37

ducing dust emissions to almost zero since 2016. Meanwhile, a conversion from oil to liquefied natural gas as an energy source has also resulted in huge CO2 emissions reductions.

The aim is to convert to biogas over the next few years with a view to operating entirely without the use of fossil fuels by 2020.

20 years of lightweight design for the automotive industry at Linz This year sees yet another milestone anniversary for a voestalpine company: Automotive Components Linz GmbH which celebrates 20 years of lightweight design know-how for automotive blanks. Also part of voestalpine’s Metal Forming Division, voestalpine Automotive Components Linz has 300 employees and generates revenue of EUR 170 million.

EUR 16 million has recently been invested in a further expansion stage. In a 32,000 m2 production area, it will be possible to produce up to 30 million blanks a year on 14 welding and three punching lines.

The order from a German premium automobile manufacturer for the production of laser-welded inner door panels marked the start of blank production in Linz 20 years ago. Since then, almost 190 million blanks have left the plants of Automotive Components Linz – formerly voestalpine Europlatinen GmbH – and made their way to international automobile manufacturers.

The most important milestones were the installation of a high-speed laser-welding system in 2015 and the construction of a second plant in 2016. With the production of the first hot-forming blanks (press hardening steel technology) in 2006, the company has set new standards in terms of weight reduction, corrosion protection and crash performance for high-strength body parts. While initially large automotive parts such as side panels, doors, and flaps were in demand, today most of the highstrength blanks are further processed into smaller, weight-saving components such as side members and cross members, A/B/C pillars, inner door panel components, and floor components.

Located in Hagfors, Sweden, Uddeholms AB produces special steels for toolmaking (Picture: voestalpine)

Uddeholms AB is expanding its metal powder capacities for additive manufacturing (Picture: voestalpine)

Setting international standards in digitalized production On April 24, a groundbreaking ceremony marked the official start of the three-year construction phase for a new voestalpine special steel plant in Kapfenberg, Austria. The state-ofthe-art plant will set international standards in digitalized production processes. Around 8,000 process data will be recorded in parallel, and implemented or evaluated on an ongoing basis.

Preparations for the major project with an investment volume of up to EUR 350 million are already fully underway. From 2021 onwards, the fully digitalized plant will produce sophisticated high-performance steels.

The plant will be designed to produce premium quality pre-materials for aircraft components, tools for the automotive industry, equipment for oil & gas extraction, and for the 3D printing of highly complex metal parts.

Once operative, the new production facilities are intended to replace the MPT International 5 / 2018

38

››› COMPANY PROFILE

Additive manufacturing (Picture: voestalpine)

Wolfgang Eder, Chairman of the Management Board of voestalpine AG (Picture: voestalpine)

existing voestalpine Böhler Edelstahl GmbH & Co KG plant in Kapfenberg.

The investment is also setting new standards in environmental protection. The centerpiece of the plant – an 60-t electric arc furnace (EAF) which melts down ultra-pure scrap combined with various alloy metals into special steels – will be operated with electricity generated from renewable only. In addition, an efficient heat recovery system ensures that the heat generated during the process is used within the plant, as

MPT International 5 / 2018

well as being fed into the public district heating network. In terms of cooling the production facilities, using closed circuits allows the volume of cooling water to be reduced by up to 90%.

After start of production in 2021, the fully digitalized plant will annually produce around 205,000 tons of sophisticated high-performance steels, especially for the international aviation and automotive industries as well as for the oil & gas sector, while at the same time securing more than 3,000

highly skilled jobs in the region over the long term.

The high tech Kapfenberg plant will further demonstrate voestalpina’s track record in additive manufacturing, digititization and environmental protection.

References [1] Advanced steel plant being built in Austria. MPT International, 2/2018, 32-33

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››› IRONMAKING – STEELMAKING

Almamet newly provides advanced desulfurization technology Almamet has acquired the technological knowledge and workforce of thyssenkrupp Industrial Solutions. This includes about 50 desulfurization stations for torpedo and open ladles. The new entity, Almamet Industrial Solutions, specializes in the design, construction and optimization of desulfurization facilities.

Hard price competition in the steel markets generally leads to the favoring of technologies that are efficient and economical in operation. For manufacturers in times of overcapacity, the ability to offer a sophisticated portfolio of high-quality steel grades can contribute towards stable profits.

With desulfurization, the chemical process for the removal of sulfur from a material, it is known that the simultaneous injection – or co-injection – of pulverized burned lime (CaO) and granulated magnesium (Mg) provides high process flexibility. Through this method, manufacturers can better adapt to changing production requirements and achieve best performance, while also maintaining low operational expenses.

For the German company Almamet, which over the last decades has developed into a dominant actor in the desulfurization business, such factors may provide an opportunity for a new chapter in its story.

As of June, it has entered the field of plant engineering and equipment supply by obtaining the knowhow, experience and workforce of thyssenkrupp Industrial Solutions, formerly known as thyssenkrupp Polysius. The resulting entity, Almamet Industrial Solutions, based in the Westphalia region of northwestern Germany, is equipped to become a global market leader in iron and steel desulfurization.

The company’s acquisition includes around 50 desulfurization

Almamet, Ainring, Germany Contact: steinacker@almamet.com

MPT International 5 / 2018

Principle of the co-injection process, as performed in open ladles

stations for torpedo and open ladles throughout the world, each with a capacity from less than 50 t to more than 350 t of hot metal. These facilities have been equipped with injection technology by thyssenkrupp over the last 50 years. The competence to use these desulfurization technologies are now owned by Almamet while also drawing on the long-term experience of its team of experts.

As a result, the company plans to maintain the same levels of sophistication and proven designs that were offered under thyssenkrupp, at even more competitive prices. For its customers, Almamet says the high equipment quality it can provide will promise safe and reliable operations for decades at lowest maintenance costs.

Open ladles versus torpedo ladles Desulfurization is performed mostly in the ladle and most of the material is drawn off in the blast furnace.

Extremely low contents of sulfur can only be obtained by desulfurizing hot liquid steel. Here, the basic method is

to add elements – or reagents – which readily combine with the sulfur. Calcium carbide was formerly the reagent of choice, yet the trend has since moved towards a safer and more environmentally friendly combination of Mg and CaO. Desulfurization is achieved with the help of injected (or otherwise introduced) calcium or calcium alloys or synthetic slags. Both processes require intensive bath agitation.

As mentioned, Almamet’s 50 desulfurization stations are for torpedo and open ladles. While desulfurization in torpedo ladles was once held as being state-of-the-art, the installation of open ladle treatment stations has become the number one technology since the 1990s.

The advantages of desulfurization in open ladles versus torpedo ladles include: ▪ A more suitable ladle geometry, which leads to the uniform distribution of the reagents, ▪ A high reagent efficiency combined with a low reagent consumption, ▪ The high conformity of final sulfur in the melt, ▪ A clear 1:1 allocation of the desulfurized ladle to the blast oxygen furnace (BOF) with no hot metal blending,

IRONMAKING – STEELMAKING

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Side-by-side comparison of a dynamic co-injection desulfurization process, versus standard co-injection

▪ Efficient slag removal in integrated desulfurization stations for a higher yield, ▪ Easier ladle cleaning and refractory maintenance, ▪ The full utilization of the torpedo capacity with no freeboard provisions for reagent injection, ▪ Fewer torpedoes required for continuous operation.

At the heart of Almamet Industrial Solutions’ desulfurization system are the pneumatic injection conveyors. These are powered by a programmable logic control (PLC) based injection control system, MEPOL, as well as the accurate batchwise calculation of process parameters. The sulfur content of hot metal is practically unlimited and therefore tol-

erates higher input values of raw materials and pulverized coal in the blast furnace. This leads to reduced hot metal production costs and puts the system at the center of Almamet’s objectives for process efficiency and economy.

Flexibility for better control and economics One of the most important aspects of hot metal desulfurization lies in the combination of the used reagents. This makes the flexibility of the co-injection process another important factor.

While mono-injection systems allow only limited flexibility of the desulfurization mixture, well estab-

lished co-injection systems can support an enhanced product portfolio.

The selective and sequenced injection of CaO and Mg leads to excellent process control and results in a positive effect on the economics of the process. The main advantages of the co-injection process for desulfurization in open ladles are: ▪ Theoretically unlimited starting levels of sulfur which makes the use of low cost raw materials in the blast furnace possible, ▪ Very low final levels of sulfur achievable in a reproducible manner, ▪ Various reagents and mixtures can be applied, ▪ No pre-deslagging of blast furnace slag which reduces iron losses,

3D representation of the plant concept for JSPL’s desulfurization plant in Angul, India; including two stations, 260 t ladles and shuttle cars MPT International 5 / 2018

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş IRONMAKING â&#x20AC;&#x201C; STEELMAKING â&#x2013;Ş A very low hot metal temperature loss during the treatment, â&#x2013;Ş Short processing times which lead to a high throughput, â&#x2013;Ş Low reagent consumption for a smaller amount of desulfurization slag and a higher yield, â&#x2013;Ş The opportunity to treat ladles with only a small freeboard, â&#x2013;Ş Comparably low space requirements and flexible layouts.

The dynamic co-injection process makes it possible to inject pure, fluidized CaO both in the beginning and at the end of the whole injection process. It also enables flexibility to vary the injection rates for varying periods of time, again depending on the process conditions.

Pre-injection of CaO increases the basicity and reactivity of the slag. It also provides a proper turbulence in the melt for the uniform distribution of Mg and CaO in the co-injection phase. This limits the injection of the Mg â&#x20AC;&#x201C; which is highly reactive and valuable â&#x20AC;&#x201C; to the period when it unfolds to its highest effect. The result is the optimized use of Mg.

Customized and fully controllable desulfurization process Almametâ&#x20AC;&#x2122;s dynamic co-injection capabilities are designed to provide the highest possible flexibility for a perfectly customized and fully controllable desulfurization process.

The customization procedure considers all the relevant process and design conditions at the site. They include: â&#x2013;Ş The hot metal composition and temperature, â&#x2013;Ş The blast furnace slag basicity and characteristics, â&#x2013;Ş The ladle size, shape and freeboard, â&#x2013;Ş The required plant throughput and available treatment cycle time, â&#x2013;Ş The workshop space conditions and restrictions.

Based on this large matrix of influencing factors, Almamet can define the ideal reagent composition, the most suitable plant layout and the most efficient injection process.

These factors can be determined in MPT International 5 / 2018

close cooperation with the builder and operator.

Going forward, the companyâ&#x20AC;&#x2122;s model is to supply technology, reagents and services from a single source. This includes flexible business models, domestic key accounts in various countries, and services and spare parts for running installations.

New desulfurization plant in India Shortly after the inception of Almamet Industrial Solutions, its first project was agreed upon with Jindal Steel & Power Limited (JSPL), one of the top steel companies in India with a dominant presence in steel, power generation and mining.

JSPL has awarded Almamet with the erection of a new desulfurization plant at Angul in the state of Odisha, India, which works with two fully equipped treatment stations. The service contract is for the operation and maintenance of the newly-built plant. Almamet will install and operate a facility for the preparation of first-class fluidized CaO, using screened CaO fines. This fully integrated desulfurization concept will enable JSPL to count on reliable sulfur levels in all its steel grades, reinforced with Almametâ&#x20AC;&#x2122;s know-how.

/QTG GHĆ&#x201A; EKGPV GEQPQOKECN technologies The combined factors of a customized plant layout, a flexible and reproducible injection process, as well as adapted reagents, have been shown to make a noticeable difference in plant performance and economics. Co-injection can play a key role in making metallurgical injection plants more economical and future-proof.

In addition, this has opened new business opportunities and applications for Almamet with its co-injected desulfurization technology.

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş IRONMAKING â&#x20AC;&#x201C; STEELMAKING

Major reconstruction prepares Bosnia and Herzegovinaâ&#x20AC;&#x2122;s only steel plant ArcelorMittal Zenica and Danieli Corus have completed a EUR 30 million project to rebuild blast furnace No. 4 in the industrial city of Zenica, Bosnia and Herzegovina. As part of ArcelorMittalâ&#x20AC;&#x2122;s long-term sustainability plan, integrated steel production can now continue in Zenica for up to 20 years. included the energy and sinterplant..

The refurbishment means that integrated steel production can continue in Zenica for up to 20 years into the future.

The projectâ&#x20AC;&#x2122;s completion was marked with a ceremony in the heart of the steel works. Addressing more than 200 distinguished guests, Prime Minister of the Federation of Bosnia and Herzegovina, Mr. Fadil Novalic, said: â&#x20AC;&#x153;This is a step that will guarantee competitiveness in a very turbulent steel market.

Directly or indirectly, 12,000 people depend on this company which is beyond doubt the biggest in Bosnia and Herzegovina.â&#x20AC;?

He added, â&#x20AC;&#x153;It confirms our firm commitment to the future that begins here and today. I would like to thank the management of ArcelorMittal who started this project in these rough times.â&#x20AC;?

Blast furnace No.4â&#x20AC;&#x2122;s completion was marked with a ceremony in the heart of the steel works located in the industrial city of Zenica, Bosnia and Herzegovina (Picture: ArcelorMittal)

ArcelorMittal Zenica has announced the completion of a EUR 30 million project to rebuild the blast furnace of its plant located at the industrial city of Zenica, in the centre of Bosnia and Herzegovina and about 70 km north of Sarajevo.

Production of hot metal at the 2,000 mÂł blast furnace, operated by ArcelorMittal, was successfully restart-

#TEGNQT/KVVCN <GPKEC <GPKEC $QUPKC CPF *GT\GIQXKPC %QPVCEV CNGPC MCJTKOCPQXKE"CTEGNQTOKVVCN EQO &CPKGNK %QTWU +,OWKFGP 6JG 0GVJGTNCPFU %QPVCEV KPHQ"FCPKGNK EQTWU EQO MPT International 5 / 2018

ed after a comprehensive reline which has been described as one of the companyâ&#x20AC;&#x2122;s largest projects. The contract for the rebuild was signed by ArcelorMittal Zenica and Danieli Corus in early 2017 as part of a modernization programme for the plant that included upgrades for downstream as well as upstream facilities.

The production site at Zenica consists of an integrated plant with a liquid phase (coke oven, sintering plant, blast furnace) and a steel plant. The plant is unique with facilities, including both an integrated route and electric arc furnace (EAF). The ore is supplied by the nearby Prijedor Mine.

Danieli Corusâ&#x20AC;&#x2122;s rebuild was part of a larger investment program which

Modern requirements for JKIJ GHĆ&#x201A;EKGPE[ The Dutch company Danieli Corus was the lead contractor responsible for project delivery and everything related to the furnace, supported by many local contractors. The furnace was rebuilt according to its existing design from the tuyere belt upwards.

Danieli Corus approached the project as an in-kind reline. This meant retaining the furnaceâ&#x20AC;&#x2122;s original stave cooled design while completely changing the associated cooling water system to meet the modern requirements for high efficiency. The Zenica plantâ&#x20AC;&#x2122;s associated cooling water system is now split into sections, so that heat losses can be better monitored as part of the process optimization. Above burden probes â&#x20AC;&#x201C; used to measure temperature, pressure, burden charging curves

IRONMAKING – STEELMAKING

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The project’s scope included repairs to parts of the hot blast system and cast house (pictured), as well as upgrades to the furnace’s process instrumentation (Picture: ArcelorMittal)

and for gas sampling – were installed to improve the furnace’s control system.

The project’s scope included repairs to parts of the hot blast system and cast house, as well as upgrades to the furnace’s process instrumentation.

'ZEGRVKQPCN NGXGNU QH VGCO URKTKV The hearth was revamped based on a new design by Danieli Corus. Upon opening the furnace, it was found that a lot more of the hearth shell would require replacing than was originally anticipated. To ensure this was achieved within the project’s agreed timescale, Danieli Corus introduced a foldable working platform that it called ‘the third safety deck’. Three swinging decks were installed in the furnace, including one in the throat armour.

They were designed to provide safe conditions inside the furnace and ensure workers could continue with replacement of the shell plates and the refractory installation.

Nico Bleijendaal, CEO of Danieli Corus estimates that the Zenica rebuild completed approximately 30% more scope than equivalent projects

Workers in blast furnace No. 4 commence the refractory installation. Danieli Corus’s CEO, Nico Bleijendaal, praised the project’s exceptional teamwork (Picture: ArcelorMittal)

within the same timescale. He attributes this, in part, to exceptional levels of team spirit among the project’s many contractors.

He said, “We specialize in this type of work. Considering the fact that it is a complicated, 24-hour, technically demanding job with many technical and safety challenges, it is not always possi-

ble to maintain a team spirit to the end.

But, in this case, it happened – and it was actually the first time I have encountered it to such an extent,” said Mr. Bleijendaal.

“Two months before the reline started, ArcelorMittal, on the initiation of its CEO, Mr. Biju Nair, organized a team building session with all the contracMPT International 5 / 2018

46

››› IRONMAKING – STEELMAKING The rebuild retained the furnace’s original stave cooled design, while completely EJCPIKPI VJG CUUQEKCVGF EQQNKPI YCVGT U[UVGO VQ OGGV OQFGTP GHƂEKGPE[ TGSWKTGOGPVU (Picture: Danieli)

tors involved. This included exercises to reinforce team spirit and establish how we should approach the rebuild.”

He added, “Danieli are doing many projects around the world and, where possible, we now try to emulate this level of cooperation at the beginning.”

+ORTQXGOGPVU KP GEQNQIKECN RGTHQTOCPEG The rebuilt blast furnace No. 4 will produce an annual output of 1.1 million t of hot metal, with substantial headroom capacity accommodated for in the design. The total shutdown period for the furnace was 70 days, the minimum duration for a project of this scale.

Mr. Bleijendaal told MPT International: “It is only a one blast furnace

plant, so if the outage is prolonged then the effect on the bottom line of ArcelorMittal Zenica would be enormous. The project was concluded on time, on quality and with zero lost time due to injuries or incidents – quite an achievement for such a hectic blast furnace reline.”

The production facilities at Zenica are designed to accept the low grade iron ore from the local mine in Prijedor.

Mr. Bleijendaal said, “It is a very specific situation in Bosnia and Herzegovina.

“First of all, it uses its own ores and own mines to maintain a relatively low cost input. This has a tremendous price benefit although they are not, what we would call, high grade ores. They have a relatively high slag rate which lowers productivity.

“However, not having a highly productive furnace because of restrictions in raw materials is not a problem for this specific plant.

Because the blast furnace is not the bottleneck for steel production at the Zenica site, the furnace only has to produce so much hot metal.

Biju Nair, CEO of ArcelorMittal Zenica (pictured left), and Nico Bleijendaal, CEO of Danieli Corus, attend the opening ceremony (Picture: ArcelorMittal) MPT International 5 / 2018

“Therefore, it makes perfect sense economically for ArcelorMittal Zenica’s requirements. They do not have to change the raw materials and, technically, do not have to rebuild the furnace to higher specifications.”

)TQYVJ QH UVGGN EQPUWORVKQP KP VJG $CNMCPU The CEO of ArcelorMittal Zenica, Biju Nair, underlined the importance of the project to the city’s future: “ArcelorMittal Zenica is developing a long-term sustainability plan in which the recent investment in relining of our blast furnace by Danieli Corus is an important step.”

ArcelorMittal Zenica predicts a growth of steel consumption in its core market which comprises the countries of ex-Yugoslavia. The company is in discussions to increase capacity of its rebar rolling mill to 470,000 t in two years.

“This will help us to maximize the production from our rebar in coil (spooled) line, commissioned in 2016,” he said.

ArcelorMittal Zenica’s next project, currently in discusssion, is the upgrade of its wire rod mill to improve the product mix with various new grades by 2020.

The company’s on-going sustainability plans include a new joint venture with the City of Zenica, KPA Unicon Finland and FinnFund. Called Toplana Zenica, the power and heating company is now in its final stages and will provide reliable and environmentally friendly heating to the city without using coal, for greatly reduced emissions. The new UR 50 million power plant is expected to be commissioned by the first half of 2020. Another major project in progress is a mesh welding line that will increase ArcelorMittal Zenica’s downstream capacity.

Mr. Nair added, “We will continue to invest in the infrastructure of the factory, bringing further improvements in our ecological performance and our production capability. At the same time, we will continue to support, develop and encourage the young managers, engineers and production staff who will write the next chapter in the story of steel in Zenica.”

HEAT TREATMENT

â&#x20AC;šâ&#x20AC;šâ&#x20AC;š

47

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New standards for plate cooling in heavy-plate heat treatment lines SMS group has established a new technology for plate cooling in heat treatment lines, the MultiFlex-QuenchÂŽ. Standard, special and newly-developed materials with KLJK TXDOLW\ GHPDQGV FDQ EH SURGXFHG WKDQNV WR LWV Ć&#x192;H[LEOH FRROLQJ VWUDWHJLHV 7KH technology is already being used in two cutting-edge heavy-plate heat treatment lines.

From an economical point of view, the production of heavy plate is particularly efficient if it can also serve the growing market for new special steels and quarto plates. High-strength and ultra-highstrength plates are used in the growth sectors of wind energy, power technol-

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ogy, tubes and pipes, mechanical engineering and crane building, as well as the construction industry.

At the same time, these applications â&#x20AC;&#x201C; demanding increasing rigidity, excellent ductility and good weldability combined with perfect flatness â&#x20AC;&#x201C; drive the advancement of steel. The production of state-ofthe-art heavy plates requires the flexible setting of all process parameters, from austenitization and targeted cooling at optimized cooling speeds to adapted tempering temperatures and times.

The potentials provided by steel can only be tapped effectively through op-

timum coordination of all the process steps.

Development of a new cooling technology for heat treatment lines High-quality heavy plates are produced in heavy-plate rolling mills or in special heavy-plate heat treatment lines. In heavyplate rolling mills, the material properties are set in a thermo-mechanical rolling process. In heat treatment lines, the rolled plates are reheated, precisely cooled and then tempered.

MPT International 5 / 2018

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

/QFGTP JGCX[ RNCVGU FGOCPF C NCTIG RTQEGUU YKPFQY KPENWFKPI XCTKQWU EQQNKPI RCVVGTPU HTQO UNQY EQQNKPI VQ FKTGEV SWGPEJKPI

2TKPEKRCN RTGUGPVCVKQP QH RNCVG VTGCVOGPV KP C JGCX[ RNCVG JGCV VTGCVOGPV NKPG YKVJ /WNVK(NGZ 3WGPEJ VGEJPQNQI[

The key process to set material properties in both processes is cooling. Laminar cooling systems with U-shaped pipes have been widely used in heavyplate mills since the 1950s. When material advancements required ever higher cooling rates and more flexible cooling patterns, it prompted the development of spray cooling systems with pinch rollers. At the beginning of the new millennium, this technology, usually a combination of spray and laminar cooling, became state-of-the-art.

Advanced materials, however, demand that the microstructure is set precisely. This can only be achieved in a heat treatment line. Since the 1960s, roller-type quenches with separate high and low-pressure sections have been installed in heat treatment lines for plate cooling. But this measure only covered a limited process window, mainly comprising the abrupt quenching method.

SMS group has picked up the vast experience gained from spray cooling MPT International 5 / 2018

systems in the heavy-plate sector and, on this basis, developed a new flexible cooling system for heat treatment lines. This advancement of a proven technology led to the introduction of the MultiFlex-Quench in 2015.

The new cooling technology enables numerous cooling rates and patterns to be applied in heavy-plate heat treatment lines, and ensures a high degree of flatness.

Flexible cooling for multiple options and expansion stages The high degree of flexibility, wide product portfolio, and the very good flatness results of the MultiFlex-Quench are mainly due to a variety of options for plate cooling and the hydraulic clamping of plates between pinch rollers. Depending on the required plate widths, the cooling headers are subdivided into several zones over the entire width.

The MultiFlex-Quench concept is designed for multiple options and expansion stages, depending on the customerâ&#x20AC;&#x2122;s needs and production programme. The cooling header pairs are arranged in three to four segments.

Since individual areas in the segments can be controlled flexibly, a higher adjustment range of 1/60 is possible to ensure a wide range of cooling rates can be employed.

In the basic expansion stage, cooling header groups arranged in segments are fed with water from a low-pressure system. This system is preferred for high-alloy steels where carbide precipitation after solution annealing treatment is to be suppressed, and also for crack-sensitive tool steels. Up to eight cooling header pairs with nozzles are arranged in each segment. Pressures of up to 2 bar are applied in the low-pressure range. Depending on the plant configuration, up to 7,300 m3/h of water can be generated in every segment, for example.

In some segments, it is possible to operate the cooling headers as required and in a customer-requested arrangement at higher water volumes and hence higher pressures via an independent water circuit. This mode can be applied for wear-resistant steels with good ductility and for high-strength and ultra-high-strength structural steels. Depending on the material qualities, pressure levels of 5.5 and, in some cases, even up to 8 bar can be achieved. In the high-pressure segment, up to 5,800 m3/h of water can then be supplied. The segment can, nonetheless, be switched back to lower pressure operation at any time.

If surface hardness and/or hardness depth are to satisfy extreme demands, it is also possible to install a so-called slotted nozzle (curtain head) in the inlet section of the quench to provide the highest possible cooling rates. These high cooling rates are used for special heat-treated steels with high wear resistance accompanied by high ductility at low temperatures. This slotted nozzle is coupled to the water circuit of the high-pressure section. Using the slotted nozzle, it is possible to generate up to 2,200 m3/h of water along a very short section so that very high and yet uniform cooling is achieved.

For the treatment of crack-sensitive tool steels, the MultiFlex-Quench

HEAT TREATMENT may be equipped with a separate nozzle cooling system for minimum and sensitive cooling. Combined with the integrated cooling model, the system is able to exactly implement cooling rates and patterns. This helps to substantially shorten the average period needed so far for cooling such materials in calm air or by compressed air. It ensures that cooling rates of 1.3 K/s can be achieved and set very precisely. Automated systems determine the required volumes of cooling water, designated as the Level 2 cooling model.

All cooling headers are able to act upon a large cooling area and come with fine nozzle distribution and an optimized cooling header design.

Compared to conventional roller-type quenches, the MultiFlex-Quench offers a distinctly more flexible, uniform, and efficient cooling technology for heavy-plate heat treatment lines.

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Mechanical equipment Optimum flatness â&#x20AC;&#x201C; especially of thinner plates â&#x20AC;&#x201C; is ensured through the active hydraulic clamping using the roller guide.

The plates are guided and clamped in the segments between numerous working roller pairs. The rollers are driven in pairs or individually. The individual segments are applied with up to 100 t of pressure by four cylinders. The hydraulic clamping control unit consists of a combined position and force control system. The position and the current clamping force are displayed permanently in the human machine interface (HMI).

When exceeding a preset maximum clamping force, a safety function is activated that opens the clamping rollers automatically to prevent damage to the mechanical equipment. Exceedance of this kind may, for instance, be triggered by excessive stresses in the plate which are visible during the cooling process. The time of deformation in the quench can therefore be determined via the cylinder force. This information can then be transferred to the Level 2 system.

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Switchable segments for high and adaptive cooling rates The MultiFlex-Quench has a pair of curtain heads in the inlet section.

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››› HEAT TREATMENT

This enables very high cooling rates in a short period of time. The inlet section is followed by four segments, each featuring between six and eight cooling header pairs.

The design of the MultiFlex-Quench’s first segment typically allows operation with both low and high pressure.

Depending on the respective product portfolio, it is additionally possible to design further switchable segments in the quench.

Furthermore, each cooling header includes spray nozzles which can be activated as soon as low cooling rates are required.

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Online models Complex, thermal online process models for the cooling strategies are at the core of this technology. They cover a broad range in order to set varied mechanical property combinations in the heavy plates in a targeted manner. The use of proven physical Level 2 online models, such as the SMS cooling model, makes sure the process is controlled precisely. The key target variables for plant control are mechanical properties (or the microstructure), energy efficiency, and plate flatness. Furthermore, the minimized use of alloying elements, shorter process times, increased output, and greener production processes are the major advantages of the model.

Mathematical models are employed to map the partially highly dynamic heat treatment process and combined to generate a holistic approach. Calculation of the cooling rates, which determine the material properties, utilizes the SMS material database, which is the basis for all SMS process models. It provides key physical and mechanical properties for all steel grades depending on their chemical composition and temperature. The entire SMS cooling model is applied to determine cooling patterns and cooling stop temperatures.

SMS assists its customers with determining the ideal heat treatment parameters for new high-quality plate products that can be produced using the MultiFlex-Quench. Advanced tests are performed in the SMS inhouse laboratory using a dilatometer.

This involves heating up suitable material samples and cooling them down using various cooling rates. Material properties such as time-temperature transformation characteristics or mechanical core values after different heat treatment steps are determined and integrated into the automation systems to optimize the process parameters. Based on this know-how, it is possible to set the mechanical properties that can be achieved through heat treatment more precisely, minimize the use of alloying elements, shorten process times, increase the

output, and hence contribute to environmental protection.

Operating results The operating results so far obtained from applying the MultiFlex-Quench prove that a broad spectrum of steels with varying cooling requirements is feasible, while observing homogeneous material properties and high flatness.

Numerous tests revealed that the flatness results meet the respective requirements independent of the thickness range and the cooling strategy. In case of a demanded minimum deviation, of less than 8 mm/m in quenched but not yet cold status, all the measurements for plate thicknesses above 10 mm were far within the tolerance limits. Adapted cooling

Process development SMS group also supports its customers in the development of new material grades. The focus here is on new heat treatment cycles that will be integrated in the Level 2 online model after successful testing.

MPT International 5 / 2018

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HEAT TREATMENT

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as the plate conveying system, complete with the cooling beds and the plate feeding and centring equipment. The energy-efficient heat treatment line meets the highest quality and flatness requirements. The integrated MultiFlex-Quench enables the production of a wide range of products, also in extremely challenging grades.

More than 200,000 t/year of heavy plate will be annealed and further processed in the new heat treatment line. It is designed to handle plate thick6JG /WNVK(NGZ 3WGPEJ KU VJG EGPVTCN VGEJPQNQIKECN GNGOGPV QH VJG PGY JGCX[ RNCVG JGCV nesses of between 5 and 175 mm and widths up to 3,500 mm. The VTGCVOGPV NKPG HQT +NUGPDWTIGT )TQDDNGEJ between 4 and 24 m long plates strategies also enable very small flat- the MultiFlex-Quench at Acroni are have a maximum weight of 28 t. The ness deviations for quenched plates applied successfully, including the materials to be processed include highbelow thicknesses of 8 mm. model-based mode with interrupted strength carbon steels, highly wear-recooling for crack-sensitive steels. The sistant steels, steels for offshore and process time for sensitive steels can pressure vessel applications, as well 2TQFWEVKQP QH VJG Ć&#x201A;TUV JGCX[ thus be reduced through the targeted as case-hardened and quenched/teminterruption of forced cooling, a tem- pered steels.

RNCVG CV #ETQPK 5NQXGPKC In June 2016, the newly developed perature equalization process to minMultiFlex-Quench produced the first imize internal stress and the resumpheavy plate at the Acroni plant in tion of forced cooling in several steps.

Conclusion Jesenice, Slovenia. The first plate was The development of heavy-plate maproduced two days ahead of schedule terials demands a new technology for and displayed excellent plate flatness.

Investment in innovative cooling processes in heat treatment Two powerful roller-hearth furnaclines. It is clear that the requirements technologies by Salzgitter es are further key components of the Ilsenburger Grobblech GmbH, a of state-of-the-art materials can no new heavy-plate heat treatment line at wholly owned subsidiary of Salzgitter longer be met with roller-type quenchAcroni. The plant was supplied com- AG, has awarded SMS group an order es or the combined spray and laminar pletely by SMS group and is designed to supply a new heat treatment line, cooling system. to produce at least 80,000 t/year of project name â&#x20AC;&#x2DC;Adjustage IIâ&#x20AC;&#x2122;. The line Development of the MultiFlex-Quench heavy plate. is the centrepiece of a project initiat- was based on the extensive experience of The line is equipped with a high-tem- ed by Salzgitter to strengthen heavy- SMS group in plate cooling technologies. perature roller-hearth furnace for plate activities at its Ilsenburg site in This technology can be applied flexibly hardening and normalizing. The fur- Germany. to cover a wide range of cooling stratenace consists of two chambers, in With this investment in innova- gies, from standard and special materiwhich the plates are annealed in a ni- tive technologies, Salzgitter is taking als to newly developed grades.

This system has been in use at Acroni trogen-based inert gas atmosphere. Jet a decisive step towards making the tubes heat the material indirectly up Ilsenburg site fit for future challenges. since 2016 and the presented operating to 1,100 °C. The line is also equipped In total, the new facilities to be built results show that the plate quality fulwith a new low-temperature furnace there will process more than 300,000 ly satisfies the high quality demands. for plate re-heating. In this open-fired t/year of heavy plate. Commissioning This applies, in particular, to the flatroller-hearth furnace, the plates can is scheduled to take place early in 2020. ness results and hardness distribution. be quenched and tempered at temperThe new heat treatment line will Furthermore, the process time for ceratures between 400 and 800 °C. essentially consist of a shot-blaster, tain plates has been reduced.

At the beginning of 2020, the secThe plant is designed for plates with two roller hearth furnaces, the Multhicknesses ranging from 3 to 100 mm tiFlex-Quench, a leveller, a cleaning ond MultiFlex-Quench will start opand a maximum width of 2,500 mm. and priming line, and the water treat- eration in the new heat treatment line The product portfolio includes, among ment plant. SMS group will also sup- of Ilsenburger Grobblech GmbH, a others, high-strength carbon steels, ply the electrical and automation sys- subsidiary of Salzgitter AG. The Mulstainless and tool steels as well as a tems for the line and implement the tiFlex-Quench technology is therefore number of special grades. material and process models. The used in cutting-edge heavy-plate heat All the options for targeted setting supply package additionally con- treatment lines and is rapidly becomof cooling strategies as integrated in tains all the ancillary facilities such ing the state-of-the-art approach.

MPT International 5 / 2018

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş ENVIRONMENTAL PROTECTION

Liberty Steel restarts low-carbon production steelworks in South Carolina 7KH UHRSHQHG *HRUJHWRZQ VWHHO SODQW LV WKH Ć&#x201A;UVW RI D VHULHV RI LQYHVWPHQWV LQ WKH 86$ E\ *)* $OOLDQFH WRWDOOLQJ ELOOLRQ 86 2SHUDWHG E\ /LEHUW\ 6WHHO WKH SODQWĹ&#x2019;V *UHHQVWHHO PRGHO DLPV WR UHF\FOH $PHULFDĹ&#x2019;V JURZLQJ PRXQWDLQ RI VFUDS PHWDO DQG XVH UHQHZDEOH HQHUJ\ WR SRZHU LWV IXUQDFHV DQG PLOOV

Liberty Steelâ&#x20AC;&#x2122;s reopened Georgetown mill will focus on lowering its environmental footprint with advanced energy management systems (Both pictures courtesy of Liberty Steel)

Since it was first opened in 1969, the Georgetown Steel works had remained idle for almost three years following 47 years of continuous service.

This changed in June, when an opening ceremony was held to reignite the first of Liberty Steelâ&#x20AC;&#x2122;s electric arc furnaces (EAFs).

The event attracted an audience of elected representatives, local dignitaries, customers, union officials, group executives from around the world and the local workforce in Georgetown. It was the first step towards restoring full production to the 750,000 t/year plant which was shuttered by its former own-

Liberty Steel, South Carolina, United States Contact: www.libertyhousegroup.com E-mail: revansidha.gulve@libertysteel.us

MPT International 5 / 2018

er, ArcelorMittal, in 2015. Liberty Steel acquired the facilities in December 2017.

The reopening put around 125 steelworkers back to work immediately, many of them former employees returning to the plant. It also heralded the arrival of Libertyâ&#x20AC;&#x2122;s parent company, GFG Alliance, in the USA. GFG is a global metals, mining, engineering, energy and financial services group that employs around 14,000 people worldwide. Having already invested billions to secure the future of industrial assets in the UK, Europe and Australia, the group has now extended its activities to North America. The recommissioning of Georgetownâ&#x20AC;&#x2122;s furnaces and wire rod mills is the first in a series of GFG projects which should amount to more than 5 billion US$ in investments over the next few years.

Quality products for the domestic market The reopening of Georgetown followed maintenance and upgrades to its equipment with a view to operating the EAF at full capacity as soon as possible.

The plantâ&#x20AC;&#x2122;s output is focussed on wire rod products as used in automotive, construction and manufacturing applications. Liberty manufacturers these in line with customersâ&#x20AC;&#x2122; specifications and plans to increase Georgetownâ&#x20AC;&#x2122;s production capacity steadily to meet growing demand.

At the opening ceremony, GFG Alliance Group executive chairman, Sanjeev Gupta, said: â&#x20AC;&#x153;This first investment is our vote of confidence in the future of metals and heavy industrial sector in the USA. We bring a new meaning to the phrase â&#x20AC;&#x2DC;think globally, act locallyâ&#x20AC;&#x2122;. Using this model, we see huge opportunities to create competitive, robust and inte-

ENVIRONMENTAL PROTECTION grated industrial businesses across the USA.” Mr. Gupta said that GFG’s economic model is based on long-term sustainability and the production of quality products for the domestic market.

GFG has expressed interest in the development of local resources including educational and local community development. Employment figures at the reopened plant are expected to rise to 320 direct jobs in the medium term. As orders and output rise, hundreds more jobs are expected to be created and sustained in the supply chain, community and wider economy.

cling Incorporated (ISRI). The industry processes obsolete and prompt scrap into commodity grade material which is then used to produce more than 60% of total raw steel produced in the USA, predominantly with EAFs. Greensteel’s objectives include securing raw materials and resources locally to shorten the supply chain. The idea is to use local resources to make worldclass products that sell both nationally and globally. High grade steels produced

by Liberty are already used in customers’ advanced engineering operations and in the manufacture of advanced components for automotive, aerospace, marine, off-road and defence.

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the coming year to acquire and develop steel, aluminium, engineering, mining, energy generation, and financial services assets. GFG is also establishing a New York regional head office as a hub for its global business.

Strong market for wire rod Liberty has appointed Revansidha ‘Rohit’ Gulve as the new general manager of the Georgetown mill. Mr. Gulve was formerly general manager of Gerdau Steel in Beaumont, Texas, an operation very

Low-carbon steel production Georgetown also marks the first stage in Liberty’s plan to bring its operating model for low-carbon steel production, called ‘Greensteel’, to the USA. As awareness about energy conservation through the secondary production of metals increases – i.e. through metal recycling – Liberty Steel is among a number of manufacturers that are focussed on lowering their environmental footprint by adopting advanced energy management systems.

Its overall Greensteel model is designed to reduce the carbon footprint of the steel making process. The focus is on producing metal in a more sustainable way with greater use of recycling, rather than through the unnecessary production of new primary steel.

The USA’s growing mountain of scrap Mr. Gupta said that Liberty Steel is committed to low-carbon production methods. This includes recycling the USA’s growing mountain of scrap metal.

The Greensteel model is part of a wider trend among producers of ferrous and non-ferrous metals to produce metals from scrap through recycling. Continued growth is expected from of the USA’s recycled metals industry, driven by demand from the building and construction and automotive sectors.

Steel is the most recycled material both in the United States and worldwide. In 2015, America’s ferrous scrap industry was valued at more than 18.3 billion US$ and produced more than 67 million t of ferrous scrap, according to the Institute of Scrap Recy-

Global integration strategy for Greensteel Prior to the USA, GFG has so far applied its Greensteel model in Britain and Australia with plans to gradually extend it to other areas of industrial activity, including India and continental Europe.

The Group also applies Greensteel to its aluminium production.

Georgetown follows the restart, after a similar shutdown period, of Liberty’s Newport mill in South Wales, United Kingdom. Through receiving shipments from its sister plant in Whyalla, South Australia, Newport has ramped up production of hot rolled coil and awaits the installation of its own liquid steel making furnaces. Following an initial delivery of a 24,000 t cargo, Whyalla is projected to supplying Newport with around 100,000 t of slab during its first operational year.

Newport’s output of coil, which it plans to boost by about a third, will be used to meet growing demand for steel in the UK and Europe from industries such as construction and heavy engineering.

The South Wales plant is also going to upgrade its rolling mill as part of a wider development plan that will eventually include the installation of an EAF to recycle scrap steel.

Newport, Whyalla and now Georgetown are all part of a continuing development of a global integration strategy

by GFG. The company expects to invest a further 1 billion US$ in the America over

GFG Alliance Group executive chairman, Sanjeev Gupta, pictured with his son, Jai, said Georgetown’s reopening is a vote QH EQPƂFGPEG KP VJG HWVWTG QH VJG 75#oU metals and heavy industrial sector

similar to that at Georgetown. He said there had been a very positive response from the market to the reopening and was confident sales would climb quickly.

Mr. Gulve said, “I’m really excited about this project because it is one of those great challenges. Any time you restart a mill like that after three years down, it is a memory for life. My objective is to make the plant profitable, in both good markets and bad, and to have the best people working in the safest environment. I am very positive that the wire market is strong and that every ton of quality steel we produce will be sold quickly.

“The steel mill has been ingrained in the Georgetown community for a long time and the restart will bring very welcome employment and revenue to the city,” he added.

References [1] Liberty receives first steel shipment from Australian sister plant. MPT International, 4/2018, 18 [2] New general manager of Liberty Steel Georgetown. MPT International, 4/2018, 20 MPT International 5 / 2018

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş QUALITY ASSURANCE

Vallourec commissions worldâ&#x20AC;&#x2122;s Ć&#x201A;TUV WNVTCUQPKE VGUV HCEKNKV[ YKVJ ITQWPFDTGCMKPI VGEJPQNQI[ Vallourec and Baker Hughes, a General Electric company, (BHGE) have developed and implemented a 2D phased-array facility in Germany with ShapeUTTM technology. This GHYHORSPHQW WKH Ć&#x201A;UVW RI LWV NLQG DQ\ZKHUH LQ WKH ZRUOG KDV VLJQLĆ&#x201A;FDQWO\ LPSURYHG WKH possibilities of ultrasonically testing seamless steel tubes at full production speed.

Up until now, defects located beyond the 45° position could not be detected in a single test run

The new 2D phasedarray testing

Nevertheless, the existence of surface imperfections at higher angles can by no means be ruled out. Tubes should ideally be checked for defects at all conceivable orientations.

To achieve this with standard methods would require a large number of probes to cover the whole circle (360°) of potential defect orientations, as each probe can only test a small section. To set a series of transducers â&#x20AC;&#x201C; each for a specific angle â&#x20AC;&#x201C; is impractical for costs, speed and maintenance.

Such a facility could not operate economically.

technology in conjunction with the ShapeUTTM operating mode can detect surface imperfections through 360°

Hot-rolled seamless steel tubes are advanced high-tech products. Especially in the oil and gas industry, but also in power plants, they are subject to the most stringent quality requirements. A full-body test for surface and embedded imperfections is part of the normal scope of testing.

Elongating the pipe during the sizing process in manufacturing causes most of the imperfections on hotrolled seamless pipes to be positioned in a predominantly longitudinal direc-

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MPT International 5 / 2018

tion. Although, these imperfections are sometimes oriented at angles off the longitudinal axis. This raises the necessity to test the steel pipes for larger angle ranges, ideally for all potential oblique orientations.

Ultrasonic non-destructive testing (NDT) benches are best suited for detecting potential inhomogeneities at industrial speeds in rough environments. So far, phased-array technology with the additional Paint-Brush technique has enabled gapless detection of defects at up to â&#x20AC;&#x201C; but not above â&#x20AC;&#x201C; 45° of the longitudinal axis. This configuration is used at Vallourecâ&#x20AC;&#x2122;s Barreiro works in Brazil, for example, which ranks among the most advanced automatic ultrasonic test facilities for seamless steel tubes.

6JG KPFWUVT[oU Ć&#x201A;TUV ICRNGUU Â&#x152; QDNKSWG KPURGEVKQP method The use of 2D phased-array transducers has the potential to overcome this limitation since the technology naturally enables the detection of defects at any orientation. Vallourec and BHGE collaborated in initial tests with specifically designed 2D phased-array probes and new operation modes that are used in order to overcome the limitations of standard methods.

The ultrasonic specialist developed a new inspection system with extended ultrasound electronics, based on high speed instrumentation, and new operating modes to drive sophisticated and tailor-made ultrasound fields, ShapeUT. This technology is used to test the full circle (360°).

To test the full circle (360°) of potential defect orientations, an acoustic hologram is produced with just one array probe. By combining sophisticated phased-array technology with the implementation of pulse shape laws, ShapeUT is designed to provide the industryâ&#x20AC;&#x2122;s first gapless 360° oblique

QUALITY ASSURANCE inspection method for seamless tubes and pipes.

The system uses wave-shaped laws, an extension from existing techniques that are based on pulse delay laws. This enables a more holistic calculation of any single element’s excitation function. By applying wave-shaped laws appropriately to a 2D matrix array, it is possible to create ultrasonic holograms and produce sound fields with superior properties.

The addition of a Paint-Brush technique can ‘fill in the gaps’ in the oblique flaw detection of current state-of-theart machines. The specific Paint-Brush technology referred to here is based on a Vallourec patent. It was developed for industrial usage with an exclusively license by BHGE to ensure its operation at full production speed.

In the ShapeUT operating mode, the shape of the sound can be changed in a way that the full circle can be included in the test. Defects at all angles, from 0° to 360°, can be detected.

A typical inspection cycle time for the installed machine is one minute, although this can vary depending on the diameter and length of the pipe.

To increase the testing speed, additional probes have been installed for high-resolution wall thickness measurements and testing for laminations, as well as for spotting defects with a transverse orientation.

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# TGRTGUGPVCVKXG UQWPF ƂGNF IGPGTCVGF D[ VJG 5JCRG76 TM function in 360°

Comparison of a state of the art UT system equipped with 1D array probes (a)

5WEEGUUHWN KPUVCNNCVKQP CPF ECNKDTCVKQP CV 8CNNQWTGE A 2D matrix probe in combination with ShapeUT was successfully embedded into a two-carriage gantry solution for industrial application at Vallourec’s plug rolling mill in Düsseldorf-Rath, Germany.

The fully parallelized, automated UT machine is able to detect imperfection oriented on the full circle in a gapless way. High precision wall-thickness measurements and lamination detection can also be performed to fulfil the requirements of valid standards.

The new 360° technology requires new methods to ensure correct and economic calibration. Alternatively to the existing techniques the Vallourec Research Centre France (VRCF) in Aulnoye-Aymeries, Northern France, has developed a new and patented calibration method. The acceptance tests of

alongside the new system including a 2D matrix probe. Schematic sketch of a RQUUKDNG EQPƂIWTCVKQP QH XKTVWCN RTQDGU 82 KU UJQYP DGNQY E

the UT bench featured outstanding reproducibility as a criterion for the quality of its measurements.

+PURGEVKQP CV V[RKECN RTQFWEVKQP URGGFU VJTQWIJ WUG QH FCVC ShapeUT uses the BHGE USIP|xx high-speed ultrasonic testing instrument platform. The platform is designed specifically for large, data intensive automated inspection systems.

USIP|xx processes the gathered inspection data at very high speeds to offer fast online inspection.

As most of the set-up with the Düsseldorf-Rath UT machine involves the instrumentation, fast changeover

times can be also achieved because the known parameter sets can be reloaded.

Despite the large number of channels, inspection can be performed at typical production speeds. The high-performance electronic platform features a high degree of parallelization, as well as post-processing of the acquired data.

6YQ ECTTKCIG U[UVGO GPCDNGU HCUVGT VGUVKPI URGGFU The newly installed UT bench at Düsseldorf-Rath is a portal system with two carriages, two separate operating roller conveyors and operator stations.

All the UT testing results are transferred to the operator room so that everything can be monitored from MPT International 5 / 2018

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş QUALITY ASSURANCE

34 EQFG 5JCRG76 TM Technology for 5GCONGUU 2KRG +PURGEVKQP XKFGQ

there, including the control of the pipe transport.

The portal is built in a way that each carriage can move over two separate turning conveyors independently, so the two carriages can operate individually on the different turning conveyors on different pipes. For big orders, both carriages can operate together on one pipe.

This installation is highly flexible and it is possible to reach good levels of productivity, even with smaller lots, during UT testing. While the tubes on one carriage are being tested, the other carriage can either be set up for the next test lot or be used as a second carriage in the production area. This enhances the speed of testing.

Besides the significant quality benefits of enabling defect detection through 360°, this layout allows for optimum setting and production times as well as maximum flexibility in terms of plant utilization.

%QPENWUKQPU After a development period of just under three years, the installation of the ultrasonic test facility took less than two months following its successful release.

This included integration into the production flow under restricted space conditions, as well as connection to the factory IT systems to enable automatic order data input and storage of the test results.

The plug rolling mill at Vallourecâ&#x20AC;&#x2122;s DĂźsseldorf-Rath location currently operates the worldâ&#x20AC;&#x2122;s most advanced automatic ultrasonic test facility for seamless steel tubes. With the set-up of the latest UT machine, oblique UT inspections can now be conducted in directions over the full circle (360°).

This was achieved by replacing the several 1D array probes with a 2D MPT International 5 / 2018

At the new 2D phased-array facility, two carriages can operate individually on FKHHGTGPV RKRGU VQ GPJCPEG VJG URGGF QH VGUVKPI 2KEVWTG 8CNNQWTGE

The facility operates fully automatically at the same speed as the tube production. #NN 76 VGUVKPI TGUWNVU CTG OQPKVQTGF HTQO VJG QRGTCVQT UVCVKQP 2KEVWTG 8CNNQWTGE

matrix probe. The 360° detection was validated with various reference pipes all over the specified dimensional range of the UT machine.

For example, one reference pipe had a nominal outside diameter (Ă&#x2DC;) of 244 mm and a nominal wall thickness of 12 mm. The reference notches had a nominal depth of 5% of the wall thickness and a length of 25 mm (1 in), covering the full circle in steps of 5°.

Also of note is the repeatability analysis. This shows a high accuracy of the measurement with a signal to noise

ratio of above 12 dB and a reproducibility of the UT signal response, typically below 2 dB. The new UT machine is shown to have an outstanding detection capability which can be taken as a criterion for the quality of the UT inspection.

Usage of the 2D matrix not only allows for single flaw detection over the full circle range, but also the detection of a more complex pattern.

With this set-up, operators can better test steel pipes for larger angle ranges and all potential oblique orientations at full production speed.

References [1] Menne, U.; Peters, R.; Germes, A.; Nitsche, S.; Holzapfel, H. Vallourec nimmt weltweit erste Anlage mit bahnbrechender PrĂźftechnik in Betrieb. Stahl u. eisen, Vol. 138 (2018), No. 3, 52-53 [2] Peters, R.; WĂźrschig, T.; Holzapfel1, H. et al. Automated ultrasonic testing of seamless steel pipes with matrix arrays. European Conference on Non-Destructive Testing, 12th, on June 11-15, 2018, Gothenburg, Sweden

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Fluid solutions for the cost-effective tinplating of steels The tinplating of steels should always be cost-effective. But the latest efforts by operators to reduce their costs and environmental impact are necessitating expensive equipment upgrades. Quaker Chemical Corporation has devised a new, cost-effective solution that works with all existing lines.

Tin plated steel has been used for food packaging since as early as the 17th century. Steel sheets were originally hand dipped in molten tin to coat the steel with a tin coating. Today, tinplate is produced in high speed electro tin lines (ETL). The tin is deposited on the surface of the steel by an electroplating process. A current is applied to the steel strip and the tin metal is plated out on the steel surface from an acidic electrolyte (a substance that produces an electrically conducting solution when dissolved in a polar solvent, e.g. water).

Aside from the operational benefits, the main requirement for tinplating is that it remains cost-effective. That is why, in response to increasing demands to reduce costs and environmental impact, tinplate producers are looking to switch away from tinplating methods that use phenol sulfonic acid (PSA) based electrolytes. The tried and tested alternative is the methane sulfonic acid (MSA) based electrolyte.

However, there is one significant hurdle to converting an existing PSA ETL for the use of MSA: the build up of haze in the flux tank. Sometimes called ‘blue haze’, the problem is caused by the MSA itself and attributed to the fact that most PSA ETL’s have only two tanks after plating, one dunk rinse tank and one flux tank.

One way in which operators are avoiding issues of blue haze is to add extra rinse tanks or use excessive rinse water as a prevention. Some tinplate producers have installed post rinse

Gary J. Lombardo, Quaker Chemical Corporation, Pennsylvania, USA Contact: www.quakerchem.com E-mail: info@quakerchem.com

The Ferrostan electro tin line (ETL) used to tinplate steels

flux applicators when using MSA, but this solution is expensive.

To help operators avoid these higher costs, Quaker Chemical Corporation, a global supplier of process fluids, chemical specialities and technical expertise to a wide range of industries including the steel industry, has identified an alternative system.

The unique flexibility of Quaker’s latest solution means that operators can avoid expensive modifications to the PSA ETL when switching to MSA.

The difference between the PSA and MSA electrolytes Three electrolytes are used in the production of tinplate today. They are the phenol sulfonic acid based (PSA) electrolyte, the methane sulfonic acid (MSA) electrolyte and the halogen electrolyte. Overall, the PSA electrolyte accounts for 63% of global tinplate production, the MSA accounts for 24% and the halogen process for 13%.

A difference between PSA and MSA is the applied additive. In the PSA

electrolyte, this is ethoxylated naphthol sulfonic acid with the common name of ENSA -6. The method of ETL production using PSA with ENSA -6 is known, and trademarked, as the ‘Ferrostan’ process. Meanwhile, the additive used in MSA electrolytes is a proprietary blend formulated to meet the needs of modern high-speed tinplate production.

Cleaning the black plate Tinplating begins with a necessary multi-step cleaning process. Prior to tinplating, the strip is often referred to as black plate and is unsuitable for tin deposition due to the presence of oxides and residual organic oils on the surface. These contaminates block or alter the tin crystals formed during tinplating, and the produced deposits are typically dull and non-uniform in appearance. In worst cases there are large voids in the tin deposit (e.g. these are very objectionable for food packaging) The black plate is cleaned by immersion in alkaline cleaner formuMPT International 5 / 2018

58

››› STRIP PROCESSING

lated with sodium hydroxide, surfactants (compounds that lower the surface tension between interacting elements) and builders (which enhance or maintain the cleaning efficiency of the surfactant). The cleaner tanks are heated from 65 ˚C to 90 ˚C which aids the cleaning solution in the removal of organic contaminates. Typically, the strip is electrified with direct current in the cleaner tank. This creates gas bubbles on the strip surface with some mechanical agitation to aid in the removal of organic oils. The strip is then rinsed to remove residual soils and cleaner, and mechanical brushes are sometimes used.

The strip is then pickled in an acidic solution of sulfuric acid. This removes any scale on the black plate and renders it active to receive the tin deposition during what happens next: the plating step.

Tinplating via electrolytic reduction During the plating step, molecular (ionic) tin is applied to the (cathodic) surface of the black plate via a process of electro-deposition (or electrolytic reduction).

The plating section – usually a bath is normally made up of a series of cells containing an acidic electrolyte, an anode (positively charged electrode) and a cathode (negatively charged electrode which attracts the positive charge). Here, the strip acts as the cathode while pure tin is the anode, in soluble anode lines. In addition, hydrogen ions are reduced to hydrogen gas at the surface.

To produce a bright tinplate, the matte tin deposit must be reflowed.

In other words, the strip is heated to slightly above the melting point of tin: 232 ˚C. The tin becomes liquefied as a result, then flows and levels out. This develops a bright surface. The melted tin is immediately quenched in water to solidify into the bright surface.

Tin is a very reactive metal in the presence of oxygen, especially in the liquid metal form produced in the melter. This reactivity produces tin oxides which form during the reflow process.

The tin oxide will create an objectionable cloudy appearance on the deposit.

In order to prevent the formation of tin oxide in the melter, a flux (or chemMPT International 5 / 2018

A closed loop methane sulfonic acid (MSA) operation in a Ferrostan foot print

ical cleaning agent) is applied in the last rinse prior to melting.

After melting and quenching, the strip is passivated in a solution of sodium dichromate. The sodium dichromate is electrified to deposit a mixture of chromium and chromium oxide on the surface. This passive film prevents corrosion and promotes lacquer adhesion.

The strip is then electrostatically oiled to reduce its tendency to scratch during handling.

The environmental problem with PSA The major different between a Ferrostan ETL using phenol sulfonic acid, and an ETL using MSA, is the former also uses PSA as its flux.

Because PSA is an effective fluxing agent in tinplating applications, producers typically maintain a minimum concentration of PSA in the flux rinse tank. The solution from the flux rinse tank then counterflows to the drag out rinse and, from the drag out rinse, the solution flows to the plater recirculation tank.

However, there is an environmental problem with PSA. On the one hand, the Ferrostan process does recycle water and chemistry very effectively. Because it is a closed loop system, no water or plater chemistry is lost to waste treatment during the operation of the line.

Instead, the environmental problem with the PSA line is excessive sludge production. Sludge consumes both PSA and tin and must therefore be re-

moved from the system. Nevertheless, it costs money to make the sludge and also, in most cases, to dispose of it.

(There can be monetary payback when the tin is recycled, but this is comparatively small.) Therefore, the best practice is to reduce the amount of sludge produced.

The hazardous nature of sludge is due to the presence of PSA, which is toxic. In addition, commercially supplied PSA typically contains 2% free phenol that is more toxic than the PSA. This toxicity adds to the operational costs of tinplate production.

Because more sludge is generated in the PSA system compared with MSA, it can be said that tin utilization in an MSA system is the superior method.

*QY /5# KP VJG ƃWZ VCPM creates ‘blue haze’ The operational procedure for using MSA is similar to that of the Ferrostan footprint, with two major differences. Firstly, the MSA line uses an antioxidant in the electrolyte. Secondly, a proprietary flux is applied to the flux tank.

The reason for the proprietary flux is that MSA is not a good fluxing agent.

The maximum concentration of MSA in the last flux tank must not exceed 5 ml/l. Excessive concentration of MSA in the tank causes an objectionable blue white cloudy deposit seen after melting – the aforementioned problem of ‘blue haze’. This is caused by a micro etch of the tinplate when the deposit is melted and quenched. (The problem does not happen with un-melted tinplate.)

STRIP PROCESSING The operational procedure using MSA follows this sequence.

‹‹‹

1.

Alkaline Cleaning

2.

Flux Rinse

3.

Rinse

4.

Dry

5.

Acid Pickling

6.

Reflow and Quench

7.

Rinse

8.

Passivate

9.

Tin Plate

10.

Rinse

11.

Drag out Rinse

12.

Oil

Because most PSA lines converted to MSA follow the Ferrostan design footprint, of two rinses after plating, this presents a significant hurdle if an operator seeks to convert a Ferrostan line to MSA.

'ZKUVKPI UQNWVKQPU HQT /5# and their shortcomings In original MSA formulations, the flux solution was incompatible with the MSA electrolyte. To get around this problem, one of the rinse tanks is converted to a flux tank. The spent flux is then discarded which results in the loss of the flux and any chemistry in the flux tank.

However, having just one rinse tank limits the rinsing capacity of the line. Two rinse tanks are better than one, particularly as two consume less rinse water.

An identified solution is to convert the last plating cell to a rinse – this gives two rinses and one flux after plating. Unfortunately, the loss of a plating cell reduces the overall plating capacity of the machine – e.g. this results in lower speeds when plating heavy deposits of more than 5 g/m2 of tin.

An alternative is to spray flux on the strip between two wringer sets after the final rinse. Nevertheless, adding a spray flux system after rinsing is a maintenance intensive piece of equipment. Some tin mill operators also maintain a spare backup spray system to insure continuous operation.

Therefore, both solutions require capital expenditures and each has a significant drawback.

59

existing equipment when converting to MSA. With this new technique, a flux is added to the second rinse (much like in cases where PSA is used as a flux).

The second rinse, or flux tank, is then flowed back to the first rinse tank.

Then the solution flows, from the first rinse, back to the plater recirculation tank.

It is in the recirculation tank that the flux becomes part of the MSA electrolyte. No chemistry is lost with this solution because the system is now a closed loop operation. What is more, this reduces the environmental footprint of the process and saves money for the operator since no chemistry is sent to waste treatment.

Finally, to maintain the proper balance of chemistry, MSA, grain refiner and antioxidant are added directly to the plating recirculation tank.

Conclusions Quaker recommends that the use of this novel MSA electrolyte and flux method can be used in the flux tank of all existing PSA lines. The system is totally compatible with the MSA electrolyte, and can be counter flowed back into the plating tank. Going forward, Quaker advises the method can help PSA ETL operators maintain cost-effective tinplating processes, without the need for costly equipment upgrades.

SHORT WAVELENGTH

INFRARED CAMERA

NEW thermoIMAGER TIM M05 for non-contact temperature measurement of molten metal Wide measuring range from 900°C to 2000°C Special wavelength range from 500nm to 540nm minimizes errors due to unknown emissivity Highly dynamic CMOS detector with frame rates up to 1kHz Optical resolution up to 764 x 480 pixels Robust cooling and protection housing available License-free analysis software and complete SDK included

References

A new solution, without GZRGPUKXG NKPG OQFKƂECVKQPU In response to these shortcomings, modern formulators have developed a flux that is totally compatible with the MSA electrolyte. An advantage is that, through the use of this flux, an operator of an ETL (using the Ferrostan footprint) needs not modify the

[1] Lombardo, G.J.: Tinplating: Conversion of Phenol Sulfonic Acid (PSA) Electrotin Lines to Methane Sulfonic Acid (MSA), Quaker Chemical Corporation, 2018 [2] Surface Treatment Experts: The Tin Plating Process, A Step-By-Step Guide. URL: https://www.sharrettsplating.com/ blog/the-tin-plating-process-a-step-bystep-guide MPT International 5 / 2018

Phone +49 - 8542 1680 www.micro-epsilon.com/tim

60

››› TECHNICAL INNOVATIONS

Non-contact speed and length gauges ready for Industry 4.0 MEASURING TECHNOLOGY Proton Products, specializing in non-contact laser Doppler speed and length measurement technology, offers a broad suite of products with embedded industry-standard communications and smart technologies. These form the fundamental building blocks for the successful implementation of Industry 4.0.

Proton Products were among the first to provide smart field instruments with their InteliSENS product lines using embedded Ethernet TCP/IP, RS232 and CANbus communications. Subsequently, Ethernet I/P, DeviceNet, ProfiBus, ProfiNet, Bluetooth and WiFi have been added, enabling these to be networked with programmable logic controllers (PLC), distributed control systems (DCS) and other compliant platforms. Operators can view InteliSENS data on tablet devices in real-time while collaborating with supervisors and technicians.

The Proton Products InteliSENS family supports intelligent decision-making for the metals industries. The InteliSENS SL/SLR series of non-contact laser Doppler speed and length sensors are designed for outstanding results with a measure-

Non-contact gauges for real-time implementation of Industry 4.0

ment update rate of 100 kHz, a repeatability of ±0.02% and product acceleration rates of over 500 m/s2. Proton’s advancements in integration and intelligence offer a flexible automation value chain for industrial processes. With a modular approach, InteliSENS supports the smart factory concept with physical measurements, connectivity and intelligence for minimized production costs and maximized output.

Contact: www.protonproducts.com

,@BGHMD SNNK HMCTRSQX ADMDÖSR EQNL SGD BKNTC DIGITALIZATION Siemens has presented new applications for its open, cloud-based Internet of Things (IoT) operating system, MindSphere, that are designed specifically for the machine tool industry.

They include the Analyze MyPerformance/OEE (overall equipment effectiveness) Monitor application which is now available on the latest version of MindSphere. With the Analyze MyPerformance/OEE Monitor, users can capture machine data for configuring important parameters; carry out availability and utilization analyses; and compare estimated productivity with actual results. Customer-specific OEE calculations are also available. In addition, users can also produce a shift calendar with the application, so that machine utilization can be calculated even more accurately and production planning is made significantly easier.

Meanwhile, the Manage MyMachines application is also now available on the latest version of MindSphere. It provides machine manufacturers and operators with cloudbased access to the field of condition monitoring. The system gives an overview of the most important data and operation conditions from connected machines. Users can capture, analyze, and visualize relevant machine data via the application. Advantages include increased machine condition transparency and progress over time.

The added application, Manage MyMachines /Remote, extends Manage MyMachines with an extra remote feature. It provides remote access to the CNC (computerized numerical control) and failsafe, encrypted communication via the internet. This increases machine availability, reduces costs MPT International 5 / 2018

Siemens has expanded its cloud-based operating system, MindSphere, with new apps for the machine tool industry

in the event of disruption and simplifies maintenance and servicing. Manage MyMachines /Remote will be available for the latest version of MindSphere in the near future.

Contact: www.siemens.com

TECHNICAL INNOVATIONS

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61

Forging press with new design features FORGING Schuler has developed a new servo forging press, MSE 2000, for a leading forging company. Delivery of the press is planned for the end of the year. The new press will be used to produce shafts, bevel gear wheels and other joint components.

The highly-dynamic servo drives in the head unit of the 2,000 t press make it possible to precisely control the speed of the die as it approaches and moves away from the part. This not only increases the number of parts produced per time unit, but also the lifetime of the die. A distinct rise in productivity can be expected from the ServoDirect technology, thanks to which

the overall process is no longer dependent on the speed of the slowest sub-process.

The table ejectors of the MSE 2000 have been decoupled from the main drive by fitting them with independent servo drives, too. This provides more flexibility in the part transport and accelerates the production process. Schuler has implemented a traverse shaft design in the head unit instead of a longitudinal one. This makes machine operation extremely smooth, as a result of the two eccentric wheels rotating in opposite directions.

Contact: www.schulergroup.com

-DV RSDDK ENQ GHFG ODQENQLHMF VDKK BNLOKDSHNM DPTHOLDMS SPECIAL APPLICATIONS In oil and gas exploration and extraction, the materials handling and production systems are subject to corrosion due to contact with acid gases and chlorides at high temperatures. To limit or prevent the failure of the well equipment, oil and gas companies approve only selected materials for use in these demanding environments.

In introducing Corrodur 4418 Mod, Deutsche Edelstahlwerke, a company of the Schmolz + Bickenbach Group, offers a

high-grade steel that is superior in durability to conventionally used 13% chromium steel grades, such as 1.4006 (AISI 410) and 1.4021 (AISI 420). The unique features of the new special steel are its high strength and outstanding toughness, as well as good resistance to pitting corrosion and stress corrosion cracking. Corrodur 4418 was modified based on the material properties data suitable for mild sour gas (less than 0.01 bar ppH2S) conditions, as defined by leading oil and gas companies like Statoil ASA.

© Utz Peter Greis, Düsseldorf

Cartoon

Cloud-based steelmaking is really taking off MPT International 5 / 2018

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â&#x20AC;şâ&#x20AC;şâ&#x20AC;ş TECHNICAL INNOVATIONS

SENSORS Full Capacity Supplier for Rolling Mills

Load Cells Width Gages Tensiometers Plate Outline Gages Laser Speed/Length Measuring System

With controlled heat treatment, Deutsche Edelstahlwerke systematically improved the steel properties, reaching a tensile strength of at least 862 MPa, a yield strength of at least 758 MPa and ductility (toughness) of at least 68 J at -10 °C. The materialâ&#x20AC;&#x2122;s enhanced resistance to pitting corrosion and stress corrosion cracking and its high strength gives users more flexibility in the design of components, or to improve performance while keeping the same dimensions. Corrodur 4418 Mod is available in the diameters 50 to 216 mm, rolled and peeled. This grade is also described in international standard NACE MR 0175. Here, the range of dimensions covers sizes up to 280 mm in forged and peeled condition.

Contact: www.dew-stahl.com

Weighing Applications Fluid Pressure Transmitters Hot Metal Detectors Absolute Displacement Transducers

For details call +1-416-445-5850 or kelk.sales@vpgsensors.com

kelk.com Š2017 Vishay Precision Group, Inc.

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MPT International 5 / 2018

One-stop portfolio of process solutions for SGD LDS@K BNHK HMCTRSQX STRIP PROCESSING With more than 80 years of expertise in metals processing solutions, Henkel has firmly established itself as a global one-stop partner of the metal coil industry.

New product innovations are strongly focused on helping customers manage the process needs of next-generation alloys while meeting cost and regulatory challenges. There is a clear trend in the metal coil industry towards greater process and cost control. While new high-strength steel, aluminium and magnesium alloys open up new opportunities for increased lightweighting, sheet metal manufacturers and coaters are faced with ever stricter environmental regulations.

Henkel offers the Bonderite portfolio of efficient, safe and sustainable solutions for the metal coil manufacturing chain.

It includes pickling inhibitors (added to hydrochloric or sulfuric acid to avoid over-pickling and provide a uniform surface for the next process step); cold rolling oils for best lubrication results; and cleaners that are designed to remove grease, oil and metal fines from the sheet surface.

Also offered in the portfolio are wet temper fluids used to increase the lifetime of work rolls; surface treatment agents to prepare the substrate for reliable paint adhesion while adding excellent corrosion protection; passivates, applied to galvanized sheet and tin plate products to avoid corrosion during storage and transport; and thin organic coatings which provide anti-fingerprint and other effective properties for decorative surfaces, as well as improved weldability and forming.

Additionally, Henkel offers adhesives, engineered for reliable and cost-effective coil lamination in compliance with thelatest environmental regulations.

The use of chromium (VI) has already been restricted in Europe, with further prohibitions to come. Henkel has a history of 20 years in chromium-free products for painted sheet, and has successfully extended the technology to other processes, such as passivation.

Contact: www.henkel.com

TECHNICAL INNOVATIONS

‹‹‹

63

Measuring the full contour of rebar during hot rolling SPECIAL EQUIPMENT Zumbach Electronics, Switzerland, a leading 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.

The system’s sophisticated capabilities allow the measurement of rebar products in hot rolling processes. With a unique processing feature, the full contour of a rebar is captured and the cross section is extracted in such a way that core diameter, rib height, width and height, among other characteristics, can be measured and monitored.

The Profilemaster SPS 80 is specially designed to measure the rebar in the rolling mill without having limitations in terms of the rolling speed. Since many rolling mills produce rebar in more than one strand, Zumbach’s Profilemaster can handle up to three strands simultaneously with one single gauge. Every individual strand is measured and related statistics can be generated.

Drawing on Zumbach’s experience of supplying measuring systems into the metal and steel market, the new system is designed to be solid, reliable and help customers produce rebar products with higher quality and higher efficiency. It reduces start-up times, improves process control and increases the repeatability and precision of the end product.

The SPS 80 is a further addition to the Profilemaster family which consists of various models best suited to different product sizes. Its systems are available with four to eight laser/camera modules that continuously measure the cross section of the moving rebar. The SPS 80 measures in real-time irrelevant to rolling speed, detects process problems at an ear-

ly stage and is Industry 4.0 ready.

All relevant dimensions, such as width, height, angle and radius or other geometric quantities, are computed for a full cross-sectional picture. This data is presented in an operator-friendly graphic display 6JG 2TQƂ NGOCUVGT 525 ICWIG KU during the whole designed for in-line measurement of process. The nom- any rebar type inal values for the profile can be directly imported from CAD design files to allow easy and problem free configuration of the device.

The system reduces scrap and production costs, and can save raw material and post processing costs. www.zumbach.com

BRAUN Innovations for Steel Cutting-edge technology for cutting and grinding

B

TSNL@SHB $ % S@OOHMF STEELMAKING The automatic tapping system installed by Danieli at the electric arc furnace (EAF) of SN Maia in Portugal makes it possible to execute complete furnace tapping remotely from the main pulpit. This increases safety and improves process control. The system starts furnace tilting in the automatic mode, controlling the furnace position during the complete tapping process. Both the Q-Slag slag detection system and the ladle level detection system control the steel flow on a real-time basis. The former system scans the steel stream for slag. The latter checks the steel level inside the teeming ladle, triggering a signal as soon as the steel level reaches a preset height. Back tilting can be done either in automatic mode upon reaching the preset steel level/weight or by remote intervention by the EAF operator from the main pulpit. Slag carry over is controlled by the Q-Slag system, which also quantifies the amount of slag that might have passed over into the ladle.

This is useful information for fine-tuning alloys and lime additions during secondary metallurgy treatments.

• High-performance cut-off machines • Multi-functional grinding machines • Automated turn-key solutions • Technical consulting • Life-time service support

INNOVATIONS FOR STEEL

www. b ra u n -s t ee l . co m

BRAUN Maschinenfabrik GmbH - Austria BRAUN Machine Te T chnologies, LLC - USA BRAUN Machine Te T chnologies (Beijing) Co., Ltd. - PR China

Contact: www.danieli.com MPT International 5 / 2018

64

››› TECHNICAL INNOVATIONS

Next generation @TSNL@SHB A@MC R@VR SPECIAL EQUIPMENT Specialist sawing equipment manufacturer KASTO has re-engineered its line of KASTOtec automatic bandsaws. A steel-mineral casting compound provides higher saw blade service lives while reducing cutting times and ensuring a high degree of damping and smooth running – even with difficult-to-machine materials such as titanium, Hastelloy or Inconel. The machines operate with pre-tensioned linear guides, featuring two grease-lubricated guide carriages each.

BLAST FURNACE VALVES Ÿ Ÿ Ÿ Ÿ Ÿ

HIGH-GRADE – TAYLOR-MADE SPECIAL VALVES UP TO ND 5000 mm – 100 t UP TO 1600°C / 3000°F IN ACCORDANCE TO PED, ASME, ATEX AND SIL REPAIR AND UPGRADE SERVICES Band saw cutting round material of up to 530 mm diameter

BLAST FURNACE CHARGING Ÿ Ÿ Ÿ Ÿ Ÿ

PERFECT BURDEN DISTRIBUTION AND CENTER COKE ALL CHARGING MODELS EASY MAINTENANCE QUICK CHUTE EXCHANGE EASY REPLACEMENT OF ALL BF-TOPS BY VERY COMPACT HEIGHT

Küttner GmbH & Co. KG Essen/Germany MPT International 5 / 2018

info@kuettner.com www.kuettner.com

The new KASTOtec machines come with an infinitely adjustable electromechanical saw feed, using two servo motors and ball screw spindles. The saw feed control system, which makes minimal use of sensors, allows the cutting parameters to be continuously adjusted not only at the beginning and end of the cut, but also during the sawing process. The user benefits from maximum performance and low tool wear.

The tool service life also benefits from a new double saw blade cleaning facility. A mechanical system automatically adjusts the brushes over their entire life, thus ensuring that they are always optimally positioned relative to the saw blade. All of this contributes to a further increase in sawing performance.

A further new feature is the frequency-controlled bevel spur gear saw drive with a power of 15 kW and an infinitely adjustable cutting speed of 30 to 300 m/min. The intuitive controller minimizes tool costs and cutting times, as it adjusts all parameters optimally to the type of saw blade used.

The new saw generation includes KASTOrespond, a system that ensures the machine is always ideally set up for the product being sawn – solid material, tubes or sections.

Without additional and often error-prone sensors, the system continuously measures the forces acting on the tool, calculating from these measurements the optimum digital feed speed. KASTOrespond continuously detects changing engagement lengths on round product or hard spots in solid material and adjusts the feed accordingly.

Contact: www.kasto.com

I am aggressive!

New stainless steel for parts subject to heavy wear and tear MATERIALS Hardness, corrosion resistance and impact strength are all determinate factors in the lifecycle costs of wearing parts made of steel bar. The material’s machinability, however, is just as relevant for quality and cost effectiveness.

Ugitech, the manufacturers of stainless steel long products and part of the SCHMOLZ + BICKENBACH Group, has introduced to the market a stainless steel with outstanding values to meet all of these criteria.

UGIMA® 4116N is extremely hard due to the addition of nitrogen. It is much more resistant to corrosion, as a competitive alternative to commonly-used conventional martensitic steel grades such as EN 1.4125 (AISI 440C) and EN 1.4112 (AISI 440B).

Both standard mateMachinability should not be rials have high hardoverlooked as relevant to a steel’s ness values. Howevquality and cost effectiveness er, due to their high carbon content (0.9% and 1.0%, respectively), they contain primary carbides; thus their corrosion resistance is comparatively low and their resistance to impact loads even lower. These properties directly effect the quality and service life of wearing parts such as cutting tools, valve seats and bending guides as well as nozzles for the flow control of liquids containing abrasive particles.

With 57 HRC when tempered, UGIMA 4116N has a comparable hardness value to that of EN 1.4112/AISI 440B and EN 1.4125/AISI 440C. By adding nitrogen (0.1%), Ugitech specifically improves the corrosion resistance of stainless steel containing carbon. Its resistance to pitting has a potential of 200 mV/ECS (in NaCl 0,02 M at 23°C and pH = 6,6) in a quenched and tempered state. The new material is therefore a lot more resistant to pitting corrosion than comparable products.

In contrast to other martensitic steel grades, UGIMA 4116N also has greater impact strength. The added sulfur content improves machinability and produces short chipping lengths during machining. As a result, users can profit from cost-efficient manufacturing and high-quality, long-lasting wearing parts.

Contact: www.ugitech.com

But that’s no problem for our corrosionresistant fans.

With special alloys and gas-tight shaft seals, we protect our fans from corrosive gases containing sulphur, hydrochloric acid, chlorine DQG Á XRULQH

Long service life High availability Very reliable

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Process and hot gas fans Process gas dust collection Process gas cleaning plants Secondary fuel technology Belt drying plants Vapour exhaust plants

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››› LITERATURE SERVICE Four leading trade fairs for metals 9 pages, German and English Issued by Messe Düsseldorf, this booklet offers a definitive overview of the upcoming GIFA, METEC, THERM PROCESS and NEWSCAST trade fairs which take place at the venue between June 25 to 29, 2019. Information and useful statistics are provided for all the exhibitions with background research into Germany’s current trade fair status. Supporting programmes, the “ecoMetals” campaign and visitor marketing resources are also covered.

Contact: www.tbwom.com

Laser-based thickness measurement 5 pages, English In this brochure, Germany’s nokra presents its alpha.ti 4.0 laser-based thickness measurement product. It is designed to be simple to integrate, handle and use while providing increased accuracy and precision. Future software options are also available for Industry 4.0. The high measuring accuracy of the laser sensors developed by nokra are temperature independent when used at between 10 °C to 40 °C. Contact: www.nokra.de

Forging, one of the oldest handcrafts 25 pages, English Dirostahl, headquartered in North Rhine-Westphalia, Germany, is a leading family-run businesses in the sector of open die forging. Here, the company presents a detailed overview of its forging traditions which stretch back centuries, continuing today to its production of open die forgings from 10 kg to 35,000 kg and rings with a diameter of up to 3,500 mm.

Contact: www.dirostal.com

Slit strips, sheets and coils 3 pages, English This brochure from Hagener Feinblech Service (HFS) GmbH provides information on its extended production site in Hagen-Haspe, Germany, which has developed into an innovative and high output steel service centre. Information includes specifications of the company’s cut-to-size sheets and slit strips, its material testing and certification. There is also a glimpse at HFS’s new state-of-the-art plant in Hagen-Hohenlimburg.

Contact: www.hfs-hagen.de

Industrial sludge treatment and dewatering 5 pages, English Filtratec specializes in sludge dewatering and oil sludge seperation for industrial companies.

Here, the German company explains its infrastructure, related expertise and services including sludge dewatering with filter presses and oil-sludge seperation with three-phase decanters.

There is information on successful approaches to sludge dewatering as the company outlines its approach to meeting customers’ high demands.

Contact: www.filtratec.com

MPT International 5 / 2018

IN THE NEXT ISSUE…

‹‹‹

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Additive manufacturing Three-dimensional manufacturing: the key issue for future production engineering 3D printing continues to create new opportunities from steelmakers – whether for foundries, steel mills or forging and sheet processing companies. Components like spraying nozzles for swaging presses are already being additively manufactured. Three-dimensional manufacturing processes (the term used for the various additive production technologies with all the different kinds of 3D printing systems) are where the future lies.

Heat treatment Transfer bar cooling system from Primetals Technologies commissioned at Port Talbot Tata Steel has commissioned the transfer bar cooling system in the hot strip mill of its Port Talbot integrated steel plant located in South Wales, United Kingdom. The purpose of the 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 results in an increase of production capacity by approximately 150,000 t of hot strip p/year.

Automation New digitized manufacturing execution system for smart factories X-Pact® MES 4.0 by SMS group is a complete modular solution for planning and control of the whole metallurgical process. Its software modules include sales, production planning, material management and quality analysis, as well as supply and dispatch. These are available through mobile access, everywhere and any time. The automated system has already been successfully applied at Hadeed Saudi Iron & Steel’s Al Jubail steelworks in Saudi Arabia.

This preview may be subject to change.

Metallurgical Plant and Technology

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MPT International 5 / 2018

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