Steel Times International Digital August 2020

INNOVATIONS

INDUSTRY NEWS ROUND-UP

ENVIRONMENT

HISTORY

Pages and pages of the latest new products and recent contracts

A six-page round-up of the latest global steel industry news

Turboden’s Sabrina Santarossa discusses EAF waste heat recovery

If you thought the USA’s Hoover Dam was only made of concrete, think again!

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CONTENTS DIGITAL EDITION – AUGUST 2020

INNOVATIONS

INDUSTRY NEWS ROUND-UP

ENVIRONMENT

HISTORY

Pages and pages of the latest new products and recent contracts

A six-page round-up of the latest global steel industry news

Turboden’s Sabrina Santarossa discusses EAF waste heat recovery

If you thought the USA’s Hoover Dam was only made of concrete, think again!

Front cover photo courtesy of Since 1866

Friedrich Kocks GmbH & Co KG www.steeltimesint.com Digital Edition - August 2020 - No.15

Quality made in Germany – KOCKS workshop 4.0 in Bremen, Germany

1

2 Leader

by Matthew Moggridge.

4 News round-up The latest global steel news.

HYDROGEN STEELMAKING – AN INDIAN PERSPECTIVE

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com Consultant Editor Dr. Tim Smith PhD, CEng, MIM Production Editor Annie Baker Advertisement Production Martin Lawrence SALES International Sales Manager Paul Rossage paulrossage@quartzltd.com Tel: +44 (0) 1737 855116 Sales Director Ken Clark kenclark@quartzltd.com Tel: +44 (0) 1737 855117 Managing Director Tony Crinion tonycrinion@quartzltd.com Tel: +44 (0) 1737 855164 Chief Executive Officer Steve Diprose SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com

10 Innovations The latest new products and contracts.

28 Sustainability Sustainable production planning 32 Environment 32 Low-emission steelmaking.

38 Ecosystems, environment and hot data.

46 Hydrogen-based green ironmaking for a low carbon environment.

60 Special and stainless steels Making light of heavy vehicles.

4

64 Oxygen steelmaking Elemental, my dear Watson.

68 History Steel: The backbone of Hoover Dam.

Steel Times International is published eight times a year and is available on subscription. Annual subscription: UK £178.00 Other countries: £254.00 2 years subscription: UK £320.00 Other countries: £457.00 ) Single copy (inc postage): £40.00 Email: steel@quartzltd.com Published by: Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, England.

Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034

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2

LEADER

Life goes on and confidence will return

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

Digital Edition - August 2020

I will always remember the closing line in the movie, It’s Alive, a horror film about mutant babies. At least I think that’s what it was about; you can probably find out more by Googling it. Anyway, the closing quote: ‘Another one’s been born in Seattle’.

Despite all the attempts of the ‘good guys’ to eradicate the problem, another mutant was born in Seattle, paving the way, perhaps, for It’s Alive 2. If it exists, I never saw it.

These days, of course, that word ‘sequel’ is old hat. Instead, we have ‘second wave’ and everybody’s talking about a second wave of corona virus and the potential of another ‘lockdown’. Here in the UK they are having localised lockdowns wherever a virus flare-up occurs, and I can’t say that anybody’s looking forward to the winter months.

The whole situation is strange at the moment, and every nation is at a different stage of development: some are easing lockdown rules, others are still fighting to keep a lid on the pandemic, and meanwhile the world carries on doing its own thing. The global steel industry is no exception. There’s good news and there’s bad news. Blast furnaces are

being restarted, but some are still idled, awards are being presented (POSCO and Fives Group won big at the recent Global Metal Awards) and trade wars continue unabated – and now Indian steelmakers are getting involved. JSW Group is talking about cutting trade links with China following military tensions.

Where steel and the environment is concerned, Hybrit has announced successful fossil-free trials; leading plant builders are busy supplying steel manufacturing technology to steelmakers around the world and there are many notable examples: Berry Metal Company commissioning a state-of-the-art lime injection system for US-based Big River Steel; ThyssenKrupp announcing plans to invest in a new walking beam furnace; ArcelorMittal intending to build an EAF facility at its Calvert plant in the USA. Life goes on and will improve as we hurtle towards the New Year when, hopefully, confidence will return, the live conference circuit will re-establish itself and steel industry executives will find time to meet with their peers to share experiences and discuss the way out of the crisis for good.

www.steeltimesint.com

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4

NEWS ROUND-UP

• Society publication Tatler reports that Lakshmi Mittal’s brother Pramod has been declared bankrupt with debts of £130 million. Quoting the original source of the story (The Times), the magazine says that the two brothers are estranged and live separate lives. It is alleged that Pramod is suffering financially after being caught up in investigations into organised crime.

Source: Tatler, 29 June 2020.

• Voestalpine Railway Systems is expanding globally through acquisition. The company has purchased Lietaert Industrial Equipment Company in France with a view to supplying the French national railway company, SNCF. Lietart is described as a ‘turnout manufacturing plant’ based near Paris. There are plans to expand activities in other areas where SNCF is active, such as North Africa.

In railway terminology, a ‘turnout’ is a set of points that guide a train from one track to another.

Source: International Railway Journal, 30 June 2020.

• South Korean steelmaker Hyundai Steel plans to speed up the development of high strength steels for the automotive market and give itself a head start on its competitors. Last year the company developed 218 different types of ultra high strength steel (UHSS) and this year the plan is to make 1Mt of steel plate and supply it to leading car makers around the world.

Source: The Investor, 30 June 2020.

• US Steel’s number six blast furnace at its Gary Works in Indiana, USA, was restarted after the 4 July holiday weekend following closure in April due to the COVID-19 pandemic.

According to the company it was being restarted to meet increased demand.

Source: Argus Media, 30 June 2020.

• Pomini Tenova, a leading global specialist in the production of roll grinders, completed the installation of three roll grinders for the Hoa Phat Group, one of the largest manufacturers of construction steels, coated steels and steel pipes in Vietnam. The Italian plant builder claims it has now installed and successfully commissioned 18 machines in the country.

Source: Tenova, 1 July 2020.

• Steelmakers in China and Thailand are both working with Italian plant builder Danieli. In China, Changshu Longteng Special Steel has ordered a 400kt/yr continuous mill for flat bar products. A new SBQ mill and wire rod line was recently started up at the same site and was also supplied by Danieli. In Thailand, Sahaviriya Steel Industries contracted the Italian plant builder to replace a downcoiler reel for its Bang Saphan hot strip mill.

Source: Danieli, 1 July 2020.

• German plant builder SMS group has acquired two Brazilbased companies, joined them together and renamed the business Vetta Tecnologia SA. The two companies – Viridis and Vetta – were both based in Bela Horizonte, Brazil, and specialised in industrial digitalisation, with emphasis on efficiency and sustainability.

Source: SMS group, 1 July 2020.

• 1 July will go down in history as the day when the muchdiscussed USMCA went into effect. For those who have been living in a cave, the USMCA is an agreement between the USA, Mexico and Canada that supersedes NAFTA, the North American Free Trade Agreement, which came into force back in the early nineties. Some people refer to the USMCA as NAFTA 2.0.

Source: Steel Times International, 1 July 2020.

Digital Edition - August 2020

www.steeltimesint.com

NEWS ROUND-UP

• Two leading steelmakers have been recognised by General Motors in their annual awards. Nucor Corporation was named the automaker’s Supplier of the Year and remains the only electric arc furnace steelmaker to receive the award. ArcelorMittal was recognised with the 2019 Supplier Quality Excellence Award, claiming that ‘only the best suppliers from around the globe were recognised and several ArcelorMittal facilities in North America were among the awardees’.

Source: Nucor Corporation and ArcelorMittal, 1 July 2020.

• Jindal Steel & Power (Mauritius) aka JSPML has divested its entire stake in Jindal Shadeed Iron and Steel (JSIS Oman). The aim of the decision is to bring down debt and deleverage its balance sheet. According to an online report, the enterprise value of the deal is over US$1 billion.

Source: Business Standard, 1 July 2020

• Steel Authority of India Ltd (SAIL) announced that it had shipped its first batch of R 260 grade vanadium alloyed rails for Indian Railways. The first consignment was sent out from SAIL’s Bhilai steel plant and the company has started to produce the rails at its Universal Rail Mill in Chhattisgarh.

Source: CNBVTV18.com, 1 July 2020.

• Liberty Steel’s head honcho Sanjeev Gupta says he is ready to look again at Tata Steel’s Port Talbot facility in what amounts to a repeat of his offer made three years ago when he nearly bought the plant. Tata is going through a rough time. It needs a Government bail-out in the UK and is experiencing industrial unrest in the Netherlands.

Source: Moneycontrol.com, 2 July 2020.

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• Russian steelmaker Severstal announces that maintenance work on one of its four blast furnaces at the company’s Mill 2000 facility will take around a year. The plan is to take the existing furnace down and build another one. The remaining three furnaces will ensure no loss of production.

Source: Steel Orbis.com, 1 July 2020.

• COVID-19 is delaying expansion plans at Indian steelmaker JSW. The company was planning a 5Mt/yr expansion of its Dolvi Works, taking it to 10Mt/yr, but with contractors heading home and a lack of foreign production technology experts, due to international travel restrictions, delays into the second half of FY21 are likely.

Source: Financial Express, 3 July 2020.

• South Korean steelmaker POSCO won the steel industry leadership award at the Global Metals Awards, hosted by S&P Global Platts. The company claims it received the award for its business performance during times of growing protectionism and worsening market conditions. It is also the only Korean recipient of a Global Metals Award and was a winner in 2018.

Source: The Korea Herald, 1 July 2020.

• The JSW Group’s Parth Jindal, managing director of JSW Cement, claims that the group as a whole will bring down $400 million worth of imports from China to zero in the space of two years (24 months). The JSW Group, headed up by Sajjan Jindal, Parth’s father, has its fingers in many pies in the steel, energy, cement and infrastructure sectors.

Source: Times of India, 3 July 2020.

Digital Edition - August 2020

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NEWS ROUND-UP

• Production at ArcelorMittal’s 370kt/yr coke plant in Monessen, PA, USA, was idled at the end of June because of the COVID-19 pandemic and its impact on the steel industry. The plant employs 180 people and there is no indication of when it might come back on stream.

Source: Steel Orbis, 3 July 2020.

• There won’t be any forced job cuts at Tata Steel’s Ijmuiden steel plant, according to the FNV union, following continuous strike action at the facility in protest against potential job losses of up to 1,000 people.

Source: CNBCTV18.com, 3 July 2020.

• Indian steelmaker Jindal Steel & Power produced more steel than its Indian peers in the quarter ended June 2020.

Production in June alone rose over 23% over preceding months and was up 37% yearon-year.

Source: Bloomberg, 7 July 2020.

Digital Edition - August 2020

• Sajjan Jindal, chairman of JSW Group, has talked about cutting trade links with China following military tensions between the two countries. He said his company was already looking at suppliers in Turkey and Brazil for his blast furnace refractories. Mr Jindal said he knows it won’t be easy to cut China out – 40% of auto industry components come from China – but commented: “If they (China) have killed 20 of my soldiers, I’m not going to buy products from them and strengthen their armies more.”

Source: Economic Times, 6 July 2020.

• The European steel industry has welcomed the launch of the European Commission’s Hydrogen Strategy for a Climate-Neutral Europe’, which sets out a plan to establish an integrated hydrogen energy network in Europe by 2050. “Clean energy at competitive prices is key to achieving the steel industry’s low-carbon goals,” said Axel Eggert, directorgeneral of the European Steel Association (EUROFER).

Source: EUROFER, 8 July 2020.

• Russian steelmaker Severstal has started to ship 100kt of ‘low-basic fluxed’ iron ore pellets to Companhia Siderurgica Nacional (CSN), Brazil’s largest fully integrated steelmaker.

Source: S&P Global Platts, 7 July 2020.

• Tenova Goodfellow, a Canadian subsidiary of Tenova, the Italian parent and part of the Techint Group, is collaborating with ArcelorMittal Dofasco on a new project surrounding the digital transformation of secondary metallurgy. The aim is to demonstrate how digitalisation can improve production by minimising manual intervention in the process, reducing process variation and improving final steel properties.

Source: India Education Diary.com, 9 July 2020. www.steeltimesint.com

NEWS ROUND-UP

• South Korean steelmaker POSCO claims it has restarted its third Gwangyang blast furnace following 20 months of maintenance and repair work estimated to have cost 400 billion won (US$332.6 million). The furnace’s production capacity has been increased by 25% to 4.6Mt, it is claimed.

Source: Yonhap News Agency, 10 July 2020.

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• Russian steelmaker NLMK Group’s flagship site in Lipetsk and the world leading industrial gas producer, Air Liquid, have signed a package of agreements on expanding co-operation. Under the newly signed agreements, Air Liquide will construct a cuttingedge air separation unit (ASU) in Lipetsk and purchase assets for producing hydrogen and rare gas concentrates from NLMK. Source: NLMK, 16 July 2020.

• GMB, the steel workers’ union, announces it is to hold urgent talks with Tata Steel over job loss fears following reports that plans exist to shut down two blast furnaces and replace them with electric arc furnaces (EAFs). Such a move, it is claimed, could lead to thousands of job losses in the UK. Source: GMB, 21 July 2020.

• Global production and use of molybdenum fell in Q1 when compared to the previous quarter (Q4 2019) according to figures published by the International Molybdenum Association (IMOA), a non-profit trade association representing the interests of most of the world’s molybdenum producers and converters, as well as users and traders.

Source: IMOA, 14 July 2020.

• State-owned steelmaker Steel Authority of India Ltd (SAIL) achieved domestic and export sales of 12.77 Lakh tonnes (1.27Mt) during the month of June. The figure represents a jump of over 18% when compared to last year’s corresponding figures. The company exported 3.4 Lakh tonnes (340kt) of steel and sold 42kt of pig iron.

Source: Hellenic Shipping News, 13 July 2020.

• Japanese car maker Toyota intends to buy some of its electrical steel from China’s Baowu Steel Group, forcing Japanese steelmakers to compete on price. The leading car maker’s endorsement of the Chinese steelmaker’s steel sheet means that the latter is catching up with Japanese rivals in terms of quality.

Source: Nikkei Asian Review, 13 July 2020.

• Roland Junck has been appointed as the new global lead for the GFG Alliance’s CN30 programme, responsible for delivering the company’s ambition to become carbon neutral by 2030.The role sits alongside his existing duties as president, LIBERTY Steel Group Europe & UK and will co-ordinate the GFG Alliance’s CN30 strategy and activities globally across R&D, technology, partnerships, commercialisation, supply chain, and public policy.

Source: Liberty Steel, 29 July 2020.

• Magnitogorsk Iron and Steel Works (MMK) has been awarded the international Energy Management Insight Award for energy saving and improving the energy efficiency of its production processes in accordance with ISO 50001.The steelmaker received the award at the Clean Energy Ministerial, a global international forum organised by the Energy Management Working Group (EMWG), part of the United Nations Industrial Development Organisation (UNIDO). Experts from 25 countries took part in the event. Source: MMK, 14 July 2020. www.steeltimesint.com

Digital Edition - August 2020

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NEWS ROUND-UP

• World crude steel production decreased by 7% in June 2020 when compared to June 2019, according to figures released by the World Steel Association (worldsteel).

The figures, compiled based on data supplied by the 64 countries reporting to the World Steel Association, showed that 148.3Mt of crude steel was produced last month based on estimated production due to the ongoing difficulties presented by the COVID-19 pandemic.

Source: World Steel Association, 29 July 2020.

• Tata Steel claims it is creating the next generation of schools in the United Kingdom (UK) which will give thousands of children access to education in safe, purposedesigned, environmentally efficient buildings. The company, working with construction industry experts in the UK, is developing a kit of parts allowing highly energy-efficient schools to be built off-site and then shipped to their final location.

Source: Tata Steel, 29 July 2020.

Digital Edition - August 2020

• NLMK Group, which claims to be the largest steelmaker in Russia, and one of the most efficient in the world, has completed a follow-up audit of its management systems in the areas of environmental protection, occupational health and safety, and energy efficiency. Amid the COVID-19 pandemic, the British Standards Institution (BSI) conducted the audit online.

Source: NLMK, 29 July 2020.

• The American Iron and Steel Institute (AISI) has applauded passage of a measure that would set sufficient funding levels for trade enforcement activities conducted by the International Trade Administration (ITA) Office of Enforcement and Compliance (E&C) to ensure adequate resources to combat unfair trade practices.

Source: AISI, 3 August 2020.

• A seaweed regeneration project initiated in November 2019 is bearing fruit, according to leading partner Nippon Steel Corporation.

The Japanese steelmaker, the coastal village of Tomari in the Furuu District of Hokkaido and the Furuu District Fisheries Co-operative Association launched the Creation of Sea Forests project late last year using something called the BeverlyTM Unit (an iron-supply steel slag product) in a seaweed bed that was lost because of sea ‘desertification’.

Source: Nippon Steel Corporation, 3 August 2020.

For more steel industry news and features, visit www.steeltimesint.com

• Trials using fossil-free fuels in LKAB’s pellet plant have produced successful results within the framework of the HYBRIT initiative. The world’s very first fossil-free iron ore pellets are within touching distance and the three companies involved in the project – SSAB, LKAB and Vattenfall – intend to be the first in the world with a value chain for fossil-free steel.

Source: HYBRIT, 3 August 2020.

• Fives Group and US steelmaker Steel Dynamics Columbus, which is being described as the most modern mini-mill in the US, has produced the first coil with a new continuous galvanising line (CGL 3) in Columbus, Mississippi, USA. The first prime coil was produced on 9 July, 2020 on time and in the midst of the COVID-19 pandemic.

Source: Fives Group, 3 August 2020.

www.steeltimesint.com

NEWS ROUND-UP

• British Steel is to resume operational control of Immingham Bulk Terminal (IBT), a British port handling millions of tonnes of the steel company’s raw materials. The move to ‘take back control’ follows acquisition by the Jingye Group. IBT is owned by Associated British Ports.

Source: Insider Media.com, 4 August 2020.

• A massive meltdown in demand has led to a sharp fall in earnings for Austrian steelmaker voestalpine. The company has posted an aftertax loss of 70 million Euros (US$82.6 million) and lays the blame firmly at the doorstep of the COVID-19 pandemic.

One year ago the company posted profits of 90 million Euros.

Source: Marketwatch.com, 5 August 2020.

• The US steel industry’s capacity utilisation rate rose to 59.3% for the week ending 1 August, with production standing at 1.33Mt (net tons), according to figures released by the American Iron and Steel Institute (AISI). The figures reflect an increase of 0.6% on the previous week’s figures when the rate stood at 58.9%.

Source: Metal Miner, 4 August 2020.

• Mark Bush has been appointed CEO of JSW Steel (USA) and JSW Steel Ohio.

Mr Bush joins from Swedish steelmaker SSAB where he headed up the company’s cut-to-length operations in Houston, Texas. In his new role, Bush will be based in Houston.

Source: The Hindu Business Line, 4 August 2020.

• London, UK-headquartered steelmaker and mining company EVRAZ has announced that its HI 2020 earnings have fallen 28% because of the COVID-19 pandemic. The company’s EBITDA dropped to $1.07 billion (£800 million) in the six months to the end of June.

Source: Sharecast.com, 6 August 2020.

• A sharp decline in demand is behind South Korean steelmakers POSCO and Hyundai Steel’s decision to cut crude steel production. POSCO had planned to produce 36.7Mt in 2020 but has since revised that figure down to 35.3Mt, citing the COVID-19 pandemic as the reason behind its decision. It’s a similar story with Hyundai Steel. The company produced 9.8Mt during H1 2020 against an annual target of 21Mt. Source: Yonhap News Agency, 5 August 2020. www.steeltimesint.com

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• South Korean steelmaker Hyundai Steel has received a GR certificate in recognition of its eco-friendliness, according to an online media report.

The company, the country’s largest (and first) electric steelmaker, produces 10Mt/ yr of steel and steel bars and received its Goods Recycled Products certification from the Korean Agency for Technology and Standards (KATS) which is part of the Ministry of trade, Industry and Energy.

Started in 1997, the GR certificate certifies the quality of recycled products.

Source: Korea IT Times, 6 August 2020.

• German steelmaker thyssenkrupp is planning to invest in a new walking beam furnace in its Hot Strip Mill 2 in Duisburg as part of the company’s Strategy 20-30. It is claimed that the new equipment will ensure a significantly improved surface quality of premium sheets, which are used for exterior car body shells.

Source: ThyssenKrupp, 5 August 2020.

• Austrian steelmaker voestalpine says it will restart its idled blast furnace in Linz once its capacity utilisation rate reaches 80%. It is currently at 75%, but it’s impossible to know when it will improve by the required 5%. Until then the Linz site will meet demand using its other two blast furnaces.

The idled blast furnace reduces pig iron production by 20%. The site as a whole has a 5Mt/yr pig iron capacity.

Source: S&P Global Platts, 5 August 2020.

• Two blast furnaces at US Steel’s Gary Works in Indiana, are likely to remain idled throughout 2020.

Source: NWI Times, 9 August 2020.

For more steel industry news and features, visit www.steeltimesint.com Digital Edition - August 2020

00 10

INNOVATIONS

Bloom casters all the rage

CONDRIVE oscillation systems from SMS Concast have been successfully commissioned on a five-strand bloom casting machine at TMK’s Seversky Pipe Plant (TMK Seversky) in Polevskoy in Russia. The company is part of the TMK Group, a Russian producer of tube and pipe products for the oil and gas industry.

TMK Seversky produces hot-rolled and welded steel tube at an annual production rate of around 1Mt. According to SMS group, the CONDRIVE direct-drive systems have been operating at TMK Seversky for over six months ‘with the expected high precision and reliability’ and, for the first time ever, on the resonance oscillation Digital Edition - August 2020

system of a bloom casting machine.

The caster is designed to produce round blooms in diameters ranging from 150mm to 400mm.

The aim of installing the CONDRIVE system was to enhance the control of the continuous casting process, improve product quality and guarantee long-term process reliability as well as minimised operating costs, especially when casting small-diameter blooms.

SMS group claims that TMK Seversky has been able to reduce the break-out rate to almost zero as a result of using CONDRIVE oscillation technology.

TMK’s head of metallurgy, Alexsandr Murzin, commented: “Thanks to the excellent co-operation between our

commissioning team and the SMS Concast specialists on-site, we were able to grant the FAC just one week after the commissioning.”

There are different types of oscillation technologies and TMK analysed each one and decided that SMS group’s CONDRIVE system won the day because of its lower capital and operating costs.

It is claimed that the system performs ‘significantly better’ [than others on the market] in terms of acceleration and speed control.

In fact, bloom casters appear to be all the rage with SMS group at the moment. The company has also announced that Chinese steelmaker Nanjing Iron & Steel (NISCO) has www.steeltimesint.com

INNOVATIONS

11

Spooler line for Nucor Sedalia

commissioned an upgraded four-strand bloom caster at its Nanjing plant No.2, also with SMS Concast, part of the SMS group.

The modernised caster is designed for an annual production of 800kt of blooms. SMS claims that the chief aims of the project – to improve product quality and production flexibility – have been achieved.

The upgraded caster has a nominal radius of 12m and is designed to cast two bloom section sizes. Currently in operation is a 255mm x 300mm format, but a second bloom size is planned for the year-end.

The Nanjing facility produces high-carbon grades, such as bearing www.steeltimesint.com

and spring steels and a full range of steels to serve the automotive industry.

SMS argues that the upgraded caster gives NISCO greater production flexibility and enhanced responsiveness to market demand.

Zhu Ping, vice general manager at NISCO said that SMS Concast was the ‘perfect partner’ for the project. “The excellent co-operation between both project teams enabled us to achieve the specified product quality immediately.”

For further information, log on to www.sms-group.com

Nucor Steel Sedalia in Missouri, USA, has started up a new spooler line for the production of rebars and rounds in coils weighing up to 5 tons. The line was supplied and installed by Italian plant builder Danieli, and managed by Danieli Automation’s Q-VID system.

Danieli claims that the new line will deliver twist-free compact and regularly shaped coils at up to 30m/ second. High efficiency and high material yield during downstream processing is possible, claims the Italian production technology giant, because of the ECR® Endless Casting and Rolling process, which allows the lowest production costs.

According to Danieli the new line also offers high mechanical characteristics and good weldability of the finished product, not forgetting optimised coil handling.

The spooler line consists of a 4-pass Delta-type fast finishing block (which will extend the Nucor Steel Sedalia product range to rebar #3); five water-boxes for heat treatment; cropping and high-speed shears; two 5-ton horizontal spooler machines; and a coil handling, strapping and collecting area.

The equipment was installed in parallel with the start-up of the MIDA ECR® minimill in order to minimise plant downtime.

This is the third spooler line installed and started-up downstream of a Danieli MIDA ECR® micromill, and the first in operation at Nucor Corporation, allowing the expansion of its current production range. A second spooler line for Nucor is currently under erection at Nucor Steel Florida and will be commissioned by the year end, bringing the total number of Danieli spooler lines installed in North America to five.

For further information, log on to www.danieli.com

00 12

INNOVATIONS

New CGL for Steel Dynamics in Columbus Fives Group and US steelmaker Steel Dynamics Columbus (SDI), which is being described as the most modern mini-mill in the US, has produced the first coil with a new continuous galvanising line (CGL 3) in Columbus, Mississippi, USA. The first prime coil was produced on 9 July 2020 on time and in the midst of the COVID-19 pandemic. The project

involved equipment delivery from several countries experiencing different forms of lockdown, namely France, Spain, Czech Republic, Italy, Mexico and the USA. “Our team persevered, and using a strong focus, work ethic and stringent policies to prevent COVID-19 infection on-site, we achieved a positive result safely,” said SDI’s galvanising/paint

Fives has also picked up not one, but two awards at the prestigious 11th Annual Fastmarkets Global Awards, held ‘virtually’ last month. The awards set out to identify and acknowledge world-class innovations and excellence for companies and key partners throughout the steel industry.

The company received the Technology Provider of the Year award for its ground-breaking heat treatment and real-time quality management technologies, enabling steel manufacturers to improve operational efficiency, increase the quality of finished products and enhance the flexibility of operations.

Guillaume Mehlman, president of steel and glass at

manager, Jeff Roach.

“We worked together 24/7, including remote expert assistance to achieve this goal. For example, we programmed the annealing furnace remotely from Europe with local support. This success could not be achieved without close co-operation from the team on-site,” added project manager Anthony le Blan of Fives DMS, a Fives subsidiary located

Fives, said that the company had been a global leader in a variety of industries for more than 200 years.

“We have been involved in landmark projects leading technological innovations for the steel industry with solutions that provide increased productivity and flexibility of operations, while drastically reducing environmental impact," Mehlman said at the virtual ceremony. "I am very proud of our team and am honoured to receive this prestigious award,” he added.

Fives was also announced as a joint winner of the Information Technology Services Provider award.

Fives and Marcegaglia developed the SmartLine, a fully

INNOVATIONS

in the company’s native France.

Kevin Bertermann, vice president of sales and marketing (North America) at Steel Business Line (Fives) said: “We believe success is achieved through teamwork. Operating in the COVID-19 situation offers a unique set of challenges. The team managed a dynamic set of complexities, seemingly dayby-day, stemming from supply chain

constraints to travel restrictions to challenging site erection conditions.”

In December 2018, Fives was awarded a supply contract for a galvanising line at the existing SDI Columbus plant.

The new CGL with a production capacity of 400kt/yr is designed to diversify SDI’s product portfolio.

The scope includes the design and supply of entry and exit coil handling,

automatic strip processing line control system based on predictive modelling. In 2019, the SmartLine was commissioned for Marcegaglia's continuous galvanising line in Ravenna, Italy.

According to Guillaume, "Marcegaglia had a vision for a fully integrated control system of the coil finishing lines based on predictive modelling, incorporating all the upstream metallurgy and all the processing steps down to the finished coil in order to achieve the highest quality yield and productivity. The result has been a great success for both of our organisations."

13

degreasing, horizontal annealing furnace, cooling, skin-pass mill, strip leveller, strip inspection sections, automation, as well as metallurgical assistance for various steel grades and types of coating.

For further information, log on to www.fivesgroup.com

00 14

INNOVATIONS

Revamped EAF for Ferriere Nord

Danieli Service has revamped the EAF in operation of Ferriere Nord, part of the Pittini Group, in Osoppo, Italy.

According to Danieli, the skill of the Ferriere Nord team and the ‘excellent melting practices developed by the Ferriere Nord meltshop team’, the furnace – previously supplied by Danieli in 2013 – has been recognised as one of the world’s benchmark EAFs for many

years. The revamping consisted of a tailor-made supply of two sets of shells and water-cooled roofs.

The new shells are supplied in a larger diameter of 7.1m as this enables the two-buckets charging process, which results in reduced power-off time and minimised emissions.

“Excellent chemical packages already in operation were maintained,” claims

Danieli Service.

From order to implementation took 11 months, was delivered on-time and was performing at full power right from the beginning, the company claims.

For further information, log on to www.danieli.com

POSCO’s new slab-grinder commissioned Danieli Centro Maskin has commissioned a new HGS300 slab-grinding unit at the STS1 Plant at POSCO’s Pohang steel works in South Korea.

Equipped with a 250-kW motor on the main unit, the new grinder works on 140mm to 220mm thick stainless steel slabs, up to 1.65m wide and 10.5m long, to ensure an output of approximately 200kt/yr in full skin-grinding mode at an average removal depth of 2mm per slab face.

The plant is equipped with Danieli’s CastGrind technology to process material with a surface temperature of up to 700°C, as well as Hi-Grind, the E-Cube set-up for stepless-angle grinding from 45 to 90 degrees.

Digital Edition - August 2020

An updated automation platform was developed by Danieli Automation.

According to Danieli, this is an important milestone in the collaboration between Danieli Centro Maskin and POSCO, which started in 1979 and developed through various conditioning applications for long and flat products, and for stainless steel as well as for

low- and medium-carbon grades.

To date, Danieli Centro Maskin has put a total of 30 grinders into operation with POSCO, 18 of which are for slab grinding.

For further information, log on to www.danieli.com

Introducing RHI Magnesita

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Find out more at rhimagnesita.com

INNOVATIONS

16

Scalable advanced analytics The ABB Ability™ Genix Industrial Analytics and AI Suite is described by ABB as ‘a scalable advanced analytics platform with pre-built, easy-to-use applications and services’. It collects, contextualises and converts operational, engineering and information technology data into actionable insights that help industries improve operations, optimise asset management and streamline business processes safely and sustainably.

According to ABB, analyst studies suggest that industrial companies typically are able to use only 20%¹ of the data generated, which severely limits their ability to apply data analytics meaningfully. ABB’s new solution operates as a digital data convergence point where streams of information from diverse sources across the plant

and enterprise are put into context through a unified analytics model.

Application of artificial intelligence on this data produces meaningful insights for prediction and optimisation that improve business performance, the company claims.

“We believe that the place to start a data analytics journey in the process, energy and hybrid industries is by building on the existing digital technology – the automation that controls the production processes,” said Peter Terwiesch, president of ABB Industrial Automation. “We see a huge opportunity for our customers to use their data from operations better, by combining it with engineering and information technology data for multi-dimensional decision making. This new approach will help our customers make literally

billions of better decisions.”

ABB AbilityTM Genix is composed of a data analytics platform and applications, supplemented by ABB services that help customers decide which assets, processes and risk profiles can be improved, and assists them in designing and applying those analytics. Users can subscribe to a variety of analytics on demand, as business needs dictate, speeding up the traditional process of requesting and scheduling support from suppliers, ABB claims.

ABB AbilityTM Genix is scalable from plant to enterprise and supports a variety of deployments including cloud, hybrid and on-premise. It also leverages Microsoft Azure for integrated cloud connectivity and services through ABB’s strategic partnership with Microsoft.

Rajesh Ramachandran, chief digital officer for ABB Industrial Automation, said that the new software brings unique value by unlocking the combined power of diverse data, domain knowledge, technology and artificial intelligence. He added that it also helps asset-intensive producers with complex processes to make timely and accurate decisions through deep analytics and optimisation across the plant and enterprise.

“We have designed this modular and flexible suite so that customers at different stages in their digitalisation journey can adopt ABB AbilityTM Genix to accelerate business outcomes while protecting existing investments,” Ramachandran concluded.

For further information, log on to www.abb.com

WISCO happy with hot strip mill revamp Chinese steelmaker Wuhan Iron & Steel (WISCO) has issued a final acceptance certificate (FAC) to SMS group following the completion of a modernisation project.

The German plant builder has modernised finishing stands F4 and F7 of WISCO’s high capacity hot strip mill number two, the aim being to increase plant availability.

The mill itself was supplied by SMS group and has been in operation since 2003 and was modified in 2015 to exDigital Edition - August 2020

pand WISCO’s range of high-strength and pipe grade products.

The recent revamp of finishing stands F4 and F7 included the installation of CVC®plus systems with ±150mm shifting stroke and the adaptation of hydraulic valve stands. These modifications took place in 2019 during the mill’s annual shutdown as only very few adaptations were required.

For further information, log on to www.sms-group.com www.steeltimesint.com

00 18

INNOVATIONS

Electric wheel brake for cranes Pintsch Bubenzer has developed an environmentally friendly electric wheel brake – the BRBe – for electric overhead travelling (EOT) cranes at ports and steel mills, and other heavy duty applications.

The BRBe is currently available for cranes with wheels from 500mm (19.68 in.) to 1,000mm (39.37 in.) diameter and wheel flange widths from 160mm (6.29 in.) to 254mm (10 in.).

It is also suitable for steel mill outside service cranes, stacker and bulk storage cranes.

The most common sizes for the new range are the BRBe70, with 56000N braking force (70kN contact force); and the BRBe90, with 72000N braking force (90kN contact force). The brake can be sized up or down based on the application along with adaptation to the bolt pattern of existing wheel brakes or retrofitted to a new application.

Joel Cox, president at Pintsch Bubenzer USA, said: “The product is launched as an alternative to lessen the impact on hydraulics on cranes and make installation improved while reducing costs to owners. The product is greener and avoids the typical hydraulic cylinder repairs or potential for leaks and contamination at docks. Our BRB120

Primobius GmbH is the name of a new 50:50 joint venture company set up

by Neometals and SMS group for the recycling of lithium batteries and the sustainable recovery of value constituents from end-of-life batteries.

The chief objective of the new business is the commercialisation of joint recycling technology for fast-growing volumes of end-of-life batteries.

Primobius is planning a demonstration plant in Germany based on the ‘hub-and-spoke system (a model which arranges service delivery assets into a network consisting of an anchor establishment (hub) offering a full array of services, complemented by secondary establishments (spokes) offering more limited services).

According to SMS group, ‘the object

The product is greener and avoids the typical hydraulic cylinder repairs or potential for leaks and contamination at docks.

Picture next page: The BRBe brake is for cranes at ports, steel mills and other heavy duty applications.

Battery recycling JV for SMS of this enterprise is the commercialisation of joint recycling technology for lithium-ion batteries (LIBs). The idea is that valuable materials can be recovered from vehicle batteries and storage batteries for electronic devices using a particularly sustainable process.

The two companies (Australia-based Neometals and Germany-based SMS group) are pooling their experience in project development and mechanical engineering) to make it happen.

Neometals will lend its technical and commercial expertise to the project, including in recycling technology, and SMS will bring its engineering

and construction of recycling facilities know-how to the table, and will handle the operation and maintenance of the equipment.

The next step is the construction and commissioning of the aforementioned demonstration plant in Europe, the further development of process technology, the financing and the conclusion of long-term supply and offtake agreements. The demo plant will allow potential customers to assess the materials recovered from their own or external end-of-life batteries.

Herbert Weissenbaeck, senior vice president of strategic project develop-

19

INNOVATIONS

and BRB90 designs are popular hydraulic wheel brakes, but this was built with greater ease and simplicity in mind both for OEMs [original equipment manufacturers] and end users.”

Cox stressed that installation of the new brake doesn’t eliminate the need for runaway or storm brakes. “Specifications still call for storm brakes. And ports, for example, still use mechanical tie downs during hurricanes and big storms when they have time to prep for them. Our wheel brakes are good to keep the crane from rolling and preventing them from catching momentum down the runway. It is up to the end client or OEM discretion whether to use wheel brakes, push down [on rail] brakes, or rail clamps for everyday use,” he added.

Importantly, the BRBe, which can be retrofitted, is designed for outdoor cranes, such as ship-to-shore, rail-mounted gantry and rubber-tired gantry cranes. In the event of microburst wind, gale storms, tornados, or hurricanes, a traditional storm brake would determine the wind speed and lock; in other words, it would push down on the rail, wedge rail or grab rail head, and squeeze the wheel flanges.

“If a known storm is coming,” Cox said, “Operators typically have storm tie downs that are more mechanical and binding to the earth. However, depend-

ing on the location of the crane and the special tie down points on a dock or runway, it might be in danger of traverse to get to those points in unexpected weather conditions. With storm brakes, long runs of piping, hoses, cylinders and valves are all subject to leaks and water ingress, for example, – and potential failure. A wheel brake design might have 16 brakes with between 16 to 32 locations; that’s a lot of potential fail spots. The reaction time is also very important to what operators can achieve.”

On the all-electric BRBe wheel brake, there is no hydraulic power unit (HPU); instead a low-amperage, three-phase power unit (the largest produces only 1.8 FLA) is used, which comes ‘water-intrusive-ready’ with IP67 class and is suitable for a standard temperature range of -30°C to +60°C. The electric wheel brake originated from the RWBe, a green concept that removed all hydraulics. Pintsch Bubenzer added its BUEL thruster lineup, which had a traditional thrusting version (H model), a self-contained

group and Neometals ment at SMS group, said that the company looks forward to the next stage of its engagement with Neometals. He said that the company was looking forward to applying its metallurgical plant and engineering expertise to fast track commercialisation. “SMS group sees

compelling growth and opportunity in the sector. The timing is good to secure a foothold and build credibility with OEMs who value closing the loop in the battery value chain,” he said, adding that there was plenty of support in Europe for sustainability and circular

HPU version (G) and a version for storm brakes (S) that would pull and not thrust. The new, all-electric version is used with the BUEL S model. The BUEL G is used to remove traditional HPU units on other applications not related to traveling motion.

“The [BRBe] unit is already showing up on cranes in the USA and has environmentally friendly design since it requires no oil change, lifetime internal filling and intermittent operation. It requires no bleeding, no special wiring, and no pipes or hoses to worry about.

Further, operation is coil spring applied,” said Cox. He added: “Since it is hurricane season, we are raising awareness about an often overlooked issue: how do you tie your crane down? If you assume that when you see a storm coming you can grab a sling and shackle, it is too late.

Having proper braking and storm brake prevention is an important consideration.”

For further information, log on to www.pintschbubenzerusa.com

opportunities.

At Neometals, managing director Chris Reed commented: “The entry of Primobius comes at a time marked by major confluence of regulatory initiatives to stimulate the electric vehicle sector to decarbonise transportation, secure battery material supply chains and support circular economies generally.”

Reed added that Primobius offers responsible recovery and ethical battery material supply with a view to lowering the carbon footprint of battery manufacturing.

For further information, log on to www.sms-group.com

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INNOVATIONS

21

Four orders for Bronx straighteners

An Indian state-owned company has placed several orders for Bronx straighteners to process bars and tubes at its two facilities in Telangana and Rajasthan. The company was looking for precision engineering, advanced technical capability, a strong reputation and quick delivery. Several rounds of technical tenders preceded the commercial tender process to ensure that only the best designs were considered.

According to Peter Clarke, technical director of Fives Bronx, a UK-based subsidiary of Fives Group, “They knew the name and they knew the brand – as they have been using one of our machines since the 1980s – but what stood out to the customer was the www.steeltimesint.com

technical advances of our machines.”

Fives has been specialising in Bronx straightening machines for more than 80 years. “Our Bronx straighteners are fully automated, which is a distinct advantage to a customer looking for precision.

“Roll positions and angles are computer-controlled for the utmost accuracy. In the end, through all the tenders, that was what set us above the competition,” Clarke explained.

All the machines will be able to process stainless steel and speciality alloy bars and tubes, with a cut length of 6 metres. The order covers: • A 2-roll Bronx machine to straighten round bars with a diameter

up to 30mm, to be delivered by the end of 2020 • Two 10-roll Bronx straighteners for tubes with up to a 20mm diameter, to be delivered by Q2 2021 • A 6-roll Bronx machine to straighten tubes with up to a 30mm diameter, to be delivered by Q3 2021 The straightening machines will be manufactured, assembled and tested in the presence of the customer at Fives Bronx’s new facility in Wombourne, West Midlands, UK, where the company has recently moved.

For further information, log on to www.fivesgroup.com Digital Edition - August 2020

00 22

INNOVATIONS

Spedition Kübler praises new Scheuerle FL02 Global logistics company Spedition Kübler has taken delivery of its first lowbed semi-trailer, part of the EuroCompact FL series. The vehicle, produced

by Scheuerle, was chosen because of its outstanding versatility and load capacity in the payload segment up to 30 tonnes.

Felix Mangold, Spedition Kübler’s technical manager, was handed the keys to the new vehicle by Scheuerle’s area sales manager, Martin Rössler.

Scheuerle is a subsidiary of the Transporter Industry International Group (TII Group).

“With the two-axle EuroCompact low-bed semi-trailer, we can now offer our customers additional services in the payload class up to 30 tonnes,” said Mangold.

Owning the EuroCompact FL02 means that Spedition Kübler will be able to carry out oversized transport assignments and this not only includes machine relocations, but also the transportation of construction material as well as ‘sensitive and costly shipments’.

Mangold claims that the new vehicle is ‘an extremely versatile transport solution’ because of its extensive range of equipment. This is important, he said, in order to optimise the vehicle utilisation capacity and because every load and return load contributes to the economic efficiency of the low-bed trailer.

The EuroCompact FL02 is capable of handling loads of up to and over 37,000kg and is 20% lighter than comparable models, according to

Mangold, who argues that the payload is outstanding for a vehicle with only two axles.

There are, according to Scheuerle, many plus points for its EuroCompact FL02 including easy handling and manoeuvrability and, of course, safety.

The FL02’s ‘Clever Coupling System’ is claimed to be easy to use and allows the gooseneck to the separated and connected on even and uneven ground, improving driver safety. According to Mangold, the logical arrangement of the control elements on the gooseneck and the optional remote control make life considerably easier for the operator.

For further information, log on to www.tii-group.com

Pneumatic lime injection at Celsa Ostrowiec Ostrowiec-based CELSA in Poland has taken delivery of a new sidewall lime injection system for its 150-tonne EBT electric arc furnace (EAF). The system was supplied by MORE. The steel plant manufactures long and forged products and belongs to the CELSA Group, which is the largest producer of long products in Spain and one of the main European producers.

The order includes: two L-ONE sidewall injectors (burner, lime lance) to be installed inside CNC copper bulged blocks, two MOLI dispensers for pneumatic lime transportation with

a capacity of 3,000 litres (793 gallons) each, new oxygen-natural gas valve stands that comply with the latest PED and ATEX requirements, one EBT-SAND for remote filling of the EBT channel after tapping and a new PLC automation cabinet to manage the new MORE package.

The installation of the lime injection system, claims MORE, will generate a much cleaner shop environment. As a result, dusty discharging bin practices and the use of maintenance-demanding conveyor belts can be reduced.

Moreover, it will enhance the slag

foaming practice, which shall lead to improvements in process control and increased productivity, consequently reducing transformation costs.

Commissioning is scheduled to take place in Q1 2021.

MORE describes itself a ‘an experienced contractor’ with over 100 lime pneumatic injection systems in operation or being manufactured worldwide.

For further information, log on to www.more-oxy.com

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INNOVATIONS

Coke oven gas injection starts on time In November 2019, ROGESA Roheisengesellschaft Saar GmbH, Dillingen, Germany, commissioned Luxembourg-based Paul Wurth to design and supply coke oven gas injection systems for its No. 4 and No. 5 blast furnaces.

According to Paul Wurth, with this new technology, coke oven gas becomes a metallurgical process gas that will partially replace metallurgical coke as a reducing agent, thus lowering carbon intensity in the blast furnace as well as the carbon footprint of the overall ironmaking operations.

In preparation, Paul Wurth accompanied the customer in research work and pilot plant trials. The current order is being executed on a turn-key basis and includes design and engineering for the two coke oven gas injection sub-plants, supply of technological key items like flow control and check valves, supply and erection of vessels, piping and supporting structure, automation of the plants and integration into the existing process technology and plant configuration.

Despite difficult project execution conditions and a challenging economic environment, Paul Wurth fulfilled all contract obligations and supported the operator to start commissioning the first section of the new coke oven gas injection plant at Blast Furnace No. 5 by

the initially planned date of early June.

Paul Wurth’s particular responsibility was to have ready injection lines and coke oven gas supply for half the number of all the 32 tuyeres of blast furnace No.5. Once fulfilled, Rogesa and Paul Wurth started the application of the new technology for four injection lines. The operation with coke oven gas followed a jointly developed start-up procedure and was executed by trained personnel in a safety-focused manner.

According to Paul Wurth, ROGESA will now observe the development of the blast furnace’s ironmaking process parameters and strive for further evolving injection rates.

Paul Wurth and its sub-suppliers managed to keep on track within a demanding project schedule and in a business environment that changed unexpectedly and dramatically because of the pandemic, lockdown, economic slowdown and related consequences.

In the frame of Paul Wurth’s strategy to support steel plant operators on their journey to a carbon neutral primary metallurgy, coke oven gas injection at tuyere level is part of a readily available portfolio of solutions for stepwise CO2 emission reduction.

For further information, log on to www.paulwurth.com

40 years serving steelmakers IMS Isotopen-Meßsysteme GmbH (IMS) is celebrating 40 years in business.

Over the past four decades the company has established itself as a world market leader in the field of non-contact x-ray, isotope and optical measuring systems.

Established in 1980, IMS has been based in Heiligenhaus-Hetterscheidt in Germany since 1987, employs 350 people and has 11 branch offices worldwide – some wholly-owned subsidiaries. Numerous agents around the globe represent the business.

Since its inception, IMS has focused on computer-aided signal processing, which, 40 years ago, was the prerequisite for simultaneous multi-channel measuring systems. The best-known IMS multi-channel measuring system was the first-generation profile measuring system for hot-rolled flat products in 1983. In the following year IMS extended its product range with optical measuring systems. X-ray technology was introduced at the end of the 80s.

Today, 20 of the world’s largest steel manufacturers are relying upon high-precision measuring systems sup-

plied by the company.

There are currently more than 4,500 of the company’s measuring systems working as integral components of production facilities in hot rolling mills, cold rolling mills, continuous casting plants, tube mills as well as metal service centres. These systems measure precisely even under the toughest conditions, display their results visually and offer a long service life.

According to IMS, more than 700 satisfied customers in over 60 countries benefit from the performance of the company’s high-tech measuring sys-

INNOVATIONS

tems, some of which are genuine world firsts and make a significant contribution to optimising processes and reducing scrap rates, leading to economical and profitable production.

IMS believes that open eyes and ears, as well as the right questions at the right time, form the basis of its numerous new developments, all of which are in step with the times and demands of its customers. “Collaboration with renowned partners in the industry as well as in research and technology perfect our competence team and guarantee not only our progress, but also that of our customers,� says the company.

IMS describes itself as a global pioneer for non-contact detection technology. The company is privately owned and, as such, has maintained a high degree of independence and individuality.

The company claims that its goal and wish is to shape its future together with its customers, partners and interested parties. IMS says that it looks forward to future relations and challenges, successes and the next milestones that the coming years will bring.

For further information, log on to www.ims-gmbh.de

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INNOVATIONS

Plibrico saves th Berry technology for Big River Steel US-based Berry Metal Company has commissioned a newly developed, state-of-the-art lime injection system at Big River Steel (BRS) in the USA. The scope of the project included the design and supply of a comprehensive technology package for pneumatic lime injection at BRS’s greenfield facility in Osceola, Arkansas. The system, which was installed as part of the BRS Phase I EAF, was successfully commissioned in May. Berry has also been contracted to install a similar system when BRS completes its Phase II EAF in 2021.

The custom-designed system hit the targeted flow rate of 1,000 lbs/ min for Dolomitic and HiCal, which, it is claimed, is one of the highest flow rates in North America.

This new lime injection technology provides two critical advantages. First, it allows for successful flow of various gradients and sizing of lime particles from lime dust up to 1½” nominal sizing without clogging. Second, the lime injectors provide an accelerated punch into the bath increasing yield and efficiency in the steel making process.

The system includes all components from the outside transporter to the injector and was installed and cold-commissioned while the mill was running so that no normal operations were reduced. All calibrations and tests were performed on scheduled downtime.

Berry formed an exclusive partnership with Nol-Tec Systems to incorporate their patented Air Assist Injection and Transport Technology, enhancing Berry’s complete lime injection system from silo into furnace via Berry’s patented lime injectors/burners.

According to Berry, the system is completely self-contained and sealed, reducing lime consumption and yield losses that typically occur in transport, Digital Edition - February 2020

delivery and at injection points. By preventing lime dust from entering the work environment, plant cleanliness is also improved, the company claims.

“The pneumatic lime system will give BRS operators fast and precise control of their lime mix so operators can better utilise raw materials in the melting process,” said David Werner, president of Berry Metal Company. “The system features BMC proprietary accelerator nozzles that increase carbon jet velocity by 18-20%, as well as air ‘boost’ to enhance lime efficiency and minimise line clogging and maintenance. Our system can inject a large volume of lime in a very short time frame, with improved homogenous dispersal throughout the heat.”

The Berry system, which encompasses outside conveying, storage, inside conveying and EAF Injection of lime, is designed to improve BRS’s flexibility in controlling slag characteristics and help with overall improved steel process performance and efficiency.

“This lime injection system allows steel producers to have fluctuations in their lime sizing, which has been the primary problem with clogging and related loss of productivity in existing lime injection systems. We are very pleased with the results of this key installation. It further expands our comprehensive offering of lime and carbon solutions, from storage to injection into the furnace.” said Werner.

The Berry portfolio includes chemical energy, lime injection, carbon injection, ladle and tundish pre-heaters, cooling panels, leak detection systems, repairs and engineering in and around the furnace and caster areas of the EAF. For further information, log on to www.berrymetal.com

Thermal processing plants re-opening across America face challenges and uncertainties never witnessed before and these include re-establishing supplier channels for critical materials and servicing new orders resulting from pent-up demand. They also need to ensure the health and well-being of their employees.

Plibrico is claiming that it is going the extra mile and helping to make plant re-openings successful. The company is a major supplier of refractory solutions for the metals, minerals and petrochemical processing industries, and offers specialist expertise in ensuring the safe, productive operation of high-temperature furnaces, boilers, and incinerators.

Plibrico is playing a major role in the safe return-to-work strategies of its industrial customers by instituting a robust COVID-19 response plan that includes swift action to the dynamic needs of its clients.

Many thermal processing plants have been idled or are running on a reduced schedule and now they are returning to work and starting to reopen. According to Plibrico, as production starts to ramp up, organisations find themselves in critical need of refractories

ArcelorMittal c ArcelorMittal, the world’s biggest steelmaker, has chosen Danieli Corus to revamp its primary gas-conditioning systems for three 160-t converters at the Kryvyi Rih integrated steelmaking plant,

27

INNOVATIONS

he day in turbulent times for unplanned repairs or maintenance.

Refractories are vital for them to ensure a reliable and safe return to operation.

Brad Taylor, president and CEO of Plibrico Company, is proud of his employees for making life a little easier for the company’s customers to return to work in what he rightly described as ‘turbulent times’.

"Today's demand for refractories has presented both a challenge and an important opportunity for us to demonstrate our flexibility and commitment to customer success," said Brad, pointing to Plibrico's Oak Hill, Ohio, manufacturing site as an example of the company's strengthened resolve.

The majority of Plibrico's refractory materials are manufactured at Oak Hill where an extensive inventory of raw materials are stored and processed. In fact, the plant is known industry-wide for its fast turnaround of quality refractory products.

"Even during April and May when customers were grappling with the volatility of the marketplace, Plibrico increased its commitment to its customers through increased inventory and staffing. The increases allowed added flexibility to ensure on-time delivery at a time when our customers needed us

the most," said Taylor. "Plibrico customers have come to rely on the flexibility and strength of our manufacturing facility to be able to help them meet their challenging schedules, and that’s what we deliver. These are the situations where Plibrico has always excelled."

One example was a customer that had an unexpected schedule change and required a large expedited order of multiple refractories. The catch? All refractories needed to be produced and delivered to Nebraska in just two days.

The purchase order was received on a Tuesday morning and the plant sprang into action. The Plibrico team manufactured the entire order by Wednesday.

Next up was Plibrico's logistics team which put in extra hours processing the paperwork, loading the truck, and getting the shipment delivered to Nebraska to satisfy the customer's short timeline.

As the economy starts moving forward, thermal processing plants are beginning to increase their production schedules. Shuttered plants are starting to re-open. Successful safe return-towork strategies are being developed and include re-engagement of supplier channels for critical materials like refractories. Pivoting plant schedules

and changing demands, make supplier flexibility and superior customer service key to achieving success. Plibrico’s customer-centric core values, safe robust response plan, and willingness to go the extra mile are helping its customers achieve their return-to-work goals.

Plibrico claims that its customers are emerging stronger and better prepared to meet their production and competitive market demands.

For further information, log on to www.plibrico.co.uk

chooses Danieli Corus for revamp project in Ukraine. The systems are designed to collect and treat gases generated during the steelmaking process and consist of a gas capture and cooling section followed by a gas cleaning section. All

lower hoods and cooling stacks will be replaced, and movable skirts will be installed.

BOF steelmaking produces large amounts of high-temperature (≥ 950 °C) gas, loaded with substantial amounts of dust (70 – 200 g/Nm³).

This gas has to be cooled and cleaned before further processing can occur.

Process equipment is installed above and alongside the converter mouth to enable energy recovery as well as collection and recycling of the dust produced.

In most systems the gas is cleaned in Venturi-type scrubbers, which have inherent disadvantages including limited efficiency, blockages and maintenance

requirements.

The scrubbers at the Kryvyi Rih BOF Plant Block 1 will be upgraded to Danieli Corus technology, based on the proven ‘Annular Gap’ scrubber design.

Optimised water- and gas-flow patterns make the process more efficient and Annular Gap scrubbers have proven to be virtually maintenance-free.

The operational expenditures (OpEx) will also be lower, it is claimed.

After completion, the final dust-emission levels of the BOF plant will be significantly reduced – and the system will operate at lower cost.

For further information, log on to www.danieli-corus.com Digital Edition - February 2020

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SUSTAINABILITY

Sustainable production planning

For more than 50 years, PSI software solutions have been helping the energy industry and energy-intensive sectors increase efficiency and make responsible use of energy, raw materials and labour. Particularly in the metals industry, the company makes a special contribution to sustainable production with its advanced products. Reducing carbon dioxide emissions (CO2) and optimising energy consumption has been at the heart of PSI’s technological and environmental vision. By Raffael Binder*

IN light of the environmental situation and the challenges it presents for the global steel industry, PSI is certain that it must do more for nature and its customers. The company wants to inspire positive change and help steel producers to better meet the needs of their customers, stakeholders and governments. That is why it wants its planning module to expand its overall efficiency.

Sustainable iron and steel The iron and steel industry is one of the largest industrial emitters of CO2,

accounting for between 4% and 7% of anthropogenic CO2 emissions worldwide.

According to the World Steel Association (worldsteel), 1.85 tonnes of CO2 on average were emitted per tonne of steel produced in 2018. One beech tree binds about 12.5 kg of CO2 per year - so you would have to plant 148 trees to compensate for one ton of steel produced. Considering that over 1.8Mt of crude steel were produced worldwide in 2018, this calculation seems alarming. It is no wonder that the level of environmental awareness is growing and more and more policies and initiatives are

being developed to protect it.

One such initiative is the Emissions Trading System (ETS), which is a marketbased instrument that serves to protect the climate. It is designed to help achieve the 2030 goal of reducing greenhouse gases (GHGs) by 40% over 1990 levels – or even by 55%, according to the new EU Commission’s current plans for a ‘Green Deal’.

Companies require certificates for the approved amount of GHG emissions, socalled ‘emission allowances’. One certificate covers one tonne of carbon dioxide

*PSI Metals Digital Edition - August 2020

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SUSTAINABILITY

emissions. Certificates are traded on special exchanges and in the capital markets and their price reflects not only the rules of supply and demand, but is also influenced by speculation. However, the overall number of issued certificates is limited, and will be gradually reduced through to 2030. Emissions-intensive industries such as steel production are issued with a certain volume of emission rights at no charge (‘free certificates’). This ‘carbon leakage’ protection is intended to prevent certain industries from shifting their production to countries with less stringent climate protection regulations.

Supporting the Planner Supporting metal producers in reducing their CO2 emissions and optimising their energy consumption has been one of PSI’s product requirements for some time now.

With PSImetals/Planning the planner in the steelworks is already able to monitor and adjust the expected energy consumption and CO2 emissions for a production line, the entire plant or individually per production order. Through the selection of an individually defined time interval, the planning solution supports the preparation of production plans as well as the creation of optimised line schedules. Furthermore, the user can access and use the energy forecast data stored in PSImetals for different time periods: • The long-term prognosis can be used for strategic planning since it gives the user an overview of the expected basic energy consumption for the upcoming year.

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• The mid-term prognosis is based on a monthly basis and enables the planner to adjust energy purchasing by looking at daily buckets.

• As soon as planning becomes a detailed short-term prognosis on a daily or hourly basis, the forecast is generated in, for example, 15-minute time windows.

During this time horizon, quick reactions to production events are required, and adjustments allow for quick profits by matching the forecast energy availability.

(Fig 1).

Breaking the silos Silos are the great hidden constant of the industrialised world. But we need to think bigger if we are to break through them to meet the future need to control green energy and minimise emissions. The biggest challenge here is the fact that business areas in the plant environment have always been, and still are, organised more or less separately from each other. This means

Fig 1. By linking energy measurement data and production data from the past, it is possible to derive an energy demand forecast from the planning situation © PSI Metals

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SUSTAINABILITY

that the steel plant is at the centre and the MES system has a direct, strong link to the production area of logistics and quality management.

But on the other hand, this also means that production planning works independently of the energy software.

Consequently, the planning solution does not take into account energy prices, energy contracts or energy availability. It is the same vice versa: mills have to report, announce and calculate their energy consumption, but as the energy systems are not connected to the MES, the actual data resulting from production are not taken into account and neither the energy system nor the MES informs the other system about needs, schedules and priorities.

(Fig 2).

That seems pretty disruptive, doesn’t it? No battle was ever won with silence – so why do we stick to silos that were set up a long time ago and are no longer necessarily valid? Opening a conversation

and encouraging more connections within the plant environment can open up a world of new possibilities. To break down the silos and meet future needs in controlling green energy and minimising emissions, there must be a change – a transformation!

Just imagine, what if …?

Just imagine if we were to break the current silos and connect PSImetals’ planning solution to the energy exchange and the existing trading system within a plant.

Through a connection between the units, the system would be able to manage and optimise the energy position of the plant and the emission certificates in possession of the corresponding certificate types. The operators in the steel mills would thus know as soon as possible when it is necessary to buy additional CO2 certificates.

The software would be able to support the forecast of the steel mill's demand for CO2 certificates for the next few years based on long-term planning and historical

production data. In addition, certificates could be allocated to different departments to manage the departmental and overall position. Mechanisms for banking and borrowing during the trading period would also be possible.

Through a direct connection to the plant's energy management system, supported

by PSImetals, the system would be able to trigger warnings if a production plan led to a sudden increase in energy costs or even to a violation of the applicable energy contracts.

Spinning the idea further, by connecting to the plant's contract management system, the planning solution would have access to the terms of the plant’s energy contracts and: • advise the best time to consume additional energy in times of high energy availability on the market; • propose early energy procurement on the market; • re-schedule production by efficiently

Fig 2. The actual silo environment © PSI Metals

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Fig 3. Possible future planning solution with PSI © PSI Metals

considering the content of the energy contracts In addition to these interconnections, the planning solution could also directly control energy distribution within the production system.

A direct connection to the energy control system could balance power and thus help avoid power bottlenecks.

The information exchange of system forecasts could be considered in order to react quickly to undesired influences or to use quick compensation possibilities. Thinking ahead, the system would even be able to use parts of a process line buffer that supplies energy when a production process is slowed down when energy is needed (load shedding), or start it up when energy is available (feeding). Driven by price effects in the market and existing energy contracts, it is even conceivable that energy could be stockpiled, for example, during the production of H2. (Fig 3)

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Integration To conclude, one can say that the integration of PSI’s production planning system with an energy management system, an energy load management system and the emissions trading system would lead to cost-effective and sustainable production.

Energy-efficient decisionmaking and compliance with environmental regulations are all key factors in the discussion.

In view of the existing regulations and future changes regarding independent energy and production management systems, the status quo will not be sufficient for many metal producers to remain in a best-inclass position.

Imagine the benefit of seamless integration between your production planning and energy management systems, delivered by a single solution provider with the know-how and expertise in each area. �

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ENVIRONMENT

HISTORY books will mark 2020 for the Coronavirus pandemic hitting the entire world, causing over half a million deaths and other countless problems.

Covid-19 changed our day-to-day lives and affected the global economy in a way that will be felt for many years to come.

One must hope that the lessons of 2020 will teach us how to be more proactive in order to create a more just and sustainable world for our children.

In this context, European citizens, institutions and governments have very clear tasks outlined in the European Green Deal, launched by the European Commission (EC) in December 2019 .

In the words of the EC, the Green Deal aims to transform the European Union into a fair and prosperous society, with a modern, resource-efficient and competitive economy where there are no net emissions of greenhouse gases by 2050 and where economic growth is decoupled from resource use.

Within the Green Deal roadmap, the steel industry at large is seeking to put forward innovative technologies, mostly focusing on hydrogen, in order to reach zero-carbon iron ore-based steelmaking processes by 2030. This effort, which runs in parallel with research and development on cost effective renewable hydrogen, relies on strong EU financial support through the old European Coal and Steel Community fund and the Emissions Trading System Innovation Fund.

Pilot installations at several steel plants are showing how, in the coming years, the emissions of large integrated steel plants can be drastically reduced. At the same time, a small but significant group of family- owned minimills have already demonstrated how to reduce the intrinsically low emissions of steelmaking based on recycled scrap, even further.

The feasibility of steelmaking with extremely low carbon emissions is the result of continuous EAF process improvements particularly with continuous scrap feeding and preheating combined with off gas waste heat recovery (WHR).

This best available technology to decarbonise steelmaking is largely a European achievement, thanks to the development work of dedicated technology and equipment suppliers and the forwardlooking attitude of steelmakers willing to

Low emission steelmaking Sabrina Santarossa* argues that the steel industry can play a huge part in helping to reach the European Commission’s net zero target by way of recovering heat lost in the atmosphere. In this article she discusses EAF waste heat recovery

invest in innovative applications.

The most important metal technology specialists like Danieli, Primetals Technologies, SMS, and Tenova supply advanced WHR systems to steel plants in Europe and Asia and put to good use thermal energy that would otherwise be wasted.

In instances where steel melting shops are within large integrated facilities, these WHR systems utilise existing steam networks to

feed the thermal users (i.e. pickling lines).

In case large thermal users are not available within the complex or in the nearby area, the most logical solution is to convert the recovered energy from the WHR system to mechanical/electrical energy.

This conversion could be done with steam turbines or more commonly with Organic Rankine Cycle (ORC) systems guaranteeing safety, reliability, and flexibility with minimum O&M.

*Chemical engineer, industrial heat recovery specialist, Turboden Digital Edition - August 2020

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ENVIRONMENT

The main advantages of ORC compared to traditional steam technology are both technical and operational. On the technical side, the organic fluid does not need to be superheated before expanding into the turbine due to the shape of the liquid vapour equilibrium curve. In fact, the expansion of an organic fluid in the turbine is always in dry condition, with no liquid formation.

Additionally, ORC modules have a high level of automation and do not need personnel supervision in normal operating www.steeltimesint.com

conditions or in shut down procedures. This allows the steel plant technicians to focus on their core activity, steel production. ORC modules are designed to automatically adjust to the actual operating conditions: variations on exhaust gas temperatures and flows will not affect the functionality of the system, only the power output will. In fact, ORC plants can operate in a wide range of thermal power loads (from 10% to 110% of nominal load) with high efficiency, even at partial load.

Finally, ORCs are remote-monitored

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and require minimal yearly maintenance activities compared to steam turbines, due to several characteristics of the ORC technology such as: organic fluid dry expansion in the turbine (no erosion of blades), non-aggressive and non-corrosive organic fluid, low rpm of the turbine, etc.

ORC life is longer than 25 years without the necessity of a major overhaul. Looking at all Turboden ORC units in operation, the availability is higher than 98%.

The following table (Fig.1) summarises the advanced WHR systems for electricity Digital Edition - August 2020

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production installed in the last year by two companies particularly active in this field: Tenova, whose heat recovery system is called iRecovery® and Turboden, that developed the ORC system.

The technical solution – ORC (Organic Rankine Cycle) Thanks to over 30 years’ experience and

CUSTOMER

almost 400 ORC units that are mostly used in distributed generation systems fed by renewable heat sources, ORC is now the preferred choice for demanding WHR applications in energy-intensive industries like cement, glass and electric steel melting shops.

With power ranges up to 15 MW, ease of operation, dependability and minimum

personnel are mandatory; traditional steam turbines cannot compete with ORC. In EAF heat recovery, where the thermal power available in the exhaust gas is not constant, the flexibility of ORC technology together with high reliability and selfadjusting automatic operations are defining characteristics of this solution. Because the temperature and flow-rate of the furnace

PLANT TYPE

FURNACE HEAT SIZE

AVG. DESIGN STEAM PRODUCTION

USE OF STEAM

ORC POWER

START UP

ECS

EAF, 100 t

22 t/h

ECS, WHB, ORC

EAF, 100 t

30 t/h

ECS, WHB

EAF, 90 t

27 t/h

Thermal only

2014

ECS, WHB

EAF, 80 t

26 t/h

Thermal only

2015

WHB, ORC

EAF Consteel, 100 t

16 t/h

ECS, WHB

EAF, 100 t

33 t/h

ECS, WHB, ORC

EAF, 150 t

25 t/h

Thermal & Electric

2,500 kW

2019

WHB, ORC

EAF Consteel, 260 t

52 t/h

Electric only

7-10,000 kW

2018

GMH Germany

Thermal only

2007

Feralpi Germany

Thermal & Electric

2,700 kW

2014

Hyundai Steel Korea Hyundai Steel Korea ORI Martin Italy

Thermal & Electric

2,200 kW

2015

TPCO China

Thermal only

2015

Aichi Steel Japan Arvedi Italy

Fig 1.

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fumes change continuously during the furnace tapping cycle, the design of the heat recovery system is optimised to store part of the steam produced during power on so that during power off, the steam accumulated is sent to the ORC allowing it to work continuously and automatically.

An example of the variable working load of a working EAF WHR plant is detailed in the charts below. The steel shop is located in Italy at Acciaieria Arvedi in Cremona and the actual EAF is a Consteel® of 250

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ton. Arvedi has a large iRecovery® system coupled with an ORC unit converting the off-gas waste heat generated steam to 7 MW power. The ORC will soon reach 10 MW once the present Consteel® EAF is finally upgraded at the end of summer 2020 to increase production and maximise waste energy recovery.

The data shown in the chart was collected over 10 EAF heat cycles. In Fig.2 it is shown in green the furnace power On and Off, in violet the thermal power

Fig 2.

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Still, the investment cost and the resulting payback time, often-exceeding five years, are restraining the growth of EAF WHR plants unless capital grants or other incentives on actual energy saved in industrial operation become available.

The further growth of new and improved EAF WHR installations will depend on the future of EU policies and countryspecific policies. Right now, there are few incentive schemes. There needs to be increasing implementation across multiple geographies in order to support the use of waste heat actually present in ambient air.

Another opportunity for steel producers is the use of cooling heat generated from a melt shop to power the heating of nearby towns. When melt shops are located next to cities or even industrial parks that require hot water for heating, very often the temperature from the EAF cooling system is lower than what is required. In this case, it is possible to increase the water temperature to optimal levels by using a heat pump; the first large heat pump will be installed in Ori Martin thanks to a Life 2020 project financed by the European Commission.

Fig 3.

available from the off gas and in red the thermal power sent to the ORC. In the second chart, (Fig.3) the steam produced by the heat recovery exchanger in grey and the steam input to the ORC is in red.

In both charts, the highly variable steam/ thermal power available during power on and off is made clear. Additionally, the almost constant steam/thermal power sent to the ORC thanks to the buffer tank that smooths the picks and allows the maximum energy recovered and produced by the system, is evident.

The relation between steam input (in blue) to the ORC and electric power production (in white) is shown in Fig.4.

Steam sent to the ORC is in the range of 40-55 ton/hr and is continuously converted into 6-7 MWe even when EAF furnace power is off. As expected, the WHR system was designed to produce up to 70 ton/hr of steam and 10 MWe; soon it will reach this capability after a Consteel® upgrade.

Conclusion The steel industry can play a huge part in helping to reach the European Commission’s net zero target by way of recovering heat lost in the atmosphere.

Heat recovery in the steel industry is possible and there are already some great examples of WHR plants in the world. The Green Deal should aim to incentivise the steel industry to improve and implement this solution. �

Fig 4.

Economic feasibility Both the heat recovery exchanger that generates steam and the ORC unit guarantee minimum overall O&M costs thanks to inbuilt technology and improvements resulting from operating experience.

Additionally, the specific capital costs of WHR systems have been decreasing from the first to the most recent plant with increasing size (scale factor) and improved simplified design. It is expected that this trend will continue into future projects with further lower cost per kW of produced energy.

Digital Edition - August 2020

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DIGITALISATION

Ecosystems, environment and hot data The disruptive vectors of climate change, globalisation and technology are infusing seismic shifts in the energy and natural resources industries. To analyse their impact, IBM has developed the threedimensional DiSETM Model. By Bala Seshank* and Pritam Pritu*

THE world is fraught with galloping change and compounding uncertainty, and the 2018 message from Thomas Friedman is pertinent like never before.

“We’re in the middle of three climate changes, not just one.

The world is moving from being an interconnected one, to being interdependent, and it is the most adaptive that survive” These disruptive vectors are infusing seismic shifts in the energy and natural

resources industries.

While the focus on the environment has been there for some time, this is to broaden perspectives and include the other two facets – globalisation and technology – to build an holistic image; to ensure a coordinated effort in adapting to the change.

We formulated a 3-dimensional “DiSETM Model” based on the three vectors, to analyse their impact on the future of the industry. (Fig.1) The framework intuitively draws attention to the 4th quadrants in each of the planes, while steering clear of the ‘no-

fly zones’. To thrive, challenges must be addressed holistically. Future leaders will be the ones who adopt a business strategy that balances, and leverages, these three dimensions. Neglecting even one will be a recipe for trailing into oblivion.

Digital technologies are essential to progressing along sustainability and business networking objectives. The E2E steel value chain has a great responsibility to be the builder in both economic and societal capital.

In the ‘new normal’ there are seven themes that demand attention. (Fig.2)

Fig 1.The DiSETM Model

Do you know your DiSETM Quotient? *Bala Seshank is a Partner with IBM with over 20 years in the natural resources industry. He leads the global metals practice for IBM. bala.seshank@in.ibm.com linkedin.com/in/bala-seshank-61b3491/ **Pritam Pritu is the Japan leader for the global metals practice at IBM with over 20 years of experience working in the metals industry. pritam.pritu@ibm.com linkedin.com/in/pritam-pritu-521b0a7/ Digital Edition - August 2020

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Fig 2. Seven themes that demand attention

Fig 3. Company performance after recession

Fig 4. Action areas where Natural Resources leaders and operations need to remain focused

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Fig 5. Resolve, recover and reinvent

It is vital to measure digital success at the right granularity and standardisation. We need to take a cue from macroeconomics, wherein a metric as fundamental as GDP has been augmented by its digital twin ‘the GDP-B’.

Similarly, we need to ‘componentise’

overall equipment effectiveness (OEE) with specifics for each stage of the value chain.

For example, for break-out detection in steel casting, this translates to identifying the true metric for the process. Here, false negatives could be the measure, which eventually translates into OEE (via casting

speed and hence throughput), while being more measurable.

Eventually, industry needs a standardised set of metrics, which become common language in the steel ecosystem helping define new benchmarks, paving the way for focused and measurable digital

Fig.6: Imperatives for Steel Industry for COVID-19 Response

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Fig.7. The two chapters of the journey of digital excellence

interventions.

Looking at the current economic slowdown, we see a lot of lessons to be learnt from the ongoing phase, correlations from past economic downturns and cues for a future resilient industry. (Fig.3) This leading HBR paper also calls out

that organisations that maintained a growth perspective and continued making processes efficient, most specifically with technology, have gone on to flourish in the post-recession period. Our endeavour is to help our clients to continue their transformative agendas largely undeterred

by the current situation.

Coming to specifics, the current pandemic and the expected immediate post-pandemic phase has four areas of focus, as shown in Fig.4.

Organisations need a balanced approach while formulating their strategy for the

Fig 8. Key success factors for improving the DISETM quotient and become a Cognatuve Enterprise

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Fig 9a. Examples of organisations collaborating on industry platforms

pandemic response as well as the future, covering short-term, mid-term and longterm priorities; and have an integrated action plan. We call this the 3R – Resolve, Recover and Reinvent (Fig.5) For the steel industry, the key actions in the three horizons are summarised in Fig.6.

How to infuse digital into the steel business?

At the outset, let us suggest that we are in a transition to a new digital chapter for the industry. Let us refer to this as Chapter 2.

So, what then is Chapter 1 and how is Chapter 2 different from Chapter 1? (Fig.7) The industry has been in an exploratory phase that had a lot of experimentation and proof of concepts to satisfy the inquisitive.

Now is the time for cynics to become believers.

Now, believers are taking charge to move into a stage where businesses transcend experimentation towards scaled transformation, leveraging AI and other exponential technologies into their business workflows.

The Cloud provides the right level of Digital Edition - August 2020

elasticity – process, storage, orchestration and collaboration and, above all, the confidence to take large strides.

Companies that get this journey right are on their way towards becoming a ‘Cognitive Enterprise’, the optimal state for the Industry 4.0 revolution.

What are the levers of success for this journey, and how is progression along the three dimensions of the DiSETM Model helping to achieve the cognitive enterprise vision?

Organisations should leverage the DiSETM model to arrive at their position based on their DiSETM quotient. (Fig.8) We explain next what each of these means, by alluding to specific experiences from IBM’s work with clients in the energy and natural resources industry.

I. “Collabtition” – openness and collaboration: The current era is witnessing a fundamental shift towards open. This comes from the realisation that companies cannot acquire all of the capabilities in areas where they

need innovation. Having a culture that is able to actively innovate as part of the community is vital.

The steel industry can take a cue and accelerate along this vector.

A. Partnering in ‘Collabtition’ Partnering across ecosystems, learning from other industries, and each other, allows companies to contribute their own insights leading to an ecosystem-wide benefit maximisation.

• A typical example in the oil and gas industry is an open sub-surface data universe (OSDU), to define open data standards that would substantially improve the efficiency and effectiveness in the workflows around analysis, exploration, drilling and sub-surface (Fig.9a).

B. Collaborate on Industry Platforms Investment in platforms is a big bet that almost all digital leaders are making, by building, buying or joining different platforms. These ‘crowd-contributed’ resultants will evolve into industry platforms, which serve as channels to www.steeltimesint.com

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Fig 9a. Examples of organisations partnering in collabtition

sharing and trading digital assets. This fosters social responsibility along with a culture of innovation.

Responsible Sourcing Blockchain Network (RSBN) is an example of pervasiveness of social responsibility across the ecosystem.

There are learnings for steel companies here, to replicate and lift their DiSETM Quotient.

Another example is TradeLensTM which is revolutionising the world of container shipping, bringing efficiency, accuracy and trust.

Urban mining of aluminium from construction, batteries, cans and electronics is seen to be the next big thing in recycling as the industry strives in its progression towards a low carbon value chain. (Fig.9b) C. Inter-operability with ecosystem partners The era of democratisation of knowledge is here and businesses will win or lose based on their openness to embrace this principle.

Inter-operability for exchange of insights is key and will fuel the cognitive steel enterprise.

IBM Research is working with MIT to

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advance the body of knowledge of AI along with industry partners and is working with multiple global chemical companies with its world-leading quantum computer to advance new material discovery. Steel/ metals as an industry is next in line for such a collaboration, as the quest for newer, lighter, ‘greener’ alloys grips the landscape.

The OptimineTM Data & Analytics platform that Sandvik and IBM have built for driving operational efficiency in underground mining is another strong example. Sandvik recognises that many of its customers operate rainbow fleets and has made this platform inter-operable with its peers’ equipment.

At ThyssenKrupp Additive Manufacturing, securing intellectual property and data sovereignty of the members in an Additive Manufacturing business network is considered paramount. This needed to transcend conventional constraints and move towards a secure, trust-centred collaboration aided by smart tech, such as blockchain.

The DiSETM Model prescribes that digitisation of processes needs to be accompanied by an openness to collaborate

and deliver an ecosystem-wide elevated baseline for maturity.

II.INTEGRATED AND INTELLIGENT WORKFLOWS: Intelligent workflows transform operations from the ‘inside out’. Scaling up digital transformation needs re-imagining and the creation of intelligent workflows that change the way of work.

These workflows ensure data-derived competitive advantage and are exposed as SMART services, shared on its own or collaborative industry platforms, to create the cognitive enterprise.

There are applications across the value chain, that have helped address process constraints and scale maturity: (Fig.10) Materials discovery amplifies R&D capabilities to expedite product development with a specific ability to investigate new ideas and product possibilities faster.

AI-enabled order dressing at Gerdau Speciality Steels require the analysis of hundreds of variables and the investigation of many thousands of previous materials.

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Fig 10 Examples of organisations embedding intelligence in their workflow

This learning process is significantly impacted by the level of experience of the metallurgists.

Cognitive Asset Management at JFE Maintenance in steel plants needs a very high degree of technician expertise, which is fast becoming scarce due to attrition/ retirement of the workforce. Newer technicians are aided by this solution for faster resolution.

Smart Plant at Tier-1 Canadian Steel Major Using AI to predict process stability in the ladle metallurgy furnace and provide

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prescriptions for efficiency improvement.

E2E Supply Chain Operations – MineHubTM Technologies has launched its trading platform to help improve operational efficiencies, logistics and financing and reduce costs in the high-value mineral concentrates supply chain ­­– from mine to end-buyer.

The World Economic Forum-driven MMBI – Mining and metals blockchain initiative is an emerging example.

A common thread across these examples is diversity of operations, geographies, plant OEMs, data granularity, latency and volume,

and a need for open communication standards. This needs a hybrid data foundation (edge + on-prem + private + public cloud) supported by a heterogeneous mix of technology infrastructure and service providers.

The DiSETM model prescribes that digitisation and embedding of intelligence into workflows needs to be accompanied by an unwavering linkage to sustainability in order to render supply chains traceable, responsible and efficient.

III. CULTURE AND SKILLS: The Cognitive Enterprise is one that thrives on a culture of learning and innovation

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where skills are of great importance.

A. New ways of working Co-creation using design thinking and agile development with frontline employees is vital to progress along the DiSETM model.

An example of convergence of people, practices, places and platforms is the ‘IBM Garage’, which has been critical to help clients achieve scale in their digital journey.

There are many successful examples of this across natural resources industries including with BP, Shell, Exxon and Sandvik.

In an industry first, IBM is in advanced discussions with a Tier-1 steel company to build an enterprise-wide platform to onboard blast furnaces/ladle metallurgy furnaces etc. The objective is to bring about a ‘Federated Learning’ mechanism across plants, so as to maximise overall knowledge (human and algorithmic) of operations for higher consistency as well as eventual time-to-skill for new operators.

This concept is spreading across the metals industry including to other complex core areas such as smelting, casting, shaping and treatment.

B. CULTURE: Companies in the steel and metals industry have a critical role to play in addressing the gap between their brand perception and the benefits of their products and services, particularly for the younger generation who represent the future investors and workforce. Agile, multi-disciplinary teams with T-shaped talent characteristics greatly accelerate this transition.

A case-in-point is IBM’s active transformation of its culture to adopt the

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various items mentioned above, making it the world’s largest design agency, adopting agile and design thinking as a way of life.

C. TALENT TRANSITION Skills are top of the agenda for all CEOs. This is a realisation from a recent IBM study of 1,000 CHROs across industries as well as from the Big Bets conference. Skills availability and quality are in jeopardy. The half-life of hard skills continues to shrink (now estimated at 3-5 years), while the time it takes to close a skills gap has ballooned tenfold in just four years. Organisations must find ways to stay ahead.

Intelligent automation is an economic game changer; AI and automation will definitely change 100% of jobs. Most executives don’t believe their organisation is prepared for the required re-training. Of greater concern is that only 38% of CHROs believe their organisation has an obligation to retrain or re-skill workers impacted by AI or automation.

While there is clear recognition that digital skills remain vital, executives tell us that behavourial skills are critical for organisational agility and adaptability.

Organisations must broaden their hiring strategies beyond traditional methods of seeking college education degrees and former job experience.

They must do so by taking advantage of two critically important talent pools that possess those behavourial skills that are imperative to success in the workplace: Mid-career (who have the wealth of experience and soft skills) and ‘newcollar’ workers (who bring technical and professional competencies). The key is

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continuous learning and re-skilling.

Closing the skills gap requires action at multiple levels – at individual, enterprise/ industry and government level.

Examples IBM is rising to this challenge with its P-Tech programme, which is a public-private partnership – Pathways in Technology Early College High Schools (P-TECH) are innovative public schools spanning grades 9 to 14 that bring together the best elements of high school, college and career, combining industry internships and classroom education. In six years, students graduate with an associate degree and much sought after technical and soft skills. Today, there are 200 P-TECH schools with more than 100,000 students in 18 countries.

We urge the steel industry to engage in P-TECH or similar programmes to make a meaningful impact on the skills needed for the future.

In summary, organisations, while progressing on their journey towards the cognitive enterprise, will need to be cognizant of the three dimensions of the DiSETM Model and measure their DiSETM Quotient; not just to track where they stand, but to strategise appropriately.

The Chapter 1 initiatives have served well to establish the value potential of the three dimensions of digitisation, ecosystems and sustainability, individually.

The impact has been locally pronounced.

What is needed is the scale, integration and intelligence of Chapter 2 to create a significant movement of the needle along the DiSETM Quotient. �

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Hydrogen-based green ironmaking – f In this article, the author asks if hydrogen can be a potential replacement for carbon as a reducing agent for iron ores and ore agglomerates. Hydrogen would open the possibility of a dramatic reduction in the emission of the global warming gas, carbon dioxide. Laboratory studies and industry efforts are under way to realise such a scenario. The key enabler for this, however, hinges on the availability of hydrogen produced from renewable sources at a much cheaper cost than at present. By Debasis Mukerjee*

In 2019, global crude steel production accounted for 9.6% of the world’s CO2 emissions, this figure rising to 12-15% when further processing, transport and mining is taken into account.

THE concept of developing green technologies, without emissions of carbon dioxide (CO2), a greenhouse gas (GHG), into the atmosphere, or with a substantial reduction of CO2 and other GHG emissions, started gaining ground in the early 1990s when global warming became a matter of serious debate. Out of the six greenhouse gases (CO2, CH4 (methane), N2O (nitrous oxide), HFC (hydrofluorocarbons), PFC

(perfluorocarbons) and SF6 (sulphur hexafluoride)), CO2 was identified as the most serious offender because of the quantity emitted, and the principal reason for global warming. In terms of the global warming potential (GWP), the other five gases have a much more aggravated effect on the environment compared to CO2.

However, their volumes of anthropogenic generation being much smaller than that

of CO2, their effect on the environment is less severe. From a level of 280 ppm of CO2 concentration in the pre industrial revolution era (prior to 1760 AD), the planet currently has an alarming level of 416.39 ppm (as of June 2020)[1] This is expected to touch a dangerous level of 450 ppm by 2030 or even earlier unless we wean ourselves from the over dependence on fossil fuel-based technologies. There are

The author is the former Ministry of Steel Chair Professor at the National Institute of Foundry and Forge Technology (NIFFT), Ranchi, India and the former Executive Director In-charge, R&D Centre for Iron and Steel, SAIL, Ranchi, India Email: debasismuk@gmail.com Digital Edition - August 2020

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from a futuristic Indian perspective discussions and protests, world over, to reduce carbon emissions to decelerate its adverse effects on climate change. The face of the protest in 2019 was led by a 17 year -old young Swedish environmental activist, Greta Thunberg.

Kyoto Protocol The Kyoto Protocol is an international treaty which extends the 1992 United Nations Framework Convention on Climate Change (UNFCCC) that commits state parties to reduce GHG emissions, based on the scientific consensus that (in part one) global warming is occurring and (in part two) it is extremely likely that humanmade (anthropogenic) CO2 emissions have predominantly caused it. The Kyoto Protocol was adopted in Kyoto, Japan, on 11 December 1997 and entered into force on 16 February 2005[2]. There are currently 192 parties/nations signed up to the Protocol. The only nations that did not sign were Afghanistan, Sudan and the USA, while Canada withdrew from the protocol in December 2012.

Between 1990 and 2012 the original Kyoto Protocol parties reduced their CO2 emissions by 12.5%, which was well beyond the 2012 target of 4.7% (CO2 only, rather than all greenhouse gases, and includes Canada). The Kyoto Protocol was, therefore, a huge success. In February, 2005, the Kyoto Protocol to the UNFCCC came into force, but without the participation of the United States.

Melting of glaciers from global warming results in large scale ecological damage

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consortium.

Starting around October 2004, the ULCOS programme aimed to halve the CO2 footprint of the integrated blast furnace (BF)-basic oxygen furnace (BOF) route, from an average of around 1.8 tonnes of CO2 per tonne of steel produced, by 2050 compared to 2004. This was a very ambitious target.

In the initial phase of ULCOS, several new iron making technologies were explored and investigated at pilot plant scale. In the next phase, starting 2010, further development of selected technologies to create an industrial demonstration plant and commercialisation was foreseen. Some of the commercial technologies, under ULCOS, that are currently being used in the steel industry, in the primary iron making area, includes, Top Pressure Recovery Gas Turbines in Blast Furnaces (BF) for power generation, Top Gas Recycling BF (TGR-BF; a variant of blast furnace (BF) where the top gas of the BF goes through CO2 capture and the remaining reducing gas is reinjected at the base of the reactor), Carbon Capture and Storage (CCS) and HIsarna (this process is based on the combination of a hot cyclone and of a bath smelter and incorporates some of the technology features of the HIsmelt process and uses iron ore fines and non-coking coal).

Coke rates in the blast furnace have fallen below 500kg/t but hydrogen injection offers further reduction. Photo: Primetals.

Response of steel post Kyoto In the post-Kyoto era, the resolve to lower the carbon footprint of the steel industry was initiated by the European steel industry when it embarked on the ULCOS (Ultra Low Carbon Dioxide Steelmaking programme) [3] . ULCOS was a unique partnership of 48

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organisations across 15 nations of European steelmakers, technology and equipment suppliers, institutes and universities. Tata Steel, in April 2007, by virtue of taking over the UK’s Corus Group (the merging of British Steel and Hoogovens, Netherlands in 1999) created an Indian participation in the

Future steel production Present steel production technologies are based on coal, and on natural gas – a mix of carbon and hydrogen – and on scrap based electric arc furnaces (EAFs).

To identify CO2-lean process routes, three major possible paths are: • A shift away from coal, ie decarbonising, whereby carbon would be replaced by hydrogen or electricity, in

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processes such as hydrogen reduction or electrolysis of iron ore; • The introduction of carbon capture and storage (CCS) and mineral carbonation technologies, and; • The use of sustainable biomass.

Hydrogen replacing carbon Now let us explore the advantages, status and possibility of using hydrogen (H2) as an alternate reductant to carbon (C) and carbon monoxide (CO) in iron and steel making processes and the evolution of hydrogen-based green technology especially during iron making. We know that coking coal accounts for more than 65% of the primary source of energy in a conventional iron and steel complex (BF – BOF route).

Moreover, the energy costs represent 2040% of production costs in an integrated steel mill. And out of this cost component, the major share is on account of energy costs related to the primary area, namely, coke making, sinter production and iron making. Therefore, any other form of fuel, replacing mainly coking coal, has to demonstrate that it can be effectively used as a cheaper and safer alternative and in a technologically efficient manner providing a positive impact on the economics of production.

Primarily, hydrogen as a fuel has the potential and can replace other forms of reductants such as coke, pulverised coal, natural gas (mainly CH4), tar, plastics or other forms of hydrocarbons presently injected into some blast furnaces to lower coke consumption. There are two advantages of using hydrogen as a reductant. It is a superior and more efficient reductant than carbon/carbon monoxide4,5]; being at least 3-4 times faster when in its

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Hematite ore is used in preference to magnetite as reduction by either CO or H2 is an exothermic reaction, while reduction of magnetite to iron is endothermic when using H2 as reductant

Reaction

Heat

Description No

3Fe2 O3 + CO → 2Fe3 O4 + CO2

Exothermic

Reduction by CO

3Fe2 O3 + H2 → 2Fe3 O4 + H2O

Exothermic

Reduction by H2 2

1

Fe3 O4 + CO → 3FeO + CO2

Endothermic

Reduction by CO

Fe3 O4 + H2 → 3FeO + H2O

Endothermic

Reduction by H2 4

3

FeO + CO → Fe + CO2

Exothermic

Reduction by CO

FeO + H2 → Fe + H2O

Endothermic

Reduction by H2 6

5

Table 1. Stage wise reduction reactions from hematite to iron by CO and H2

atomic state (H) compared to molecular hydrogen (H2)[6]. The diffusivity of H2 in liquid iron and solid iron is also an order of magnitude faster than for carbon[7]. The overall time for the reduction process to be completed can be significantly reduced if hydrogen is used in its plasma state (ionic state). Ionic hydrogen (H+) is known to act as a far superior reductant than atomic

hydrogen (H) or molecular hydrogen (H2) , which can, therefore, have a profound influence in speeding the reduction process so increasing productivity and yield. Using hydrogen for reduction of iron ores is classified as a green technology because the interaction of hydrogen with oxygen in the iron ores produces water vapour, which has an atmospheric cooling effect, as [5,6]

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Using hydrogen to replace oxygen during lancing in a BOF steel converter is not possible. Photo: Primetals.

opposed to the warming effect of carbonbased reduction processes that lead to the production of CO2. The use of natural gas (CH4) as a reductant has also gained popularity. Compared to coal, which has a larger fixed carbon concentration and some hydrogen, methane has one atom of carbon linked to four atoms of hydrogen by covalent bonding. More water vapour is generated by volume than carbon dioxide when using methane as a reducing agent. Methane is a better reductant than coal because of its larger hydrogen concentration and hence technically is a superior reductant besides producing less CO2. However, methane as a reductant is not popular in India (other than in western parts where it is available from offshore platforms) because of the price and lack of availability in volume. All the carbon entering a steel complex leaves as CO2.

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Therefore, it is important to restrict carbon use to the barest minimum possible. The use of hydrogen as an alternative to carbon will be welcome and efficacious provided it meets certain specific paradigm conditions.

fuels by steam reforming of natural gas, partial oxidation of methane, and by coal gasification[8]. Other methods of production include biomass gasification and electrolysis of water.

Restraints of using hydrogen Of the problems in using hydrogen in a steel complex, safety of handling and availability of the gas at a competitive price are major concerns. Hydrogen, being a potentially explosive gas, requires an immaculate handling protocol. Storage and safe technical handling of the gas has to be mastered. The cost of hydrogen in India is relatively expensive, presently around Rs 875/kg; ~ US$11.7/kg). Efforts are being made to produce hydrogen through electrolysis of water in an efficient and cost effective manner. As of 2018, the majority of hydrogen (~95%) is produced from fossil

Use of hydrogen in blast furnaces The blast furnace is by far the most versatile, process-efficient and cost effective counter current convertor for the production of liquid iron. To use hydrogen gas as a reductant, injected through the tuyeres, the blast furnace has to undergo several design modifications. Some of the salient ones entail: • Lance and tuyere design (tuyere technology) has to be fine-tuned to maintain thermal and raceway stability adjacent to injection zone; • Proper distribution of the gas across the radius of the furnace is needed for

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uniform conditions; • Development of advanced sensors for monitoring temperature, pressure, gas composition and burden descent at various levels in the furnace, and; • Ensure injection of hydrogen in ionic or plasma state (at a temperature around 3000°C) to achieve fast and consistent reduction.

Presently blast furnaces operate at around 2000°C at the tuyere level to around 200°C in the top throat area. To withstand very high temperatures (~3000°C), near the tuyere level, the development of very high temperature resistant refractories, made from pure graphite and/or a mixture of high quality alumina have to be designed.

Additional and appropriate cooling panels for extending refractory life have to be put in place. Several artificial intelligence inputs (AI) may also be required.

Energy considerations for reduction of iron ores For any reduction process to be energetically feasible and stable, it should be an overall exothermic reaction not requiring external thermal inputs.

Otherwise, the cost of production will be prohibitive. The reduction stages of iron ore require the reactions given in Table 1. The reduction process involves hematite (Fe2O3) to magnetite (Fe3O4); magnetite (Fe3O4) to wustite (FeO) and then wustite (FeO) to iron (Fe) as solid or liquid. Reduction by CO or H2 is considered in each case. Whether the reduction is achieved using H2 or C/CO, the magnetite to wustite reduction is always an endothermic reaction absorbing thermal energy. However, the reduction reaction of hematite (Fe2O3) to magnetite (Fe3O4) is an exothermic reaction irrespective of the type of reductant, whereas reduction of

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The FINEX smelting reduction process charges iron ore fines to produce hot metal via a four-stage fluidised bed reactor. Diagram courtesy of Primetals.

wustite (FeO) to iron (Fe) is an exothermic reaction if C/CO is used and an endothermic reaction if H2 is used. The heat absorbed during magnetite to wustite reduction is less than the heat generated by hematite to magnetite reduction. Generally, the heat absorbed during the reduction of wustite to iron, using H2 as a reductant, is of a lower magnitude. Therefore, this should not pose much of an energy barrier for the overall reduction process to proceed when using H2. In the Midrex process (a vertical shaft furnace using reformed gas to produce H2), producing solid state direct reduced iron, the same set of reactions take place.

To make the process energetically sustainable, be it blast furnace or Midrex technology, magnetite alone cannot be used as the prime raw iron ore material.

Therefore, it is expected that even if hydrogen is used in the plasma state, magnetite ores alone cannot constitute the prime iron ore raw material in either the blast furnace or Midrex process. This is the reason why hematite ores of high Fe content (> 60%) are preferred in blast furnace operation. In general, whether using hydrogen or carbon monoxide as the reducing agent, a higher permeability raw material leads to better reduction of iron ores, achieved by charging pellets, and/or

sinter. This greater permeability enables the reducing gas to reach the reaction interface.

Limonitic ores have the highest porosity and show the best reducibility, followed by hematite and magnetite which has low porosity[4].

India’s progress in H2 reduction Around 2010, the Ministry of Steel, Government of India (GoI) sponsored a project submitted by the Institute of Minerals and Materials Technology (IMMT), Bhubaneswar under the Council of Scientific and Industrial Research (CSIR), established

by GoI. Formerly known as the Regional Research Laboratory (RRL), the aim was to develop process knowhow for green ironmaking technology using hydrogen.

IMMT had designed and developed a plasma reduction furnace to reduce hematite to iron. The rate of hydrogen injection was carefully controlled and the plasma torch was able to inject hydrogen at a temperature of ~3000°C. Initial trials using a graphite and water-cooled copper crucible permitted contamination of pure iron, through pick up, with reasonable contents of C and Cu. The next phase of trials, conducted with microwave-assisted hydrogen plasma, witnessed the reduction of 2 - 100g of iron ore to metal of high

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Emerging iron making technologies such as the rotary hearth ITmk3 provide a feed to electric furnaces. Photo: Midrex.

purity (typical composition (wt%): Fe-99.5, C-0.02, Si-0.085. P-0.02, S-0.005 and Al-.0.025)[6]. The starting material feed comprised pellets made from hematite fines of ~ 65% Fe content. In the next phase of the trial, involving up-scaling of the process, IMMT joined with a private partner and successfully produced 10kg ingots of high purity iron, wherein the slag and metal were segregated efficiently. The Institute patented the process technology. IMMT is currently exploring avenues of developing process technology for larger melt sizes of 100kg and beyond.

To take the initial gains made to the next higher level of indigenous development of a complete commercial level technology package, a full mission mode approach would be required, involving IMMT, other basic and applied research laboratories, large domestic steel manufacturing companies, algorithm and software development experts, simulation specialists, equipment and technology manufacturers’, sophisticated sensor development experts,

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blast furnace process designers, safety consultants, hydrogen gas suppliers, green hydrogen producers and various wings of GoI - ie Steel, Dept of Science and Technology (DST), Alternative/Renewable Energy, Bureau of Indian Standards (BIS) etc. If adequate resources are made available and properly co-ordinated – in terms of finance, optimal pooling of indigenous human and organisational talent and creation of sophisticated infrastructure – India may come out with a workable commercial solution in 10 to 15 years.

Industrial use of Hydrogen in steel Hydrogen use in blast furnace at ThyssenKrupp Steel (TKS) in Germany is the first major step toward carbon neutral steel production as reported in Renew Economy[9].TKS was the first to start trials with hydrogen injected into a blast furnace in November 2019, at its Duisburg plant.

They injected hydrogen through one of the 28 tuyeres in blast furnace No. 9. Some

encouraging results have been noted. This marks the start of a series of tests in which TKS plans to gradually extend the use of hydrogen to all 28 tuyeres on the furnace and then, from 2022, to all three further blast furnaces. The company presumably is using conventional hot blast temperatures of ~1200°C to 1250°C, which means injection of molecular/atomic hydrogen and not ionic gas has been attempted.

It is believed that hydrogen gas injection will initially aim to replace a portion of the pulverised coal presently injected into the furnace. Further, this may eventually look at the possible replacement of a part of the coke in the burden.

These tests are an important part of ThyssenKrupp’s climate strategy to become climate-neutral by 2050. By 2030, emissions from the company’s own production and processes as well as emissions from the purchase of energy are to be reduced by 30%. The project was funded under the IN4climate initiative of the state of North Rhine-Westphalia (NRW) and reflects a seamless approach of business and government working in partnership mode towards a common goal.

ThyssenKrupp has indicated that hydrogen required for iron production is to be produced by electrolysis of water.

Green hydrogen from renewable sources is not presently available in large quantities to replace coal. Two of Germany’s biggest polluters, power company RheinischWestfälisches Elektrizitätswerk AG (RWE AG) and steelmaker ThyssenKrupp, have agreed to join forces with a view to lower carbon emissions by using hydrogen. The two companies will work together towards a longer-term hydrogen partnership, with the first hydrogen generated set to flow towards the Duisburg steel mill by

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the middle of the decade. Further, the two companies agree that only electricity from renewable sources would be used to operate the electrolysers.

Hydrogen for heating at Ovako In Sweden, a reported breakthrough by Ovako Steel was essentially related to the use of hydrogen as a fuel for reheating furnaces in preparation of heavy sections for hot rolling. This has the potential to lower carbon emissions and so the carbon footprint of a steel complex, but has nothing to do with producing iron or steel.

However, technically the process qualifies as an application of green technology.

The trial at its Hofors steel mill, in conjunction with hydrogen producer Linde Gas, showed that hydrogen can be successfully used in this application, replacing liquefied natural gas (LNG) as the source of reheat furnace fuel[10]. This is the first time that hydrogen has been used in an existing production environment.

Further, it was reported the process had no adverse effect on the quality of steel rolled.

The trials clearly demonstrated that carbon dioxide emissions during furnace heating can be eliminated and significantly reduce the carbon footprint emanating from this operation in a steel mill operation.

Ovako already uses electric-arc furnaces powered by renewable energy to melt scrap steel, but was using LNG to heat rolling stock. More than 95% of the world’s hydrogen is presently derived from natural gas and coal, causing 9 to 12 tonnes of CO2 emissions for every tonne of H2 produced[10].

Although hydrogen is a clean gas, releasing only water vapour when burned, this poses a pertinent question whether replacement of coke, coal or LNG used in steel production with H2 is worthwhile, unless that hydrogen is produced from renewable energy (green H2) or if the CO2 emitted in its production is captured and stored (blue H2).

Both green and blue hydrogen are currently expensive to produce and, only available in limited quantities and would increase the cost of steel production. (See STI July/ August 2020 pp29-31 for further details).

One ULCOS pilot trial recirculates blast furnace top gas after removal of CO2

When can India use H2?

Carbon neutral technologies (for production of liquid iron, liquid steel, ladle preheating, furnace heating etc) have apparently tremendous advantages from a climate control perspective by lowering CO2 emissions from a steel mill.

These technologies will essentially entail replacement of carbon and hydrocarbons by climate-friendly hydrogen. To have a visible and significant impact for the steel industry, the replacement by hydrogen has to be mainly in the primary area, which accounts for around 65% to 70% of the total energy consumption.

As far as efforts in India towards liquid iron technology using hydrogen in the plasma state, for faster reduction kinetics, capability has been built presently producing 10kg iron ingots of high purity.

Commercial scale technology may be feasible in a time frame of 15-20 years if a concerted mission mode approach is adopted involving various stake holders.

However, the success of profitable exploitation of technology is subject to cheap availability of hydrogen gas in adequate quantities and establishment of safe handling procedures for this explosive gas.

One of the cheaper alternatives for making hydrogen is by splitting water through electrolysis employing a much less expensive catalyst than the platinum or iridium presently used. Experiments in the USA at the SLAC National Accelerator Laboratory (previously named Stanford Linear Accelerator Centre) and Stanford University, have published information that using polymer electrolyte membrane and cobalt phosphide nano-particles placed on carbon to form a fine black powder mass catalyst can prove to be an effective and cheaper catalyst for continuous production of hydrogen[11]. Hydrogen produced in a cheaper way on a continuous basis, from renewable sources, will surely trigger its use in the steel industry.

Solid iron pellets are produced in a DRI shaft furnace by reduction by H2 and CO produced by cracking natural gas. Photo: Primetals.

Issues and concerns in Indian context There are some relevant and specific issues concerning the application and use of hydrogen for iron and steel manufacture in India in future. Let us try to examine and analyse some of the evolving scenarios.

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HIsmelt uses iron ore fines and non-coking coal in a combined hot cyclone for initial reduction and a bath smelter

Using hydrogen to replace oxygen during lancing in a BOF steel converter is not possible. Oxygen, apart from decarbonisation during steelmaking, also fluxes other impurities in steel to form various oxides, which help to condition the slag and control its basicity for subsequent partitioning of impurities and dephosphorisation. Though hydrogen injection in the convertor lance can theoretically lower carbon concentration in the melt, it will not perform conditioning of the slag and control its basicity.

Can natural gas or H2 replace coal?

Replacing coking coal by hydrogen in iron and steel making is not likely in the very near future; it may be a bit far away until enabling conditions prevail. The primary reason for this is the non-availability of cheap hydrogen in requisite quantity, assuming that safety considerations related to gas handling are in place. In India, natural gas (NG) use in iron and steel manufacture is restricted and is only being used for Direct Reduced Iron (DRI) production in shaft furnaces in the western part of the country. NG is mainly exploited from off-shore basins near western India.

Access to cheap and adequate quantities of NG in the central and eastern parts, where steel manufacturing units are primarily located, has to be ensured to promote its use. DRI is also made in India in horizontal rotating kilns using non-coking coal as the reductant. The transition from coking to non-coking coal/NG use will happen in future. The feed material for DRI production, where NG or non-coking coal is used as a reductant, consists of pellets and/or lump ores. In the case of emerging iron making technologies such as FINEX, HIsarna, HIsmelt, ITmk3 etc., coking coal has been replaced by non-coking coal Digital Edition - August 2020

and these technologies simultaneously use iron ore fines or concentrates. In India these technologies presently are yet to be exploited on a commercial scale for various reasons.

Indian steelmaking by 2040 Asia, where China and India are major players, accounts for the lion’s share of global steel production. With huge iron ore reserves and likely abundance of natural gas, what is the expected Indian steel scenario by 2040?

Global crude steel production reached 1,869.9 million tonnes (Mt) in 2019, up 3.4% over 2018. Crude steel production contracted in all regions in 2019 except in Asia and the Middle East. Asia produced 1,341.6Mt of crude steel in 2019, an increase of 5.7% compared to 2018.

China’s crude steel production in 2019 reached 996.3Mt, up 8.3% on 2018.

China’s share of global crude steel production increased from 50.9% in 2018 to 53.3% in 2019. India’s crude steel production for 2019 was 111.2Mt, up 1.8% on 2018. India’s share of global crude steel production decreased from 6.0% in 2018 to 5.9% in 2019. Japan produced 99.3Mt in 2019, down 4.8% compared to 2018[12].

The Middle East produced 71.4Mt of crude steel in 2019, a decrease of 1.4% compared to 2018.[12]. The Middle East produced 45.3Mt of crude steel in 2019, an increase of 19.2% on 2018. Here DRI produced from natural gas is the predominant method.

Direct reduction (DR) processes have the advantages over conventional steelmaking using the blast furnace and oxygen converter, especially in terms of environmental issues. Some direct reduction processes are able to operate with a high hydrogen content in the reducing gas mixture. Therefore, accompanying CO2

emissions can be lowered.

India’s steel production capacity expanded to 142.98Mt in FY2019-20 when it produced 111.2Mt (78.5% capacity utilisation)[13]. As per National Steel Policy 2017, India plans to create 300Mt crude steel capacity by 2030-31. This will facilitate steel production to increase to 255Mt in 2030 and per capita finished steel consumption will grow to 158kg from 74.6kg in 2019[13,14]. By 2040 India would be aiming at a steelmaking capacity in excess of 500Mt. India ranks sixth in the world in terms iron ore resources and is a leading producer and exporter after Australia and Brazil.

India is well endowed with respect to iron ore reserves to sustain a production of around 500Mt of steel by 2040. However, it has to stretch its resources for acquiring a commensurate and large quantity of coking coal through imports as the country has limited coking coal reserves. Around 600kg of coke is required to produce one tonne of steel. Around 600kg of coke is required to produce one tonne of steel, which means that around 770kg of coal is needed for every tonne of steel produced using BF-BOF route.

Imported coking coal is a costly resource and susceptible to large price fluctuations, which in turn can adversely affect steel production costs. In an Indian context, especially when importing large quantities, for example to support 500Mt of steel production by 2040, it will be beneficial and, therefore, offers much scope for replacing coal with natural gas in India’s iron and steel sector. Furthermore, natural gas is a less polluting fuel than coal.

However, affordability and availability will be key to that transition. If gas becomes available at an affordable price, steel plants will be willing and eager to make that switch, since the steel industry needs affordable energy. The country has to aggressively exploit prospecting of gas reserves, ramp up its production capacity, utilise cost effective technology and create a matching pipeline network for making natural gas available as a viable alternative to coal.

A major share of India’s integrated steelmaking capacity is located in the central and eastern parts of the country.

Presently there is inadequate pipeline infrastructure to reach natural gas reserves from western regions of India. However, the Government is laying stress in moving www.steeltimesint.com

Q-ONE DIGITAL ENERGY FOR GREEN STEEL MELTING Q-One reduces EAF overall electric power consumption with a shorter power-on time and very low network flicker.

It is a scalable system that can be implemented on new or existing AC EAFs, and it can be directly powered by renewable energy sources as solar and wind.

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Top gas recovery turbine technology

towards a gas-based economy. Under Urja Ganga Yojana, the Government is laying an extensive network of pipes for transport of gas, of which the Gas Authority of India Ltd (GAIL) is the prime mover. Further, greater use of natural gas across various industries, including iron and steel, at the expense of coal, will be a fillip to the Government’s policy of extending support to global climate change protocols.

India’s plans if stricter laws on carbon emissions are enforced Moving towards a low carbon environment is a priority for the Indian as well as global steel sector. Towards achieving this goal of lowering the carbon footprint, the primary consideration is to substantially reduce specific energy consumption. All the carbon entering a steel complex leaves as CO2.

Therefore, it is important to restrict carbon use to the barest minimum possible. It is believed that over 90% of CO2 emissions in steelmaking is on account of energy consumption. Energy savings through efficiency, therefore, is the most vital approach to reduce CO2 emission.

During the past two decades the Indian steel industry has vigorously followed measures to reduce specific energy consumption across its entire domain of operation, starting from raw material mining to dispatch of finished products to market. The efforts made broadly cover: - Beneficiation of input raw materials; - Implementation of energy efficient technologies, through import and/or indigenous development; Digital Edition - August 2020

- Incorporation of emerging technologies; - Materials efficiency; - Waste heat recovery; - Generation of less solid wastes and recycling of wastes; - Large scale automation and IT inputs; - Application of high end process and product models; - Development of high-strength light weight steels for downstream application in different market segments for lowering customer carbon emissions.

Incorporation of these measures in Indian steel plants has helped to augment energy efficiency. Besides it has also facilitated reduction in GHG emissions, improved quality, yield and productivity and reduced waste and dust emission inside plant.

However, a lot more is still to be achieved which calls for much greater concerted effort, and at a faster rate, to bring about a more visible and tangible impact. A gap still exists in energy consumption between India and advanced steel making nations. Energy consumption in most of the country’s integrated steel plants in is generally high at 6 to 6.5 Giga Calories per tonne of crude steel as compared to 4.5 to 5.0 Giga Calories per tonne in advanced steel plants abroad.

Eventually the domestic steel sector has to move towards implementing ‘Industrie 4.0’ in its ambit, overcoming knowledge and financial constraints. The global steel industry is making initial strides towards ‘Industrie 4.0’, though it will take some

time to achieve the goal.

Presently the emission restriction standards in India are far less stringent than those in advanced steelmaking nations, such as within the European Community, Japan etc. If very strict emission adherence norms are promulgated in India, it will be difficult for both the integrated and secondary steel producers, particularly the rerolling and other medium-scale manufacturing units, where energy consumption patterns are relatively high, to comply. Integrated manufacturers, as a whole, are likely to be better placed than secondary producers, such as sponge iron (DRI) makers, re-rollers, EAF and induction furnace units. These secondary steel producers form a vital cog in the domestic steel production scenario, accounting for around 55% of the total production. Therefore, if they are affected by implementation of rigorous emission standards, the country’s steel output can be severely compromised. The plan to avoid such problems is to keep investing systematically and continually in energy efficient technologies and processes.

For fulfilling its commitment under global climate change protocol (Paris Agreement), India is focused on its plan to reduce specific energy consumption and has pledged the following: • 33% to 35% below 2005 emissions intensity of Gross Domestic Product (GDP) by 2030 and; • non-fossil share of cumulative power generation capacity 40% by 2030[15].

The Perform, Achieve and Trade (PAT) Scheme was initiated as a programme launched by the Bureau of Energy Efficiency (BEE), under the National Mission for Enhanced Energy Efficiency (NMEEE), to reduce energy consumption and promote enhanced energy efficiency among specific energy-intensive industries in the country.

In the first cycle of this scheme (PAT Cycle-I) from 2012-15, 427 energy-intensive units from eight large industrial sectors, namely thermal power plants, fertilisers, cement, aluminium, pulp and paper, iron and steel, textiles, and chlor-alkali were given specific energy reduction targets to achieve.

Those that over achieved the targets were awarded Energy Saving Certificates or ESCerts, each equal to 1 metric tonne of oil (MTOe). Those unable to meet their assigned targets were required to purchase ESCerts (from the over achievers) through a centralised online trading www.steeltimesint.com

ENVIRONMENT

mechanism hosted by the Indian Energy Exchange (IEX). According to the BEE, PAT Cycle 1 has achieved 29.7% more of this targeted energy saving, (8.67Mt oil equivalent (Mtoe) saved against a target of 6.686 Mtoe), along with a 1.93% reduction in emissions amounting to a CO2 mitigation of ~ 31Mt). The iron and steel sector performed reasonably well by achieving a 41.3% greater saving than its assigned target – 2.1Mtoe savings versus a target of 1.486Mtoe from 60 designated consumers (DC)[16, 17]. Other than thermal power plants, all the other seven industrial sectors achieved savings in specific energy reduction during PAT Cycle-I. For PAT CyclesII and beyond, where more energy intensive industrial sectors and DCs have been identified, compared to PAT Cycle-I, even if targets are made more stringent, allowing the ESCerts earned in Cycle 1 to be utilised would inject inefficiencies into the system.

And if the targets are not ratcheted up, we could see more over-achieving targets, and a failure of this market-based trading mechanism. Complete verification of PAT Cycle-V II & III is under way. Currently PAT Cycle-V (2019-22) is being monitored. The total energy consumption of DCs works out to be 15.244Mtoe and it is expected to get a total energy savings of 0.5130Mtoe (5.130kt) through the implementation of PAT Cycle –V. The PAT mechanism has to be strengthened and monitored more aggressively than before, to cover at least 80% of the industrial energy consumption, to ensure that specific energy savings are achieved by individual sectors, including iron and steel. The targets set have to be challenging while being realistic. Each sector has to fulfil the target, failing this means they may have to pay penalties. The idea of purchasing ESCerts from others to compensate for unfulfilled assigned targets should be gradually discouraged.

Product yield while using H2 in blast furnace Present BF technology uses pellets, sinter or ore pieces as input feed materials, completely avoiding fines. To use fines a fluidised bed reactor (FBR) is required. While there is the possibility of replacing coke/ coal in the BF with hydrogen, subject to the creation of enabling conditions and infrastructure, such replacement will not only be a novel breakthrough, but also have a far reaching beneficial effect on the www.steeltimesint.com

environment by eliminating large volumes of CO2 emissions. Hydrogen as a reducing agent is far superior to carbon and can accelerate the reduction process many fold[4,5]. Therefore, an increase in product yield is expected to be realised. If hydrogen in the plasma state can be employed, the reduction reaction can be enhanced by an order of magnitude, or even more, resulting in larger yield.

Efforts have been made, under laboratory conditions, to examine the application of hydrogen in a FBR environment for solid state reduction of hematite to iron. A fluidised bed reactor (FBR) is essentially a reactor device that can be used to carry out a variety of multi-phase chemical reactions.

In this type of reactor, a fluid (gas or liquid)

Charging 100% scrap to electric arc furnaces saves 75% of the energy compared with the integrated BF-BOF route. Photo: Danieli.

is passed through a solid granular material (usually a catalyst possibly shaped as tiny spheres or very fine particles) at high enough speeds to suspend the solid and cause it to behave as though it were a fluid.

This process, known as fluidisation, imparts many important advantages to an FBR. FBRs are presently used for numerous industrial applications.

The conventional BF is not a fluidised bed reactor technology. Currently the dominating process for iron ore reduction is the BF technology. This offers economies of scale of operation through its sheer (large) volume of output. Blast furnaces consist of a charge descending against a countercurrent flow of a reducing gas. However, not only are the energy costs relatively high

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for blast furnaces, pollution problems can also be quite severe. In the BF process, the input iron bearing feed stock consists of iron ore fines that need to go through an agglomeration process, namely, pelletising and sintering, or as lump iron ores or a combination of both. In fact, to improve the permeability of gases for effective reduction kinetics of iron bearing materials, fines are avoided in the BF. Charge selection – iron ore, agglomerates (sinter and pellets), coke, nut coke, limestone, dolomite, manganese ore etc – must conform to specified and calibrated size ranges.

Smelting reduction using fluidised bed process The family of iron making technologies includes three process routes: blast furnace, smelting reduction and direct reduction.

Driven by steadily increasing costs of raw materials, the sector has seen a number of new developments in ironmaking technologies; developments based on fluidised bed technology. The main advantage of a fluidised bed is that fine iron ore can be directly charged to the process without prior treatment. It does away with agglomeration (pelletising and sintering) and its consequent cost; as practiced in blast-furnace, Corex and Midrex processes.

With POSCO of South Korea, Siemens VAI Metals Technologies successfully evolved the FINEX process to use ore fines from the earlier Corex smelting reduction process which used pellets or lump ore to produce molten metal using non-coking coal. The key technology of FINEX is the four-stage bubbling fluidised bed reactor, in which iron ore fines are reduced to DRI fines in a counter current flow with a reducing gas generated by coal gasification. The DRI fines are then processed to hot compacted iron, transferred to a charging bin positioned above a melter gasifier and then charged into this, where melting takes place.

The tapped product – liquid metal – is equivalent in quality to that produced in a blast furnace or Corex plant. Besides FINEX, other advanced iron making processes using FBR technology for direct use of iron ore fines include the FINMET, CIRCORED and HIsmelt processes.

Iron ore mining generates a lot of fines.

FBR technology offers use of ore fines in an economical and effective manner.

Investigations related to reduction of iron ore using hydrogen gas using a FBR were attempted recently and reported in Digital Edition - August 2020

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ENVIRONMENT

Government’s commitment towards global climate change control measures.

References 1. Mauna Loa Observatory (MLO), Hawaii, USA for June 2020 2. Kyoto Protocol, en.wikipedia.org 3. Koen Meijer, Mark Denys, Jean Lasar, Jean-Pierre Birat, Gunnar Still & Bernd Overmaat, ULCOS: UltraLow CO2 Steelmaking, Ironmaking & Steelmaking, Vol.36: Issue No. 4, pp 249 - 251, 2009, DOI: 10.1179/174328109X439298 4. Daniel Spreitzer & Johannes Schenk, Reduction of Iron Oxides with Hydrogen—A Review, Steel

Electric arc furnaces account for a quarter of global steel production. Photo: Danieli

Research International, August 2019 DOI: 10.1002/ srin.201900108 5. K. C. Sabat, P. Rajput, R. K. Paramguru, B. Bhoi & B.

2019 . The reduction kinetics of hematite iron ore fines to metallic iron by hydrogen using a laboratory fluidised bed reactor were investigated in a temperature range between 873K to 1073K (600 – 800°C) ie solid stage reduction, by measuring the weight change of the sample portion during reduction. A 400g sample with a grain size between 250 and 500µm was used for each test. The reducing gas mixture consisted of 65% H2 and 35% N2, by volume, with a constant flow rate of 25.9 Nl min-1. N2 was added to the gas mixture to achieve fluidisation of the particles. The experiments concluded that the influence of kinetic limitation on the reaction rate of reduction decrease rapidly with increasing temperatures. At 1073K, the reduction proceeds near the thermodynamic equilibrium, while at 873K, the deviation between experimental results and thermodynamic equilibrium was much higher. The reaction kinetics of hematite reduction by hydrogen cannot be described using only one simple gas – solid reaction model. The limiting mechanism varies with temperature and the degree of reduction. Polished microsections after reduction showed that at the beginning of metallic iron formation, the iron formed uniformly and was distributed within the whole particle, which indicated that diffusion of the reducing gas does not limit the reduction in this case. It was suggested that the initial stage of reduction might be controlled by first-order kinetics and diffusion, depending on the temperature. However, the reduction of FeO to Fe was limited by first-order kinetics and nucleation, whereby the importance of nucleation increased with rising [18]

Digital Edition - August 2020

temperatures.

Moreover, diffusion was not important in the case of fluidised bed reduction, using hydrogen as a reducing agent during the reduction of FeO to Fe.

K. Mishra, Reduction of Oxide Minerals by Hydrogen Plasma: An Overview, Plasma Chem Plasma Process Vol. 34:,2014, pp1–23 , DOI 10.1007/s11090-013-9484-2 6. Private communication with Dr B Bhoi, June 2020 7. Donald R Askeland, Pradeep P Fulay and Wendelin J Wright, The Science and Engineering of Materials, Sixth

Conclusions The steel industry globally and in India, being one of the highest emitters of CO2 among manufacturing sectors, is vigilant about reducing its carbon footprint and gradually plans to move towards a carbon neutral environment. Use of hydrogen as a possible replacement for coal/coke as a reductant holds promise and potential, primarily due to its faster reduction kinetics besides elimination of harmful CO2 emission. Use of this gas in a plasma state will be immensely beneficial in terms of superior output and yield because of faster reduction kinetics.

However, the generation of hydrogen from renewable sources and at a cheaper cost than at present is a key to its use.

The application of hydrogen as a reducing agent, in lieu of carbon, will have a positive influence in blast furnace as well as in fluidised bed reactor technologies for iron production. In an Indian context, development of a suitable commercial technology package, employing hydrogen as a reductant, in the next 15-20 years is a possibility by synchronising indigenous expertise, knowledge and skill of various stake holders. By 2040, when India is expected to produce around 500Mt of steel, availability of an appropriate hydrogenbased technology will not only drastically reduce dependence on metallurgical coal, of which the country is deficient, but also significantly curtail the emission of CO2 gas.

This will go a long way to fulfil the Indian

Edition, Cengage Learning, Copyright 2010, p 169 8. Hydrogen Production, en.wikipedia.org 9. Michael Mazengarb, Another nail in coal’s coffin?

German steel furnace runs on renewable hydrogen in world first, Renew Economy, Clean Energy News and Analysis, 13 November 2019 10. Leigh Collins, ‘World first’ as hydrogen used to power commercial steel production, https://www. rechargenews.com, 28 April, 2020 11. Laurie A. King, McKenzie A. Hubert, Christopher Capuano, Judith Manco, Nemanja Danilovic, Eduardo Valle, Thomas R. Hellstern, Katherine Ayers & Thomas F. Jaramillo, A non-precious metal hydrogen catalyst in a commercial polymer electrolyte membrane electrolyser, Nature Nanotechnology, Volume 14, 2019, pp1071– 1074 12. www.worldsteel.org , Press release 27 January 2020 13. steel.gov.in, An Overview of Steel Sector, Ministry of Steel, Govt. of India, June 2020 14. steel.gov.in, National Steel Policy 2017, Ministry of Steel, Govt. of India, May 2017 15. Jyotsna Singh & Rakesh Kamal, India announces its INDC, pledges to cut emission intensity of its GDP by 33-35 per cent by 2030, www.downtoearth.org.in , 21 October, 2015 16. https://beeindia.gov.in 17. Achievements under Perform, Achieve and Trade (PAT),Publication by Bureau of Energy Efficiency, May 2017 18. Daniel Spreitzer & Johannes Schenk, Iron Ore Reduction by Hydrogen Using a Laboratory Scale Fluidised Bed Reactor: Kinetic Investigation— Experimental Setup and Method for Determination, Metallurgical and Materials Transactions B, Volume 50, 2019, pp 2471–2484

www.steeltimesint.com

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2020-03-18 15:27

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SPECIAL AND STAINLESS STEELS

Making light of heavy vehicles The drive to protect the planet for future generations is gathering momentum. Where possible, organisations are striving to reduce their carbon footprints. This is undoubtedly the case in the automotive industry, with initiatives like light-weighting and the development of electric vehicles.

Molybdenum-containing steels enable a number of exciting improvements in efficiency, safety, and sustainability in heavy vehicles.

TENS of millions of trucks drive enormous distances each year to deliver their loads.

The movement of goods is a complicated, resource-intensive affair. Despite efforts in recent years to remove freight from the roads onto alternative modes of transport, such as trains or ships, trucks remain the backbone of the industry. These heavy, gas-guzzling vehicles deliver anything from building supplies, to clothes and groceries, to fuel and heavy industrial parts. Today’s world would simply grind to a halt without the constant movement of freight on the roads. Finding ways to lessen the environmental impact of trucking is, therefore, essential for a more sustainable transport of goods and commodities.

Specialised, molybdenum-containing steels are helping to make trucks and other vehicles lighter, and more fuel-efficient.

Digital Edition - August 2020

Molybdenum – keeping things light Molybdenum has been part of the steel structures of cars and light-weight vehicles for more than 30 years. Moreover, in recent years government agencies around the world, including the US Department of Energy, have set specific targets for weight reductions in heavy trucks by 2050.

With this in mind, it is clear that molybdenum is set to play an even greater role in making trucks safer, more efficient, and more sustainable.

Such weight reduction targets can be achieved with many different materials.

Carbon fibre composites, aluminium, glass fibre composites, advanced highstrength steels, as well as steel and cast-iron materials, are all potential options. However, materials that are not traditionally used in the manufacturing

of heavy trucks, such as carbon fibre and glass fibre composites, present significant technical challenges in terms of joining and forming. Aluminium is currently used in a limited capacity but presents a different set of technical difficulties. High-strength steels and cast-iron materials have many properties, including strength, weldability, and formability, that make them ideal for heavy vehicles. And with the current state-of-the-art manufacturing technology already in use, it is possible to incorporate these materials without having to revamp existing production facilities.

Performance criteria between trucks and cars are, of course, completely different. On average, trucks cover about 150,000 kilometres per year, and they have considerably more power and torque than cars. But the weight of the truck cab is www.steeltimesint.com

SPECIAL AND STAINLESS STEELS

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Lighter trucks can reduce fuel consumption and, of course, air pollution.

surprisingly similar to that of a car – about 326 kilos – and uses many of the same materials.

Molybdenum-containing high-strength steels and press-hardened steels are used increasingly in both truck cabs and cars to reduce weight. More critically, new safety crash standards, introduced in Europe to protect truck drivers, called for improved truck designs. The use of highstrength steels provide the required levels of crashworthiness while reducing the overall weight, resulting in both a safer and greener truck.

Proven performance in China In a recent project to design new steels in China using an improved 670 MPa strength steel reduced the weight of a truck’s trailer beam by 27%, when compared to the original 520 MPa steel. This reduction was possible due to the steel – which contained 0.2% molybdenum – being stronger and thinner than the original. In this case, the higher-strength steel was found to show the best performance-to-cost ratio for many major truck components. These new, lighter parts are either cost-neutral or even cheaper than those made of traditional www.steeltimesint.com

Using a stronger steel means that the cross section of the trailer beams can be reduced, making the trailer lighter.

steel. The result is a “win-win” situation that has tremendous potential for both the environment and manufacturers.

The heaviest part of the truck is the power train, which contains the drive axles. These are ordinarily made from a fairly low-strength steel (350 MPa), and weigh between 200 and 600 kilos. Current

research projects in China are developing alloyed steels with increased strength.

If these projects can realise the target strength of 550 MPa, it will result in a drive axle weight reduction of around 31%. The axle housings under development also allow for the use of electric engines to support the ‘hybridisation’ of trucks.

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SPECIAL AND STAINLESS STEELS

Other applications in trucking Trucks have many other heavy gauge parts that have to endure significant loads, shock, and wear. One example is the ‘fifth wheel’, where the trailer is hooked to the cab.

Typically made from molybdenum-alloyed Austempered Ductile Cast Iron (ADI), it has a 10% lower density than steel, meaning it is lighter than any steel alternative. ADI also has excellent noise damping capabilities and self-lubricating properties in dry contacts.

ADI is not only used in the fifth wheel but also lends its light weight to other parts of the truck. For example, ADI wheel hubs, containing 0.3% molybdenum, are 20% lighter than comparable aluminium ones.

Molybdenum also plays a significant role in one of the vital safety features of a truck:

Digital Edition - August 2020

the brakes. When applied, brakes create substantial amounts of heat. Therefore, they need to be made out of a material that has good thermal conductivity to ensure that the heat is lost quickly.

Grey cast-iron alloys are ideal metals for brake discs and drums. The addition of 0.2– 0.4% molybdenum increases strength and thermal conductivity, while forming carbides to enhance wear resistance.

There is also an unyielding demand for greater engine efficiency. The US Department of Energy has set stringent targets for reducing weight and increasing the efficiency of engines between now and 2050. This requires yet-to-be-developed irons and steels with higher strength specifically to support engine downsizing.

Current diesel engine efficiency is around 40%. In the future, up to 60% will be achievable, reaching similar efficiency levels as a hydrogen fuel cell. These increases in efficiency demand higher temperatures in the exhaust system and higher pressure in the cylinders. IMOA is working with Shanghai University’s casting unit to develop grades of molybdenum-containing cast iron that can achieve the required results by optimising heat conductivity, strength and thermal fatigue resistance.

Research projects like this are an important part of ensuring trucking remains viable as a sustainable option for getting goods from A to B. It will take years, perhaps decades, and significant research and funding to achieve 60%

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SPECIAL AND STAINLESS STEELS

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Light-weighting truck components with stronger materials can make trucks lighter, allowing increased payload and improved operator profitability.

engine efficiency. But work is ongoing, and progress is being made. One thing is clear: for millions of vehicles around the world, molybdenum’s role is proving to be increasingly important.

Lighter trucks can reduce fuel consumption, and with that, air pollution.

Using a stronger steel means that the cross section of the trailer beams can be reduced, making the trailer lighter.

Light-weighting truck components with stronger materials can make trucks lighter, allowing increased payload and improved operator profitability.

You can read more about the advantages and plus points of molybdenum when we discuss the importance of high-strength, molybdenum-containing super and hyperduplex stainless steel in next month’s edition of Steel Times International. � www.steeltimesint.com

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OXYGEN STEELMAKING

Elemental, my dear Watson...

METALS are widely used in production and manufacturing due to their various mechanical and electrical properties, which can be tailored for each specific application.

Non-metallic trace elements such as carbon, sulphur, oxygen, nitrogen and hydrogen can all have a strong influence on these properties, as well as metallic alloying elements, and even small changes in concentration can have a significant impact on a finished product.

As such, elemental analysis has emerged as the method of choice when highly precise and fast analysis of these elemental concentrations on non-metallic elements is required. Furthermore, metallic alloying elements are usually determined with portable OES spectrometers that are easy to carry and give fast results.

Basic oxygen steelmaking (BOS) is responsible for producing around 70% of the world’s steel. The method uses carbon-rich molten pig iron to make steel by blowing oxygen through it to lower the carbon content of the alloy. The essential stations of steel production are the blast furnace, converter and finishing – the steel converter is known as a basic oxygen furnace (BOF), or Linz-Donawitz (LD) converter.

After each step, the determination of the C, H, N, S, O content is required for quality control to ensure clean steel with improved mechanical properties is produced that meets market requirements for thickness,

width, hardness and strength, while maximising mill yield and minimising scrap.

The oxygen steelmaking process Also known as the basic oxygen process (BOP), oxygen steelmaking is referred to as basic because chemical bases of lime or dolomite are added to promote the removal of impurities and protect the furnace lining.

The carbon-rich molten pig iron from the blast furnace is converted to steel in the BOF by blowing oxygen through it at incredibly high speeds via a top-mounted lance. Carbon in the molten iron reacts with the oxygen to form carbon monoxide (CO) and carbon dioxide (CO2). BOFs can handle several hundred tonnes of iron, converting it into steel within 30-40 minutes.

Common grades of steel are described as mild, medium or high-carbon, depending on the percentage of carbon it contains, although this is never greater than around 1.5%. For instance, the carbon content in mild steel is up to 0.25%, medium 0.25% to 0.45%, and high between 0.45% and 1.5%. Scrap metal can be added to the molten to improve recycling, while adding metals, such as nickel, chromium and tungsten, produces alloy steels like stainless steel.

How elemental analysis works The steel industry is incredibly competitive and so producers must ensure that processes are operating at maximum

efficiency and product quality is guaranteed, maximised and consistent, while ensuring that energy consumption and environmental impact are kept to a bare minimum.

A key requirement is to monitor, control and optimise (if needed) the composition of the molten metal. In order to do this quickly and reliably, elemental analysis is used.

Elemental analysis always requires taking a sample from the casted material. Therefore, many companies have already integrated a sample-taking process into the production process. Elemental analysers for C and S, but also for O, N and H can handle every kind of solid sample, independently if the sample is a powder, chips or bulk material.

In carbon and sulfur analysis, the sample will be completely combusted in a current of pure oxygen in order to

* Strategic international product manager, Elementar UK Digital Edition - August 2020

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OXYGEN STEELMAKING

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Elemental analysis can be used as a fast, reliable and accurate method during the oxygen steelmaking process, says Ivo Nemetz*

crack the bindings of carbon and sulfur in the sample and release gases containing these two materials. Carbon will be released as CO and CO2 and sulfur as SO2.

During the analysis process, all CO will be reacted to CO2 and finally both CO2 and SO2 are detected with infrared detection.

The amount of gas detected directly corresponds to the concentration of the respective elements C and S in the sample.

With this information, the process might be adapted accordingly in order to meet the requirements.

Oxygen, nitrogen and hydrogen analysis works slightly differently. The elemental ONH analysis is based on the principle of inert gas fusion, meaning that the material is molten at high temperatures above 2,000°C in order to crack the bindings and release gases containing oxygen, nitrogen and hydrogen. The important difference to CS analysis is the fact that ONH analysis www.steeltimesint.com

is not based on a combustion process.

The reason for that is easy to understand: combustion needs an oxygen carrier gas, but as the smallest traces of oxygen should be analysed with ONH analysis, this is obviously not a productive process.

Detection of the released gases can be realised with different detection techniques.

Instrument manufacturers use a variety of detectors and sensors. However, again, the amount of gas detected corresponds with the absolute amount of the respective element in the sample. For the oxygen steelmaking process, getting an exact and quick result about the oxygen content in the material is vital in order to secure a reliable and clean process.

Hydrogen analysis Furnaces are fitted with water-cooling systems that control process heat, and are vitally important to oxygen steelmaking

because faults and failures can affect the process, damaging (or even destroying) the furnace. If water leaks into the furnace, it will dissociate to hydrogen and oxygen, placing plant personnel at serious risk from a resulting explosion. Furthermore, this can result in hydrogen impurities in the casted material or on the surface, which can be detected with elemental ONH analysis.

Instruments, such as elemental analysers provide fast and accurate hydrogen analysis with only little sample material.

Why is elemental analysis important?

Achieving stable and highly efficient production of steel requires thorough monitoring of material quality. This means that precise analysis of raw materials and high-quality control standards for materials within the production line are absolutely essential.

Furthermore, the functionality of Digital Edition - August 2020

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OXYGEN STEELMAKING

modern materials – such as high-quality steels and alloys – depends significantly on additive elements. Therefore, it is of great interest to analyse the elemental concentration of inorganic materials precisely, and producers should always be looking for tried-and-tested quality assurance methods, like elemental analysis.

Elemental analysis makes all of this possible, allowing manufacturers to detect impurities and inclusions that might result in surface oxidations and other defects in inorganic materials.

The role played by elemental analysers is nothing new, and it has been used to provide simple, fast and reliable analysis of the properties.

It is essential for the characterisation, quality control, and certification of metals and inorganic materials to fulfill all requirements for research and development, routine and high-throughput laboratories involved in these production

processes.

The most advanced elemental analysers available today include several refinements

designed to facilitate the analysis of challenging materials. They allow multiple elements to be assessed in a single

sample, with a high mass tolerance level facilitating the analysis of large samples with challenging elemental ratios, while maintaining the highest possible data quality and accuracy.

Additionally, they are tailored to simplify the sample preparation process and function largely without manual input, with 24/7 automated responses helping steel manufacturers to scale up their production efforts without needing to commit significant extra manpower to quality control processes.

None of these techniques are necessarily new, but at a time when competition continues to increase in the steel industry, the sector will be increasingly reliant upon tried-and-tested methods that have been shown to deliver better efficiency and quality assurance standards. By selecting the right elemental analysis instrumentation, steel producers can put themselves in the best possible position to take full advantage of the opportunities ahead. ďż˝

Since 1866

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HISTORY

Steel: The backbone of Hoover Dam

7 July marked the 90th anniversary of the start of construction on the Hoover Dam. An ArcelorMittal legacy company made it possible to create this valuable source of energy, which has become one of the most popular tourist attractions in the United States WHEN you look at the Hoover Dam, you’re likely to think, ‘concrete’. After all, it took nearly 87.5 million cubic feet of concrete to construct the dam. But, if it were only made of concrete, it still wouldn’t be finished.

Steel forms held the concrete in place while it ‘cured’, or cooled, and it would have taken 125 years to cure were it not for steel.

And that steel came from an ArcelorMittal legacy company, Bethlehem Steel.

Instead of a continuous pour, engineers decided to pour the concrete in 230 large columns, reinforced with 600 miles of steel pipes. By running cold water through the pipes, the curing was done in much less time. Then, they filled the pipes with concrete for added support. All-in-all, the construction of Hoover Dam required 45 million pounds of reinforcement steel.

Steel was also used in the giant buckets that delivered concrete to the site. The Digital Edition - August 2020

buckets measured nearly 7x7 feet and, when filled, weighed 20 tons. The buckets moved from a concrete plant in Nevada, by rail, on steel tracks, then travelled down a steel cable to the construction site. At the height of construction, a bucket arrived every 78 seconds.

The inner tunnels of the dam contain 30-foot diameter steel pipes, or penstocks, in concrete-lined tunnels that are 37 and 50 feet in diameter. They connect the intake towers with the power plant and canyon wall outlet works. It took 44kt of steel to form the penstock and outlet pipes. Each section of the largest pipes is 12 feet long, 30 feet in diameter and 2¾ inches thick.

They were formed from three steel plates and each weighed nearly 68 tons.

It was a brutal, seven-day-a-week work and the men were exposed to harsh conditions, from intense heat in the

summer and extreme cold in the winter to Carbon Monoxide poisoning and electrocution. 112 men died in incidents related to the construction. None are entombed in the dam, contrary to an urban legend.

Hoover Dam wasn’t always called Hoover Dam. At various times, it was the Boulder Canyon Project, Black Canyon, Boulder Canyon and Boulder Dam. In 1930, Secretary of the Interior Ray Lyman Wilbur declared, “I have the honour and the privilege of giving a name to this new structure.” In naming it after President Hoover, Wilbur stated that Hoover was “the great engineer whose vision and persistence, first as chairman of the Colorado River Commission in 1922, and on so many other occasions since, has done so much to make (the Hoover Dam) possible.”

Today’s steelworkers can thank the

HISTORY

men who worked on the Hoover Dam for an important safety improvement: the development of the hard hat. The first hard hats were made of cloth, coated in tar.

When they hardened, they could deflect falling objects. They were called ‘hardboiled hats.’ This eventually led to the commercial production of hard hats.

All in all, it took 96 million pounds of steel and metal to create this man-made wonder. Hoover Dam solved a significant problem, putting an end to a series of historic floods that destroyed crops. Now, it can irrigate two million acres of crops and provide electricity for more than two million homes.

The sustainability of every city and state in the US depends on infrastructure as it serves as the backbone of the nation. Steel meets a wide range of needs that emerge from the expectation for more sustainable

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buildings and cities due to its unmatched strength and longevity combined with the benefits of its environmental footprint.

ArcelorMittal steel continues to drive the construction industry and provide sustainable infrastructure for the modern world.

The world’s biggest steelmaker supplied structural steel that will be utilised in the anticipated 400,000-square-foot, $680 million expansion to Terminal E of Boston’s Logan International Airport. The material that ArcelorMittal supplied included structural wide-flange sections in the ASTM A913 specification with a yield strength of 50 kips per square inch (ksi) (A913 Grade 50).

Whether past, present or future, through continued innovations, steel supports the sustainability of our infrastructure systems. � Digital Edition - August 2020

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