Issue 42 | November 2021
Director’s Update Your positive feedback on the Annual Lunch which was rescheduled to Sheffield was appreciated. I know some new contacts were made and it gave our members the opportunity to meet informally and invite their staff and clients too.It was a pleasure to have Professor Sir Keith Ridgway speak and from the feedback I received, his comments resonated with so many of you. Keith’s industry insights on changes and challenges over the last 50 years were thought provoking. Keith also spoke about the government’s plan and need to level up and the recent budget appears to be addressing some of those concerns. Keith shared the role of the AFRC with its aim to collaborate with companies involved in all aspects of metallurgical equipment and in a diverse range of manufacturing industries i.e. Defence, Nuclear (SMRs/AMRs), Oil and Gas, Renewable Energy, ie typical members of the BMPCA and why our members are critical to helping us meet these challenges I am delighted to announce the
return of the Metals Industry Apprentice of the Year awards. There are two awards: Career Development Award: designed to encourage and reward exceptional personal development and commitment to career progression. Craft Skills Award: designed to encourage and reward the achievement of high level, practical, ‘hands-on’ engineering, metallurgy or manufacturing skills. I will be sending out the application form in the next few days and it would be great to see some of our members’ employees in the running for such prestigious awards. As part of my role, I have started to visit our members and I would like to thank Sarclad and SFEL for interesting and informative visits. The strength of an organisation is in its membership and it is a pleasure to welcome new members Nigel Leeson
(Innovation Alloys) whom some of you will have met at the October Business meeting and Agemaspark. Paul Stockhill, Managing Director, showed me around their factory and I was able to see first-hand their latest innovations. We look forward to showcasing both their capabilities in our bulletins, as well as their contributions at our future meetings. High on my radar is a new website for the association as our current one is no longer serves it purpose. It is important that the BMPCA has an active media presence so that we can raise the profile of the association and our members, as well as being able to promote our activities and support the growth of the BMPCA. At the Make UK dinner on 7th October I spoke about the BMPCA with Make UK and I will be following up this contact up in early November to see how we can enhance our relationship with them.. Angela Taylor Director
Business meeting and AGM The October Business Meeting & AGM was hosted at CBE+ in Chesterfield, where we were able to use their excellent training room for the whole day which included lunch and a site tour. The ISSB statistics provided by Steve Andrews led to a interesting and frank discussion amongst members and Steve offering clarity on various questions concerning the global marketplace and reasons behind the variances. Angela Taylor Director
Vice Chair Appointment Further to my request for nominations and a vote at the AGM held on 14th October, I am delighted to confirm that Kevin Parkin has been appointed Vice Chair. Many of you will know Kevin from our regular meetings and appreciate his wealth of industrial experience as a Managing Director / CEO / NED / Chairman / Coach and Investor with considerable MBO and disposal experience within Manufacturing Companies, and currently Chairman of Castings Technology International Ltd. Angela Taylor Director
L-R: Chairman - Graham Honeyman, Director - Angela Taylor, Vice Chair - Kevin Parkin
Wedding congratulations Congratulations to our Chairman, Graham Honeyman and new wife Paula. On behalf of the members of the BMPCA, I would like to pass on our congratulations and very best wishes for a long and happy marriage to Graham and his wife Paula who got married in Crete on 8 September. 2
50th Anniversary Lunch A big thank you to all who could make it to the 50th Anniversary Lunch which was held at the Cutlers’ Hall, Sheffield in August following a year of online meetings. The Cutlers’ Hall was a great venue
for our first face to face gathering, after such a difficult year when
some many events had been postponed or cancelled. It was a pleasure to meet so many of you for the first time and I look forward to working with you and ensuring that the BMPCA continues to go from strength to strength. I would like to thank our speakers Professor Sir Keith Ridgway and Graham Honeyman CBE for sharing their thoughts. We had planned to formally present Elizabeth with a thank you gift for her hard work over the last 4 years, however Elizabeth was unexpectedly unable to join us. It was my pleasure to pass on our gifts a couple of weeks later which she was delighted to accept.
Congratulations to our champagne winner
To celebrate our 50th anniversary, we held a draw for a bottle of Champagne and the winner was Mark Russell – Managing Director of Cutting & Wear. Angela Taylor Director
ABOVE: The UK will need to quadruple its low-carbon generation by 2050 if it's to meet anticipated electricity demands
Grab the nuclear opportunity To meet anticipated electricity demands, the UK will need to quadruple its low-carbon generation by 2050. Andrew Storer reflects on the vital role of nuclear on the road to net zero
ith the latest warnings from the Intergovernmental Panel on Climate Change, and November’s UN Climate Change Conference in Glasgow (COP26) looking like a last chance to agree on international action against
unchecked global heating, we all need to think about what it will take to reach net zero emissions. Decarbonising our electricity supply is an obvious priority. We have the tools to deliver but, with the clock ticking, the UK has yet to commit
Andrew Storer is CEO of the HVM Catapult’s Nuclear Advanced Manufacturing Research Centre
RIGHT: Without nuclear working alongside renewables and other technologies, we have next to no chance of reaching net zero to the intensive action and investment needed to deploy them. Getting moving now is essential if we are to reach our net zero ambition for 2050 and capitalise on real economic benefits to be won as we restart the economy. By 2050, total electricity demand in the UK is expected to double as we complete the transition to electric vehicles and low-carbon heating. To meet that demand and to maintain progress to net zero, the UK will need to quadruple its low-carbon generation by 2050. Today, around half of our electricity comes from low-carbon sources, with nuclear contributing some 40 percent of that. It’s a vital ingredient in the UK’s energy mix, providing a low-carbon source of firm, reliable power when the sun doesn’t shine and the winds don’t blow. New nuclear technology Around the world, climate scientists are clear that the world’s climate objectives will not be met if nuclear technologies are excluded. But here in the UK there’s a problem. Our nuclear fleet is aging. Every existing nuclear power plant will have ceased operation well before 2050, in fact all but one perhaps by 2030. We therefore need an ambitious domestic nuclear programme based on existing and new technologies to deliver the power the UK will need without pumping carbon into our atmosphere. And investing in nuclear now, will also open up deeper decarbonisation opportunities including more efficient hydrogen generation, synthetic fuel production, and much more. Nuclear investment will also put the UK at the helm of a growing world market. Every nation in the world faces a similar electricity challenge: growing demand and the urgent need to decarbonise. With new types of reactors getting closer to the market, including the more flexible and affordable small modular reactors (SMRs), there is a very real opportunity for British companies to take the lead using their manufacturing expertise and innovation to reduce the cost of the low-carbon transition while driving economic growth and creating jobs across our industrial heartlands.
Nuclear investment will also put the UK at the helm of a growing world market. Every nation in the world faces a similar electricity challenge: growing demand and the urgent need to decarbonise Andrew Storer is CEO of the HVM Catapult’s Nuclear Advanced Manufacturing Research Centre
Decarbonising our electricity supply is an obvious priority. We have the tools to deliver but, with the clock ticking, the UK has yet to commit to the intensive action and investment needed to deploy them. Creating jobs The High Value Manufacturing Catapult’s Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC), part of the University of Sheffield, is a vital part of making sure that the UK can seize that opportunity. The team is deeply involved with pre-production development of the Rolls-Royce SMR, a compact 470MW power plant designed to avoid the challenges afflicting gigawatt-scale reactors. The first plant could be in operation around 2030, with up to 80 percent by value of components set to be made in factories in the Midlands and North of England – creating some 6,000 jobs by 2025, and 40,000 by 2035. BELOW: The HVM Catapult is hosting the first Nuclear Manufacturing Summit in November
Beyond that, there’s a new generation of advanced modular reactors (AMRs) in early-stage development. These include hightemperature gas reactors which could revolutionise hydrogen production and cogeneration; and commercial fusion reactors for truly limitless emission-free power. Without nuclear working alongside renewables and other technologies, we have next to no chance of reaching net zero emissions. We also face the loss of skilled jobs in some of the most economically challenged parts of the country, and the loss of vital skills and capabilities throughout the supply chain. For nuclear to play its full role in the energy mix, we urgently need to see action and leadership from government. Earlier this year, I worked closely with MPs and industry partners to understand what needs to happen in the current Parliament. That identified 10 key actions, such as legislating for a new financing model to unlock gigawatt-scale projects such as Sizewell C, and support for SMR and AMR development. Economic benefits The potential economic benefits are immense. Investment in new nuclear capacity could bring as many as 300,000 jobs and £33bn of added annual economic value across the UK, the chance to regain our global lead in technology, and some fantastic opportunities for nuclear-ready manufacturers. To help the supply chain understand the host of nuclear technologies under development in the UK – and, most importantly, to connect manufacturers with buyers – we are hosting the first Nuclear Manufacturing Summit in November. The two-day event will provide vital information about opportunities in the key nuclear programmes, what you need to do to win work now and over the next 30 years, and how we can work together as an industry to meet the challenges. We have speakers from all the big nuclear programmes – covering new build, SMRs and AMRs, and decommissioning – plus one-to-one sessions to help you really explore the opportunities with the buyers.
More info www.nuclearmanufacturingsummit.co.uk
2021-2022 EVENTS 08-12 NOV 2021
SUSTAINABLE INDUSTRY 4.0 UNLEASHED
L I TA
T AC K
Digital Manufacturing Week brings together ideas, experience and energy across a range of events engineered to support manufacturers at all levels of their digital journey. Driven by expert content, valuable peer to peer interaction and the best solutions available - listen to the world’s best speakers, see the newest and best tech, and experience global subject matter experts and solution providers. Join thousands of visitors, have important conversations, and expand your professional network. Read on to find out more about the core events...
10-11 NOV 2021
INDUSTRY’S BIGGEST DIGITAL MANUFACTURING SHOW
Exhibition Centre Liverpool
For the sixth year, Smart Factory Expo brings together all the technologies enabling the digital manufacturing revolution – creating a carefully-curated shop window for manufacturers at all stages of their digital journey. The exhibition is spread out across eight distinct Visitor Zones, each of them anchored by a Solutions Theatre with free-to-attend presentations from manufacturing and technology experts..
10-11 NOV 2021
10-11 NOV 2021
SUSTAINABLE GROWTH THROUGH DIGITALISATION
Over the 2 days we will be covering key strategic, business and technical challenges across the manufacturing ecosystem – with maximum opportunity to network, debate and engage with your peers. Manufacturing Leaders’ Summit is the go-to event for 2021. For businesses with a turnover >£100m.
Virtual & ACC Liverpool
9-11 10 NOV 2021 NOVEMBER ACC Liverpool
MakingCELEBRATING Digital a INDIVIDUAL Reality ACHIEVEMENT
DIGITALISING MANUFACTURING CONFERENCE 2021
THE SCALE UP SUMMIT FOR BRITISH MANUFACTURING
A crash course in business growth tailored for the strategic leaders of SME manufacturers - linking together strategy, product, and the workforce to your wider business ecosystem.
World-class, case-study driven content delivered by best-in-class manufacturing speakers from around the globe.
09-11 NOV 2021
SME GROWTH SUMMIT
The Summit is designed to identify the most effective avenues of growth and equip you to act on them - growing your revenue, profitability, and workforce, as well as dealing with the growing pains that come with business growth. For businesses with a turnover <£100m.
DIGITALISING MANUFACTURING CONFERENCE
MTC bring their Digitalising Manufacturing Conference to Digital Manufacturing Week! Consisting of four content modules spread over three days, the first two on Tuesday will be fully virtual and the third and fourth delivered as the morning sessions of SME Growth Summit.
11 NOV 2021 ACC Liverpool
CELEBRATING MANUFACTURING EXCELLENCE
Find out more: www.digital-manufacturing-week.com www.bmpca.org.uk
Measuring Metal Coating Thickness at Line Using the Thermo Scientific Niton XL5 Plus XRF Analyzer Author: M. Bauer, Thermo Fisher Scientific, Tewksbury, MA USA Introduction Metal coatings are applied on all kinds of items made of metals, alloys and plastics either for decorative purposes or to optimize the physical and chemical properties of their surface (corrosion, wear and heat resistance, hardness, electrical conductivity, adhesion, solderability or lubricity). Over coating can significantly increase the cost of manufacturing, but under coating can cause dramatic product failure. That is why controlling the coat weight or the coating thickness is essential in metal finishing, fabrication, automotive and aerospace industries. Among available technologies for measurement of metal coat weight, X-ray fluorescence (XRF) spectrometry has numerous advantages: it is non-destructive and element specific, and it delivers very accurate results.1 Nevertheless, for certain elements XRF cannot measure metal layers that are too thick or purely organic coatings. For many years, this was addressed by bringing the specimen to be analyzed inside or close to the analyzer chamber so it could be analyzed by benchtop XRF. Measuring coating thickness on large and heavy parts was impractical without cutting samples. This limitation can be overcome using handheld XRF. The Thermo Scientific™ Niton™ XL5 Plus, the smallest, lightest and most powerful tube-based handheld XRF analyzer, accurately measures the coat weight or coating thickness of metals in seconds. The non-destructive analysis is done directly at-line for process control or on-site for finished products. Operators can analyze large 8
The Niton XL5 Plus Handheld XRF Analyzer
and heavy parts directly, increasing productivity and improving efficiency. Having to cut samples and bring them to the lab belongs to the past.
Measuring Metal Coating Thickness at Line Using the Thermo Scientific Niton XL5 Plus XRF Analyzer Conclusion To ensure customer coating specifications are met, quality control at-line, online or during final product inspection is a necessity. The Niton XL5 Plus analyzer assists the operator to: • Ensure goods received match purchase orders by measuring metal grade and composition • Reduce production costs by minimizing production errors
References 1. S. Piorek, Coatings, Paint and Thin Film Deposits, Chapter 4 in Portable X-ray Fluorescence Spectrometry Capabilities for In Situ Analysis, Edited by Philip Potts and Margaret West, RSC Publishing 2008 2. ASTM B568-98 (2009) Standard Test Method for Measurement of Coating Thickness by X-Ray Spectrometry. 3. ISO 3497-2000-Measurements of coating thickness – X-ray spectrometric methods.
- Coatings that are too thin can result in poor corrosion resistance, high warranty costs and/or product failure - Coatings that are too thick give money away by using more product than is necessary - Non-destructive analysis means there is no need to cut or damage high-value product • Improve quality by ensuring consistent coating across a product via multiple measurements and automatic averaging • Provide faster turnaround with immediate results and no sample preparation (versus statistical sampling followed by lab analysis which is time consuming) • Generate quality reports and certificates through simple report generation tools • Create audit trails of product from goods incoming inspection to products out the door • Achieve peace of mind with compliance to international methods ISO 3497 and ASTM B568 The Niton XL5 Plus Coatings Mode provides a significant step forward from the traditional process of metal identification and composition measurement.
Learn more at thermofisher.com/portableid Americas
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Metals Industry Apprentice of the Year Competition 2022 THE WORSHIPFUL COMPANY OF TIN PLATE WORKERS ALIAS WIRE WORKERS
Two annual awards to recognise exceptional development, high level skills and commitment to progression amongst apprentices in the metals industry.
How to apply
Now in its 23rd year, the Metals Industry Apprentice of the Year competition
Applications are invited from current apprentices, or apprentices who have completed their apprenticeship since 1 January 2021, in any job or position in a UK metals company. The judges will be looking for apprentices who have made exceptional progress in developing their knowledge, skills and career in metals. They will also be seeking apprentices who have made an outstanding contribution to their company, and those who can demonstrate the greatest development during their apprenticeship. Evidence of “distance travelled”, in terms of individual achievement, together with contribution and commitment to the company will be as important as having achieved advanced skills or qualifications.
Each Award Winner will receive:
is sponsored by The Worshipful Company of Tin Plate Workers alias Wire Workers. There are two awards: Career Development Award: designed to encourage and reward exceptional personal development and commitment to career progression. Craft Skills Award: designed to encourage and reward the achievement of high level, practical, ‘hands-on’ engineering, metallurgy or manufacturing skills. The Competition seeks to raise awareness of the vital contribution that apprentices make, both to their companies and the metals industry as a whole. Both awards have excellent prizes. Previous winners have gone on to achieve significant operational roles in the industry.
Application deadline: Friday 18th February 2022 The application form, completed by the apprentice, together with a letter of recommendation from a manager in their company, should be sent by e-mail to: Elizabeth Bonfield, Worshipful Company of Tin Plate Workers alias Wire Workers at email@example.com Contact Elizabeth for an application form. 10
A cheque for £1,200, to spend on personal IT equipment A place at the official presentation dinner: Court Dinner of The Worshipful Company of Tin Plate Workers alias Wireworkers, at Apothecaries’ Hall in the City of London, on Tuesday 24 May 2022. [A payment of £200 will also be made towards overnight accommodation in London and travel expenses] A senior Director of the Award Winner’s company will also be invited. The Runner-up for each Award will receive a cheque for £100.
Our 2020 Metals Industry Apprentices of the Year were Matt Mills (William Hare Ltd) for Career Development; and Jack Ramos (William Hare Ltd) for Craft Skills.
PRECISION ENGINEERING 3D ADDITIVE MANUFACTURING REVERSE ENGINEERING TOOLMAKING
Precision Engineering at Agemaspark Agemaspark Ltd is a precision engineering company, founded in Doncaster in 2002, that serves industries including the aerospace sector for civil and military aircraft engines and power generation turbine engines, the Oil & Gas industry providing bespoke tooling aids, plastic mould tools for medical components, building products and caps and closure tooling for food industries along with many more sectors that require mould tools. We assist many businesses to solve their engineering problems to produce many individual components for a wide range of sectors.
Conformal cooling in mould tools is reducing both quality errors and cooling time Conventional mould tool making has limitations, meaning the moulds are being designed larger and larger so they can take more impressions to increase numbers of components and keep up with demand. As a result, the moulding machines are being supplied as large operational units taking up significant factory space and requiring high energy for operation. Laser sintering has been demonstrated to be a more effective manufacturing process for mould tool making. However, there remain barriers to its application for mould tooling in the plastic caps and closures industry due to concerns around the mould cooling technology and the need to provide enduring wear resistance. The current cooling channels are straight drilled and cause lengthy and uneven cooling, which often results in the formation of hot spots and high scrap rates. Conformal cooling works by creating a suitable cooling channel at a well-defined distance from the cavity—which is impossible using a conventional drilled cooling mechanism—thereby reaching areas where it is
20% reduction in cycle time
Results show that it is possible to reduce cycle times by up to 20% and at the same time increase the continued quality of the moulding.
difficult to do so using conventional methods. The temperature sensors embedded on each cavity will enable effective control of the cooling. Agemaspark seeks to overcome these barriers by developing a highly efficient advanced manufacturing process for the production of laser sintered mould tools with a novel ceramic coating. The mould tools will make use of the breakthrough process utilising conformal cooling channels embedded with temperature control sensors enabling localised temperature control. This will overcome inherent deficiencies in the current plastic caps and closures mould tooling technology (below left). In December 2020, we purchased an EOS 290 which is already demonstrating examples of how we can produce conformal cool in Maraging Steel with a hardness of 54 Rc, and if required, apply a ceramic coat to give increased tool life and a friction free release (below right). Agemaspark has used this approach on existing tooling by removing the tops and re-sintering with conformal cooling channels replacing the moulding area.
reduction in energy use with increased impressions
huge reduction in cooling water to only
Environmental advantages with this method Cooling water requirements reduced from by increasing the impression on the same tens of thousands of litres used in any 24 envelope or reducing the size of the tools hours to just 10-20 litres because the heat and therefore the size of the mould press, transfer is just local to the moulding and is reducing energy consumption. contained in a closed loop system (below centre).
Sarclad Launches New On-line Stand Condition Monitor Sarclad has unveiled and launched a new In-Chain strand Condition monitor for the steel industry. The robust Caliper designed unit is designed to provide steel producers with fully automated gap measurements data from every cast sequence produced. This continuous feed of data will allow the operator to spot trends more readily and make any necessary changes to optimise caster conditions more quickly. Grant McBain, Head of Sales at Sarclad expects the efficiency gains for the customer to be several fold. ‘’The Caliper is actually fitted to the caster chain, so it offers seamless integration with the caster activities avoiding the need for downtime for an operator to insert or remove, maximising production time. Equally, the enhanced caster control that provision of measurement data 100% of the time enables, should lead to a reduction in cast rejections caused by sub optimal conditions’.
With a nickel plated, stainless steel body and ability to retract to avoid contact with the drive rolls, the Caliper in-chain is designed to provide an unrivalled longevity despite the harsh operating conditions within which it performs. It can be used as a stand-alone measure or in conjunction with an offline Sarclad Strand Condition
First of 3! The first of three Downlegs fabricated in our 50,000 sq ft facility in Bedwas, loaded and off to the painters.
Monitor, that can be inserted periodically to cover a wider range of measures. Sarclad has already received its first order In-Chain Caliper order from a leading European steel producer and expects firm uptake for the unit in 2022 aided by buoyant steel market conditions currently being experienced.
www.metalock.co.uk Metalock Engineering UK Ltd have been in existence for 73 years and have been involved in thousands of repair projects around the world. Metalock Engineering UK focus on specialised site services: In Situ Machining, Cold Metalock Casting Repairs, Metrology/Alignment, Laser tracking, 3D laser Scanning, Orbital Welding, Thermal Spraying, Shaft journal recovery, Crankpin journal machining. After
Laser guided machining 22 meter diameter mooring buoy for FPSO
For every failed bearing there is a damaged journal diameter.
CNC milling machining Re-machining the worn vertical platen on Injection Moulding press
Our success in recent years has been based on the constant development of the specialised services our company offers and also the implementation of the latest design hardware and software that has enabled us to design and develop complex and accurate portable CNC (Computerized Numerical Control) machining equipment for all kinds of on-site machining applications.
Shaft recovery using orbital welding and machining techniques
On completion of testing procedures, we now hold the Zurich Welding Procedure Approval Test Certificate for orbital welding. The code testing was BS EN ISO 15613:2004 for fully mechanised MAG 135 Build Up Welding and this will be used in conjunction with our orbital machining equipment of the recovery of damaged bearing journals diameters. In April 2021 Metalock Engineering UK were awarded the Lloyds Register Certificate of Thermal Spraying Approval covering our thermal spraying repair works. This is also another technique we use in journal recovery to build up worn journal diameters before using our orbital machining equipment to re-machine the journal to the original size.
Laser guided facing machine in hydro turbine
Our company has also designed and built Laser Guided facing machines to machine flat surfaces from 3 meters diameter to over 25 meters diameter if required.
Metal spraying to resurface a worn drying cylinder before regrinding in situ
UK BASED OFFICES LOCATED IN ENGLAND +44 2476 338205
WALES +44 1646 622499
Metalock Engineering UK has been approved by Lloyd’s Register to the following standards: ISO 14001:2015, ISO 45001:2018, ISO 9001:2015 SSiP (Safety Schemes in Procurement)
SCOTLAND +44 141 891 5323
Sheffield Forgemasters gains coveted testing accreditation
heffield Forgemasters has been granted a coveted material testing accreditation for civil nuclear applications and work on the UK submarine programme. The company has secured Fracture Toughness certifications, ASTM E1820-20b and ASTM E1921-20 by the United Kingdom Accreditation Service (UKAS), making it one of a handful of UK organisations with this level of qualification. Securing the accreditation required significant spending on new testing equipment and the establishment of highly complex processes to undertake the tests, but having done so, we passed the accreditation at the first evaluation. Jesus Talamantes-Silva, research, design and technology director, said: “Securing the Fracture Toughness
accreditations to these levels is a significant milestone for our testhouse facility and will improve our testing time-frames and dramatically reduce costs.” “Prior to this certification, we were subjected to long waiting times on test pieces that were sent out of the company and the costs of outsourcing such tests were significant.” “These tests are crucial in the production of many safety-critical components that we manufacture, including those used in defence and civil nuclear power applications.” UKAS is the national accreditation body for the United Kingdom, appointed by government, to assess organisations that provide certification, testing, inspection and calibration services and it lists Sheffield Forgemasters as an accredited testing laboratory on its website.
Jesus continued: “This capability is almost non-existent in the UK and we can use the testing for not only production work, but also in the R&D process, helping to define material characteristics for specific applications.” The tests can be carried out on materials at both high and low temperatures and Sheffield Forgemasters stipulated specifications for the testing machines, altering them to account for higher forces required to test welded materials. Jesus’ team are also adopting Digital Image Correlation as a revolutionary new way to monitor and measure the fracture testing. The tests are carried out by the deliberate creation of a microscopic crack in the test material, which is then forced to propagate, allowing the determination of a fracture toughness parameter, which can be used as a safety parameter in the design of nuclear components. Funding for the R&D elements of the Fracture Toughness project was part funded under the £26 million Advanced Manufacturing and Materials Programme as part of the Department for Business, Energy and Industrial Strategy’s £505 million Energy Innovation Programme.
Corewire Limited at the ECC2021 Conference
t was fantastic for us to attend and exhibit at the 12th European Electric Steelmaking Conference between 13-15 September. The event had an additional buzz with it being held in, Sheffield, the original “Steel City”, considered by many as the home of Steel. There was a significant focus on the environmental challenges the sector faces and the technologies for improving existing practices as well as introducing new. As an industry we are tasked with achieving, efficiency improvements and reducing the Carbon footprint that the sector is responsible for on a global level in a safe and sustainably way.
There were many presentations and conversations regarding safety, sustainability, recycling, reuse and the future of Steel and the industry. It was clear that everyone is pulling in the same direction to improve and achieve the required and necessary improvements the industry needs. With our Weldclad brand, we only play a very small part in the process with the reclamation, recycling and improvement of roll surfaces in operation and the development of the technology associated with them. However, this has an important yet positive impact.
With improved roll surface performance comes increased productivity, efficiency and usable uptime in the mills and continuous casters resulting in lower throughput of rolls, reduced reworking and scrapping. The small, marginal gains add up to the bigger global benefits. We look forward to being a part of this as well as the 13th European Electric Steelmaking Conference. We are certainly looking to the future and what that holds.
Electric and hydrogen steelmaking can overcome challenges of creating a decarbonised steel industry, conference told electric arc steelmaking and associated techniques.
The widespread introduction of electric arc furnaces and the adoption of hydrogen production processes will transform the global steel industry over the next two decades, the European Electric Steelmaking Conference was told. Chris McDonald, Chief Executive of the Teesside-based Materials Processing Institute, told delegates: “The majority of steel producers are looking for an alternative to existing blast furnaces, which emit large quantities of carbon dioxide and are likely to be phased out over the coming decades. “Electric arc furnaces, combined with hydrogen ironmaking, is the best alternative technology and we expect significant growth in electric steelmaking as production switches to this method between now and 2040.” The 12th European Electric Steelmaking Conference (EEC 2021) is the primary event for steelmakers, product specialists, and the steel sector supply chain, including academics and research and technology organisations, to share knowledge on current and future developments involving 16
In his keynote speech, entitled ‘Development of the UK Steel Industry’, Chris McDonald outlined how electric steelmaking, alongside hydrogen and, to some extent, carbon capture and storage, will meet the challenges of the transition to a future decarbonised and digitised steel industry. He said: “In previous years this was only of interest to those steel producers who used electric arc furnaces, but EEC 2021 has taken on huge new significance with the need to eliminate carbon dioxide emissions across the industry.” The Institute played a major role at the conference, delivering six keynote speeches and chairing three discussion sessions. It was awarded £22m by Innovate UK, the UK’s innovation agency, last year to lead the five-year PRISM research and innovation programme for the steel and metals sectors to increase competitiveness and sustainability. As part of its research into developing new climate friendly approaches to steelmaking that relies on hydrogen and electric arc furnaces, the Institute has developed a unique pilot scale electric arc steelmaking facility at its Teesside campus.
Chris added: “This is being used to trial alternative raw materials and to push the boundaries of electric steelmaking, to make ever more challenging steel products.” EEC 2021 was organised by IOM3 and staged in Sheffield, with a fully interactive virtual experience for those unable to attend in person. Visits for delegates were also organised to Liberty Steel at Rotherham and to the Institute’s research facilities at Middlesbrough. Tim Goodwin, Senior Liaison Metallurgist at Liberty Steel joined the party touring the Institute’s campus, which included seeing the electric arc furnace in operation and the ongoing investment in state-of-the art research equipment and facilities commented: “It is clear from what is on show today that the work being undertaken at the Materials Processing Institute will play a major role in developing new technologies to decarbonise steelmaking.”
SAVE THE DATE to hear about the latest academic thinking on ferrous metallurgy at this research symposium. Now in its fifth year, this symposium: • Enables PhD and EngD researchers and universities from across the UK to showcase their research. • Provides a forum for industry and academia to form strong and lasting networks and collaborate on projects.
Who should attend The symposium is relevant for all students, universities and industries involved in metals, materials, and process improvement. This research symposium gives PhD and EngD students, academics, industrial researchers and industry leaders the opportunity to showcase their research, attend presentations about specific research, find out about support available and network with one another.
“The Symposium is an inspirational opportunity for young researchers to showcase their work to academics and industrialists. The Symposium is an invaluable addition to the calendar for this strategically important sector of UK manufacturing, providing support for the academic and industrial collaboration that is essential to its success.” Professor Bill Bonfield CBE, Chairman, Armourers & Brasiers Materials Science Committee
• Inspires academia and research students to engage in the research challenges of the steel and metals sector.
Don’t miss out on this opportunity to be inspired and hear about the latest metallurgy research being carried out by some of the UK’s brightest students. Find out more and register at: https://www.mpiuk.com/ postgraduate-researchsymposium.htm Email: firstname.lastname@example.org Contact: Andrew Cargill – email@example.com Tel: 01642 382000
Castings Technology announces the appointment of Graham Honeyman CBE as non-executive director
We are delighted to announce the appointment of Graham Honeyman CBE as a Non-Executive Director. Chairman, Kevin Parkin said; “Graham and I have collaborated over many years and we have produced some world class solutions by bringing together our respective company skills
and capabilities. We also share a passion for good communications and the continuous development of our workforce.”
for Apprenticeships which provides talented young people with the training and opportunities that they deserve.
Graham will be collaborating closely with the executive team to support their corporate strategy for growth and business development.
Graham Honeyman said ‘It’s been a privilege to visit the manufacturing facility at Castings Technology and see first-hand the excellent technology they bring to the science and engineering of both steel and titanium products. I am delighted to have been offered the position of Non-Executive Director on the Castings Technology Board and I look forward to supporting their Business and Management Strategy in the future’
Graham, as former Chief Executive, led Sheffield Forgemasters for 16 years following the 2005 MBO, Graham brings a wealth of industrial knowledge and management experience to further strengthen and enhance the Castings Technology team. Graham continues to support the development of engineers through his involvement with the Institute
MBO team wins Sheffield region Deal of the Year (up to £2.5m) Deal of the Year (up to £2.5m)
Insider Sheffield City Region Dealmaker of the Year was won by Cti and we are delighted to receive this recognition and to thank the employees for their support, and the financial and legal advisers who helped secure this deal. 18
Winner: Management Buyout of Castings Technology International (CTI) (Castle Square Corporate Finance, Wake Smith, BHP, DLA Piper, Nucleus Commercial Finance, Gateley, Mercia Asset Management, Deloitte) The judges said the acquisition from Sheffield University saved jobs, will lead to job creation and had echoes of the Sheffield Forgemasters deals of the 1990s, albeit on a different scale.
“We were delighted to eventually get this complex deal over the line and to receive such great recognition from the hard work of our team, City Leaders and our professionals” Richard Cook, MD Castings Technology “This deal involved many local professionals who worked so hard to complete the deal. It was good to have a deal Made in Sheffield using a local cast!” Kevin Parkin, Executive Chairman Castings Technology
OVER 150 YEARS OF ENGINEERING EXCELLENCE SERVING ALL INDUSTRIAL SECTORS
Subcon was a positive event for OEL and it was great to get back out in front of people after so long away. This seemed to be the general consensus of all those who attended. Re-connecting with current clients and sowing the seeds for new relationships is what the event is about for us and there were plenty of good conversations about the changing face of UK Manufacturing and the anticipated upswing following recent events.
Subcon fell on the same week as DSEi which OEL also exhibited at proving to be an equally successful show given our pedigree in the sector. With an enhanced presence from previous years to further solidify our position as a leading supplier the team who attended also brought back the same confidence in UK Manufacturing and how we are well placed to support upcoming investment plans in UK MOD infrastructure.
T +44 (0) 161 627 5822 E firstname.lastname@example.org W oldham-eng.com Castle Iron Works, Overens Street, Oldham, Lancashire, OL4 1LA PROJECT MANAGEMENT & DETAILED ASSEMBLIES VIDEO https://tinyurl.com/3eym2k86
Innovative desulphurisation tech is tested at steelworks Indus trial tes ting of a new hot s t ove f or bl as t f urnace 4 at Chong qing Steel , which f eatures CIS D I 's sodium - based dr y desul phurisation tech , has been succes s f ul . Tes t resul t s met the designed target . The innovative S DS tech is f ul l y adapted t o hot s t ove f ume conditions , ensuring the desul phurisation s ys tem continuousl y and s tabl y meet s ul tra - l ow emis sions s tandards . I t resul t s in higher desul phurising ef ﬁ cienc y, simpl iﬁ ed proces s ﬂ ow and easier operation , and produces eco f riendl ier, easil y - dis po sabl e by - produc t s . The indus trial tes t has veriﬁ ed the
f easibil it y of CIS D I design s cheme and resulted in identif y ing the optimal desul phurising conditions f or the S DS method by tes ting dif f erent f ume temperatures , retention time, the grain size of the desul phurising agent and the sodium t o sul phur ratio s which af f ec t desul phurising ef ﬁ cienc y. Meanwhile, the indus trial tes t has measured the desul phurising concentrations at the outl et of the thioniser and the bag ﬁ l ter, t o check if the f ront- end simulation model and parameter s were f unc tioning accuratel y. This val uabl e tes ting data and resul t s l ay a sol id f oundation f or the projec t 's applic ation .
Siemens targets F&B industry digitalisation with revamped Solution Partner Programme
he module with top system integrators focuses on updated global best practices in sync with the productivity and decarbonisation agenda. The UK Food and Beverage industry, which had a turnover of more than £104.4bn in 2020 and represents almost 20% of total UK manufacturing1, is ripe for adoption of cutting-edge solutions that will boost productivity and improve energy efficiency to help combat climate change. Siemens, which has been at the forefront of empowering the Food & Beverage sector with technology solutions for decades, has enhanced its Solution Partner Programme for the specific needs of the sector, in collaboration with seven leading system integrators across the UK and Ireland. adi Automation – part of adi Group, Briggs of Burton PLC, CG Controls Ltd, DPS Group, iTech Ltd, Kigtek Solutions Ltd, and Rockbrook Engineering Ltd have been selected for their specific process knowledge, technology capability and are able to deliver the Siemens’ holistic solution. The revamped Solution Partner Programme brings to the table the whole gamut of offerings, including automation integration concepts,
process optimisation, cloud and data analytics and energy reduction initiatives. A key aspect of the F&B Siemens module is that it is in sync with the sector’s challenges around productivity, agility and the increasing priority of a decarbonisation agenda, which is set to attain huge importance in view of the climate change crisis and government’s decarbonisation programme. “Siemens’ global focus on the Food and Beverage sector is giving great insight into solving many of the sector’s manufacturing challenges,” said Keith Thornhill, Head of Food & Beverage UK and Ireland, Siemens Digital Industries. The new expert partners will have access to this best practice and with their domain knowledge will be able to assist customers with value added solutions, driving production efficiency with the deployed integrated technology.” “Our portfolio covers the depth and breadth of automation and digitalisation. By combining this incredible end-to-end offering with solution delivery expertise of the solution partners we are opening a whole new world of value driven solutions in Food & Beverage manufacturing.”
Thornhill explains: “With our new module, our expert partners will get monthly solutions training based on best practices from our experiences from around the globe. This will drive efficiency into their solution delivery and have the evidence to show ROI. Our goal is to give the end customer a de-risked integrated package, that is future proof and attainable. “Our partners will be able to offer advanced technology lead solutions with various financial options to cater for all budgets and aspirations. This will accelerate the decision-making process, deployment and bring business performance improvements from day one.” The Siemens Solution Partner Programme is a global initiative which certifies companies to integrate Siemens’ technology into businesses. Siemens works with over 1,600 solution partners in more than 80 countries, including 50 in the UK and Ireland’s F&B sector. The systems integrators’ role includes upgrading equipment, retrofitting the upgrade and generally looking at the bigger picture, with the ultimate goal of turning data into value.
BMPCA membership benefits Who are we? The BMPCA has been established for over 50 years with its roots in the metals industry, and now represents companies who provide equipment and services to manufacturing industry seeking innovation, collaboration and growth in the UK and throughout the world. Why should I join? If you work in the manufacturing and metallurgical industries our organisation offers you the opportunity to network with the major UK players. We hold four business meetings a year hosted by leading manufacturing companies, such as JCB, Siemens, Castings Technology International, these companies include a plant tour of their facilities in our visit to enable us to share in industry best practice. The networking and sharing of
information at these meetings have led to partnerships and technical cooperation agreements within the membership. The newsletter allows you to highlight your business in a professional format to the decision makers in the industry.
What do I get in terms of benefits? •
Regular UK Steel updates Major networking/social events eg The Annual Lunch at the Painters Hall in the City of London, six tickets are included in your yearly subscription Opportunities to promote your company’s products and services in our packs that are distributed to trade events Quarterly ISSB information and presentations on the global steel industry and energy price trends Quarterly business meetings on company sites inc. technical expert sessions, eg. Energy Email bulletins on forthcoming conferences.
All members benefit from the Strategic Partnership with The Manufacturer. This includes online access to information for manufacturers, exclusive subscriber benefits such as webinars, podcasts complimentary places for conferences, sponsorship and advertising prospects
Opportunity to promote your business in the newsletter Company news in the bulletin
Contact Angela Taylor, Director on email@example.com or 07739 338305.
BMPCA membership rates
How do I join?
Company news in the bulletin magazine - produced 3 times a year.
Regular UK Steel updates.
Quaterly business meetings on company sites inc. technical expert sessions, eg Energy.
Email bulletins on forthcoming conferences.
Strategic Partnership with The Manufacturer. This inc. online access to information for manufacturers, exclusive subscriber benefits such as webinars, podcasts, complimentary places for conferences, sponsorship and advertising proposals.
Six tickets for the Annual Lunch.
Opportunities to promote your company’s products and services in our packs that are distributed to trade events.
Quarterly ISSB information and presentations on the global steel industry and energy price trends. Cost
• £250 + VAT
£2,600 + VAT
BMPCA Pin Badges
BMPCA Enamel Pin Badges are still available from Angela—please wear them to help raise the profile of the Association.
BMPCA Annual Lunch 2022 Please see initial details for our Annual Lunch. There will be a networking opportunity over reception drinks starting at 11.30am to ensure that you have an opportunity to promote and share information about your own organisations prior lunch. All the arrangements will be finalised prior to the end of the year.
Thursday 7th April 2022
The Old Library, Zellig, Gibb Street, Digbeth, Birmingham, B9 4AA
The original library first opened as one of Birmingham’s 5 free libraries in 1866, it is now the only one still standing. The public library’s doors closed in 1940 and remained closed until 1990 when the dilapidated space was bought alongside the Bird’s Custard Factory and lovingly refurbished by Bennie Gray. The building was then leased to another company from 2004 until August 2017 when it has been returned to its original owner. Times: 11.30am Welcome drinks on arrival 1.00pm Lunch including wine and port 4.30pm Close Dress code:
Closing date for tickets is the Friday 18th March 2022 6 places are included in full annual membership. Additional tickets will be available, price to be confirmed. To book your place please contact Angela Taylor , Director, BMPCA on +44 (0) 7739 338305 or email firstname.lastname@example.org www.bmpca.org.uk
Meeting of the APPG for Steel on the Energy Price Crisis This week, UK Steel was invited The APPG for Steel met yesterday, so that both UK Steel and Community could update members on the current ‘energy price crisis’. UK Steel was keen to stress that for steel, the key message is the price disparity between the UK and continental Europe for electricity prices, where we are seeing wholesale prices in the UK triple that paid by steel companies in Germany. MPs were informed that the dramatic and outrageous price spikes are still very much a critical challenge for UK steel companies. With prices over £1,000MWh last
Friday night, when normally this would be a calm period for prices, the market is still not approaching normality. As such, what the steel sector needs from Government is not loans, but to provide us with a level playing field on wholesale electricity prices and policy costs, at the same level that European steel competitors are today, tomorrow and in the future, are paying. This is not about handouts, or subsidies, but an opportunity for the Chancellor to pick up the can that has been kicked down the road by successive administrations and demonstrate his confidence and backing for the steel sector
and its workers in Wales, Yorkshire, Humberside and elsewhere across the UK. Places at the very heart of Prime Minister’s levelling up agenda. Mr Sunak can bring forward measures that would finally end the electricity price disparity between British steelmakers and their European competitors. It’s this, now significantly increasing, disparity in prices that has led to our steel sector being so much more damaged by the current cost of energy than other European steel sectors. www.bmpca.org.uk
Future BMPCA Dates
2021 Business Meetings Thursday 9th December Business Meeting 2022 Business Meetings Thursday 10th March
Thursday 9th June
Annual Lunch 2022 The Old Library, Birmingham Thursday 7th April 2022 See inside for full details
BMPCA Bulletin Dates Deadline Date Fri 15 Oct 2021 Fri 14 January 2022
Publication Date Mon 1 Nov 2021 Mon 7 February 2022
Fri 27 May 2022
Mon 6 June 2022 Associate Members Elizabeth Bonfield Nigel Leeson Kevin Parkin
British Manufacturing Plant Constructors Association (BMPCA) c/o Allen West & Foster, Omega Court, 364-366 Cemetery Road, Sheffield, S11 8FT Tel: +44 (0) 7739 338305 Email: email@example.com www.bmpca.org.uk