Steel Times International Digital December 2019

INNOVATIONS

INDUSTRY NEWS ROUND-UP

LUBRICATION

INFRASTRUCTURE

12 pages of the latest new products and recent contracts

A round-up of the latest global steel industry news and amazing facts

Choosing the right oil is crucial in a steel mill, says ExxonMobil

2205 duplex stainless steel is holding its own in bridge construction

www.steeltimesint.com Digital Edition - December 2019 - No.13

FUTURE STEEL FORUM 2019 – A PICTORIAL REVIEW

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CONTENTS DIGITAL EDITION – DECEMBER 2019

INNOVATIONS

INDUSTRY NEWS ROUND-UP

LUBRICATION

INFRASTRUCTURE

12 pages of the latest new product innovations and the latest contracts

A round-up of the latest global steel industry news and amazing facts

Choosing the right oil is crucial in a steel mill, says ExxonMobil

2205 duplex stainless steel is holding its own in bridge construction

www.steeltimesint.com Digital Edition - December 2019 - No.13

Picture courtesy of: Friedrich Kocks GmbH & Co KG. KOCKS RSB® 500++/4 for large SBQ production including SCS® and a 4D EAGLE® profile gauge currently operating in China

2 Leader

by Matthew Moggridge, editor.

31 Forum 2019 review The Forum in pictures

4 News round-up The latest global steel news.

46 Fog computing How fog is good for smart factories

8 Amazing facts & figures Well, I never knew that!!!

50 Duplex bridge Floating towards the future

10 Iron ore Iron ore 2020 - difficulties ahead

54 Lubrication Experts at the extreme

12 Metals & ferro alloys The ferro chrome market in India

59 Digital control Improving rail plant reliability

16 Innovations The latest new products

64 History Homecoming of a 50’water wheel

FUTURE STEEL FORUM 2019 – A PICTORIAL REVIEW

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

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Digital Edition - December 2019

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LEADER

Future Steel Forum – big speakers confirmed...

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

There’s nothing better than being in the heart of the city as the days edge towards Christmas.

Alright, given the choice, I’d rather be in a German city, like Stuttgart, during the festive season, but when push comes to shove, London will do, even if I don’t subscribe to the view that when you’re tired of London, you’re tired of life. I’m not a great fan of the UK capital, but that’s because familiarity has bred contempt.

Why Stuttgart? Well, a couple of years ago I found myself on a business trip related to my obsession of the time: creating the Future Steel Forum conference, which was nearing the end of a good two years of indepth research. Stuttgart was where I met Professor Dr. Dirk Schaefer of the University of Liverpool, a man with whom I have struck up a strong working relationship based around the development of the Forum, which next June celebrates its fourth successful year.

That the Future Steel Forum is ahead of the game (I hate the word ‘curve’) was brought into sharp focus earlier this month when I found myself in London at the annual BMPCA luncheon, listening to the publisher of a UK-based manufacturing

magazine as he talked to guests about the importance of digitalisation and Industry 4.0 – a subject close to the Forum’s heart.

The fourth Future Steel Forum takes place in the Czech Republic at the Grandior Hotel, Prague, 2-3 June 2020. And guess who is speaking? None other than Dave Stickler, CEO of Osceola, Arkansas-based Big River Steel, an innovative American company that epitomises what can be achieved with digital manufacturing.

Also confirmed are Stephen Pratt, cofounder and CEO of San Francisco-based noodle.ai, and Professor Dr. Katya Windt, member of the managing board of SMS Group. Both companies continue to play an important technological role in the Big River Steel project.

Also signed up to speak is Sergey Detyuk, CEO of Metinvest Digital of the Ukraine, and we are expecting papers from other leading steelmakers, technology companies and experts in the field of subjects like additive , machine learning, cyber security and other related areas linked to the factory of the future.

Visit:https://www.futuresteelforum. com for more details.

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NEWS ROUND-UP

• A restructuring plan at US Steel initiated by CEO David Burritt has resulted in a number of non-union employees losing their jobs at the company’s Gary Works in Gary, Indiana, and its Midwest plant in Portage, Indiana.

The salaried workers occupied managerial and professional positions according to the World Socialist Web Site.

Source: World Socialist Web Site, 19 November 2019.

• 640 jobs are to go at ThyssenKrupp’s System Engineering unit. The System Engineering unit makes assembly lines for the automotive, aerospace and battery industries, but has under-performed and is in need of major restructuring, according to a report by Reuters.

Source: Reuters, 20 November 2019.

• Russian steelmaker MMK is planning to keep export sales low in 2020 due to higher steel consumption locally and because the company reconstructed a hot rolling mill. CEO Pavel Shilyaev said that domestic sales were up 7%.

Source: Metal Bulletin, 21 November 2019.

Digital Edition - December 2019

• While Italy awaits a decision from ArcelorMittal so does the state-owned Indian steelmaker SAIL. The company is said to be awaiting a response from the world’s biggest steelmaker regarding the setting up of a joint venture, high-end automotive steel plant for which SAIL’s board had given the go-ahead two years ago. SAIL is said to be in negotiation with other global players.

Source: Livemint.com, 24 November 2019.

• Whether the world’s biggest steelmaker, ArcelorMittal, actually buys Italy’s biggest steel mill in Taranto is up for debate at present, although the latest news claims that a negotiated solution seems possible. Talks have taken place between ArcelorMittal’s big wigs and the Italian coalition government.

Premier Giuseppe Conte is said to be cautious about being too optimistic while suppliers to the plant are claiming they haven’t been paid for materials supplied.

The problem hinges on ArcelorMittal’s plans to cut 5,000 jobs at the plant, which Conte has already claimed is unacceptable.

Source: US News.com, 23 November 2019.

• Japanese steelmaker JFE Steel Corporation has acquired a 50% stake in China BaoWu Steel Group Corporation.

The plan is to invest US$98 million in Baosteel Special Steel Shaoguan Co (part of BaoWu) and start making high-grade speciality bar steel for Japanese carmakers in China.

Source: Japan Times, 20 November 2019.

• Baosteel Resources International, a wholly-owned subsidiary of China’s largest steelmaker, has signed a supply deal with Global Ferronickel Holdings Inc to supply one million wet metric tons of nickel ore to Baosteel. Delivery is expected to be made in April next year and consist of 50% low-grade and 50% medium-to-high grade nickel ore sourced from Cagdianao Nickel Expansion Project in Surigao del Norte in the Philippines.

Source: Philippines News Agency, 20 November 2019.

• Indian steelmaker JSW Steel has had its wrists slapped after mining for minor minerals without a licence. The Karnataka High Court in Southern India has only demanded payment of royalties for using the excavated minerals, according to an online media report.

Source: The Hindu.com, 24 November 2019.

NEWS ROUND-UP

• The production of steel ingots by Iran’s major producers during the first seven months of the current Iranian calendar year total 11.9Mt, according to figures released by Iranian Mines and Mining Industries Development and Renovation Organisation (IMIDRO). A report by the Tehran Times found that Mobarakeh Steel Company accounted for 46% of the total. Annual production of steel ingots in Iran is predicted to rise to 28Mt in the current Iranian calendar years (ending 19 March 2020). It is currently 25Mt. Source: Tehran Times, 23 November 2019.

• Job cuts and a ‘hefty restructuring plan’ are seen as likely contributors to German steelmaker ThyssenKrupp’s financial woes as the company slips further into the red. The company registered a net loss of US$337 million in the year to September, according to an online report, fives times worse than its previous fiscal year.

Underlying profits fell 71% (to US$299 million) and revenues grew 1%, making an operating margin of 0.6%.

Source: The Japan News. com, 22 November 2019.

• In an interview with George Grylls in the New Statesman, Aberavon MP Stephen Kinnock, talking about the current steel crisis in the UK, commented: “The underlying cause for the current steel crisis is decades of underinvestment. Parties of all colours have failed to come up with an industrial strategy.

Energy costs are crippling the industry – we pay 50% more for our energy than the Germans,” he said.

Source: New Statesman, 22 November 2019.

• Sajjan Jindal, chairman of JSW Steel in India, has recently said that he doesn’t view ArcelorMittal’s ‘arrival’ in India as threat, claiming instead that the presence of more companies in the market will lead to more innovations, greater quality and increased R&D activities.

Similarly, Koushik Chatterjee, chief financial officer of Tata Steel in India said there should be more competition in the market while SAIL’s chairman, AK Chaudhary, believes the presence of the world’s biggest steelmaker in India will promote healthy competition in the market.

Source: Devdiscourse.com, 21 November 2019.

• Skyscrapers left unfinished are a sure sign of a slowing economy, according to a report by the Financial Times. It is reported that China Construction Third Engineering Bureau Co is to halt construction on a 475-metre high building in the centre of Wuhan following failure by Greenland Group, a large property company, to make a ‘significant’ project payment. The FT says that China has reported year-onyear economic growth of 6% in Q3, the slowest pace in 30 years.

Source: Financial Times, 22 November 2019.

• Shandong Port Group is planning to form eight group companies to promote logistics business locally.

Shandong Port Land Sea International Logistics Company is the first of the eight and will be based in Jinan, the capital of Shandong province. The other seven companies will cover finance, equipment manufacture, technology and other industryrelated areas.

Source: Seatrade-Maritime. com, 22 November 2019.

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• The increasing importance of rare earths in IT, electric and hybrid cars, robotics and high-end medical equipment has prompted the Chinese to establish a rare earths innovation centre in Hebei province. China is a major rare earths producer and it is thought that it is planning to control its supply as a form of leverage in its trade dispute with the Americans. The innovation centre is located in the Xiongan New Area 62 miles outside of Beijing.

Source: Euronews.com, 22 November 2019.

• The EU has launched a WTO challenge against Indonesian export restrictions on the raw materials used in stainless steel production.

EUROFER said it welcomes the announcement by the European Commission that they are taking Indonesia to the WTO in order to protest against the distortive effects of these measures. According to EUROFER, the European Commission has commented that ‘these restrictions unfairly limit access of EU producers to raw materials for steel production, notably nickel as well as scraps, coal and coke, iron ore and chromium’.

Source: EUROFER, 22 November 2019.

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NEWS ROUND-UP

• South Korean steel giant POSCO is aiming for a 20% share in the global EV battery materials market as steel demand dips, according to an online media report. Park Jae-bum, chief researcher at the Posco Research Institute, claims that electric cars are about to go mainstream and that sales will rise to around 4 million units (from 980,000 units in 2017).

Source: Pulse News, 22 November 2019.

• In an effort to reduce its dependence upon Australia, the USA and Canada for its coking coal, India has entered into discussion with Russia as a potential coking coal source. So far, Indian’s Union Minister of Steel, Dharmendra Pradhan have met with a Russian delegation following on from Pradhan’s recent visit to Moscow with leading Indian steelmakers including JSW, RINL, Tata Power, Adani Group, SAIL and Hindalco.

Source: Business Insider, 26 November 2019.

Digital Edition - December 2019

• John Ferriola, CEO, president and chairman of US steelmaker Nucor Corporation, has said that tariffs have enabled the company to invest in a new US$1.3 billion steel plate mill and create additional jobs in the process.

He is reported as saying that getting a level playing field [through the introduction of 25% tarrifs on steel exported to the USA] has enabled the business to make the investment. In 2018, Nucor experienced a record year, according to Mr. Ferriola.

Source: StockDailyDish.com, 24 November 2019.

• More praise for Donald Trump, this time from US Steel. The steel giant claims that Mr Trump’s infamous tariffs had something to do with the company restarting construction on an idled manufacturing plant in Alabama. When fully functional, the plant in Alabama will have an annual capacity of 1.6Mt. Source: Stock Daily Dish.com, 25 November 2019.

• The USA imported a total of 2.1Mt (net tons) of steel in October 2019 including 1.4Mt (net tons) of finished steel (up 14.5% and down 3.5% respectively when compared with final data from September 2019).

Source: American Iron and Steel Institute, 26 November 2019.

• World crude steel production for the 64 countries reporting to the World Steel Association was 151.5Mt in October 2019, a decrease of 2.8% when compared with October 2018.

Source: World Steel Association, 26 November 2019.

• Rio Tinto has approved a $749 million (A$1 billion) investment in its existing Greater Tom Price operations (100% owned) to help sustain the production capacity of its world-class iron ore business in the Pilbara of Western Australia. The investment in the Western Turner Syncline Phase 2 (WTS2) mine will facilitate mining of existing and new deposits and includes construction of a new crusher as well as a 13-kilometre conveyor.

Source: Rio Tinto, 27 November 2019.

• German steelmaker ThyssenKrupp is feeling the heat following four profits warnings and two failed restructuring attempts. The company’s workers are losing patience with the company and have criticised management for delaying a presentation about its plans going forward. One thing’s for certain, job cuts, possibly in the region of 2,000, are on the cards, but the company’s Klaus Keysberg claims that TK remains committed to steel.

Source: UK.Finance.Yahoo.com, 25 November 2019.

NEWS ROUND-UP

• While ThyssenKrupp is seemingly not in a good place, ThyssenKrupp Elevator is rising to the occasion.

The company has recently delivered 57 escalators to four metro stations in Egypt’s Cairo Metro, according to an online media report. Escalators have been installed at Haroun el Rashied, Alf Masken, El Shams Club and Heliopolis Square. A further 12 more are planned for the El Nozha station.

Source: Construction Week Online, 26 November 2019.

• Gerdau SA is to buy a steel mill in the north east of Brazil from the Spanish company Hierros Anon for $110.8 million. Siderurgica LatinoAmericana SA (SILAT) is close to the city of Fortaleza and has an installed capacity of 600kt/yr.

Source: Reuters, 27 November 2019.

• Tata Steel in the UK is to lose 1,000 jobs, with two thirds of them taken from management and office-based roles. In the Netherlands, 1,600 positions will go along with 350 elsewhere in the world. Tata Steel Europe’s CEO Henrik Adam says that the company cannot afford to stand still, but must adapt to the changing world around it.

Source: BBC, 28 November 2019.

• A new billet welder up and running at a Steel Dynamics plant in Columbia City, Indiana, USA, was supplied by Italian plant builder Danieli. It is claimed that the mill started up 17 months after the contract award date and was a resounding success.

Source: Danieli, 27 November 2019.

• A report by Reuters claims that units of Tata Steel, Sweden’s SKF and Germany’s Schaeffler are at the centre of an Indian antitrust investigation. The three companies, which might find themselves in line for hefty fines, are claimed to have colluded on bearings prices between 2009 and 2014 with a view to passing on higher raw materials costs to auto sector customers.

Source: Reuters, 26 November 2019.

www.steeltimesint.com

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• Russian steelmaker NLMK Lipetsk, the flagship site of NLMK Group, has relaunched its basic oxygen furnace No.2.

Following an overhaul, the steelmaking facility now has a capacity of over 3Mt/yr. The replacement of BOF-2 is stage one in a large-scale, multimillion dollar overhaul of NLMK Lipetsk’s steelmaking operations. The next stage is scheduled to begin in May 2020, and will cover the overhaul of a similar capacity BOF-3.

Source: NLMK, 28 November 2019.

• John Reid & Sons (REIDsteel), an international structural steel firm, has pledged to make British Steel its primary longterm supplier. REIDsteel has made a policy decision to use the steelmaker’s products for its wide range of buildings and structures in the UK, Europe and worldwide.The strengthening of ties is a further boost for British Steel as details of a takeover deal to secure the future of the firm are finalised.

Source: REIDsteel, 28 November 2019.

• Anirban Dasgupta, CEO of Steel Authority of India’s Bhilai plant, said he was confident that India will achieve its 2030 objective of producing 300Mt/yr. He said that domestic demand will grow and that India will become steel exporters. Mr Dasgupta, speaking at the Roadmap for 300 Million Tonne Vision 2020 seminar, also said that SAIL is poised to ramp up its capacity to 50Mt from its existing 20Mt. Source: Financial Express, 28 November 2019.

• Sanjeev Gupta, the driving force behind Liberty Steel in the UK and the GFG Alliance, is said to be ready to make an offer for British Steel should the Jingye Group deal fall through, according to a report in the New York Times.

Source: New York Times, 26 November 2019.

Digital Edition - December 2019

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• The earth’s heart is thought to be a ball of liquid iron mixed with nickel and small amounts of other elements at a temperature of about 5,000 deg C, whose inner core (as big as the moon) has solidified and is very dense due to immense pressure.

Source: Living Iron by Vanessa Everts and Pauline van Lynden.

• Some of the oldest words for iron refer to the sky. In the Tibetan tradition, iron is called thotkcha or thunder iron.

Source: Living Iron by Vanessa Everts and Pauline van Lynden.

• The amount of steel in use in the world today is equal to more than 200 kg per person.

Source: World Steel Association.

• Steelmaking process gases are used to produce heat and electricity. When process gases are fully reused they can provide between 60% and 100% of the plant’s electricity requirements.

Source: World Steel Association.

AMAZING FACTS & FIGURES

• Energy consumption per tonne of steel has been reduced by 61% since the 1960s, which has contributed to a significant decrease in CO2 intensity.

Source: World Steel Association.

• Around 90% of water used in the steel industry is cleaned, cooled and returned to source.

Most of the loss is due to evaporation. Water returned to rivers and other sources is often cleaner than when extracted.

Source: World Steel Association.

• Almost every greenhouse gas mitigation technology relies on steel, including the generation of thermal and renewable energy, electrification, mass transport and the hydrogen economy.

Without steel, the 2 deg C Paris Agreement target will not be met.

Source: World Steel Association.

• Legend has it that ostriches can digest iron, but in fact they have a wide appetite and, like the magpie, seem to prefer shiny objects, which has led them to eat iron as well. In 1930 an ostrich at London zoo consumed ‘half the inventory of an ironmongers’, according to a Dutch newspaper, including a four-inch nail that killed it.

Source: Living Iron by Vanessa Everts and Pauline van Lynden

• A lot of steel is protected by means of galvanisation.

The word ‘galvanise’ comes from the eighteenth-century Italian physician Luigi Galvani, who discovered chemically generated electricity when he made the legs of a dead frog twitch by touching the animal with two different metals.

Source: Living Iron by Vanessa Everts and Pauline van Lynden.

LIVING IRON BY VANESSA EVERTS AND PAULINE VAN LYNDEN Rarely is Steel Times International sent a book to review but when Living Iron by Vanessa Everts and Pauline van Lynden arrived in the post, it was a most welcomed sight.

The book, which is illustrated throughout by some excellent photography comes with a Foreword by Ratan N Tata and is a joy from start to finish. It is a coffee table book, for want of a better description, and offers the reader a pleasurable and educational experience covering all aspects of iron and steel, not just the industrial aspect.

Readers can expect to pick up some interesting facts about iron and steel and, as Ratan Tata explains, the book will ‘stimulate

a re-awakening around a material that still has a long life to live’.

We have taken the liberty to use some of the facts from the book for this month’s Amazing Facts and Figures on this page.

The book is published

by Visual Legacy of the Netherlands.

For further information, www.visual-legacy.com

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IRON ORE

Iron ore 2020 - difficulties ahead Michael Schwartz* asks energy consultant Wood MacKenzie for some thoughts concerning iron ore in 2020. Alex Griffiths, principal analyst with the consultancy, answers his questions.

QUALITY is always a crucial factor in the iron ore sector, that is, whether the ore will increase or decrease in overall purity.

Alex Griffiths replies: “The Fe head grade of direct-shipping iron ore lump and fines products will decrease over time.”

In geological terms, “High grade, easily accessible prospects are the first to be mined and, as time goes on, the prospects left are either lower grade or harder to access.”

Turning to existing major large-scale iron ore miners such as Australia and Brazil, and how the new year will unfold for them, Alex Griffiths looked at both Australia and Brazil: “The Australian majors are producing close to capacity, but output has been disrupted by weather this year – so expect next year’s shipments to be higher. We think Brazil’s Vale will take around four years to return to 2018 export volumes: so 2020 will see a year-on-year increase in Brazilian iron ore exports.”

Then there were more localised considerations and developments. These include the restructuring of the Chinese steel sector and possible affects on iron ore prices. For Alex Griffiths, “The Chinese government’s focus on switching steelmaking from small, inland operations

to large, coastal operations will modestly boost seaborne demand (and ultimately prices) for premium iron ores in the medium term.

A decrease in domestic Chinese iron ore supply is mutually inclusive.”

Another country which has experienced recent changes is India, where a rise in Indian iron ore imports has led to the question of whether this rise was a one-off blip or whether such imports will continue next year. Alex Griffiths explained to STI that India will, in his opinion, become a net importer of iron ore, based on the assumption that steel production will continue to grow. He did, however, issue a word of caution: “…this is a long-term trend as India has domestic iron ore resources it will aim to consume before seeking ores from the seaborne market.”

One other region which has come to Wood MacKenzie’s attention is West Africa, where one particular project in Sierra Leone has experienced the country’s government suspending the project’s licence. Wood Mackenzie noted that, “Resource nationalism is a threat to West African projects and investors will continue to demand a premium for their risk.”

Two more areas of interest are

protectionism and ‘green steel.’ Alex Griffiths predicts no rise in the former and none for the latter; current green policies, however, will continue. In short, just one year is not long enough to determine any game changing impact to supply/demand dynamics.

For once, its not all about China!

By coincidence, as the article is being completed, Wood MacKenzie has published the latest edition of its review Global iron ore short-term market. It believes that iron ore has made a moderate but significant move down, taking its cue from a further deterioration in the outlook for steel prices and profitability.

For once, it’s not all about China.

Pressure on seaborne demand and pricing (particularly pellets) is being compounded by a swathe of European blast furnace curtailments.

The final two months of 2019 are shaping up to be challenging for iron ore.

At times like this, market observers often get too bearish too soon. However, Wood MacKenzie sees no reason to cut its shortterm price forecast while supply remains so delicately poised. The Q4 2019 forecast for 62% iron fines is $85/t CFR. �

* Mining correspondent Digital Edition - December 2019

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METALS & FERRO ALLOYS

The ferro chrome market in India With a growing economy and a fast-moving steel industry, India is becoming a major force to be reckoned with over the coming years. With burgeoning urbanisation driving steel demand and a corresponding need for more white goods, there is also plenty of potential for stainless steel and, therefore, a bright future for the ferro chrome industry.

Deepak Kumar Mohanty* reports INDIA being a fast-growing economy with a population of about 1.3 billion, steel consumption has been on the rise to fuel the country’s stupendous infrastructure growth. With rising per capita income and a widening manufacturing base, steel consumption in various sophisticated and specialised segments has also been on the rise and it has put a positive impact on stainless steel consumption. India has a buoyant domestic stainless steel sector with production witnessing a steady growth of 7-8% per annum over the last five years. Domestic stainless steel production has registered an annual growth rate of about 7% with an estimated stainless steel production of 3.74Mt in 2018.

The Government of India’s stimulus for infrastructure creation and proposed smart cities will drive demand for stainless steel. Further, growing urbanisation and disposable income will enhance demand

for white goods, which largely requires stainless steel. Consumption of stainless steel in India is projected to maintain its growth trajectory. Moreover, stainless steel has wide application due to its lustre and resistance to corrosion, and these very properties can’t be obtained without the use of ferro chrome.

Ferro chrome Ferro chrome is an alloy of chrome and iron with 50% to 68% chrome content.

While ferro chrome is primarily used in manufacturing stainless steel, low and medium carbon ferro chrome finds its way into the production of special and carbon steel. Ferro chrome strengthens, brings lustre and offers corrosion resistance to

stainless steel, thereby making it a unique product with multiple applications. Stainless steels are most notable for their corrosion resistance, which is intensified by increasing the chromium content. Typically, however, stainless steel contains a minimum of 10.5% chromium content by mass.

India is among the major producers of ferro chrome globally, below China, South Africa and Kazakhstan. For several years, ferro chrome production in India remained almost stable at 1.0 - 1.1Mt due to multiple reasons such as a lack of backward integration, modest growth of domestic stainless steel production, and the stressed balance sheets of several producers.

Currently, however, domestic ferro chrome production is about 1.6Mt/yr. Meanwhile,

* Senior vice president, head of ferro alloys business unit, Indian Metals & Ferro Alloys Digital Edition - December 2019

www.steeltimesint.com

METALS & FERRO ALLOYS

13

due to limited stainless steel production in India about 50% of the country’s total ferro chrome output is absorbed in the domestic market and the remaining 50% is exported.

India’s total chrome ore resources are estimated at 150Mt, with 54Mt in reserves.

About 90% of chrome ore reserves in India are located in the Sukinda Valley in Odisha.

India consumes over 4Mt of chrome ore and contributes 13% to total global chrome ore production. Indian players, particularly Indian Metals & Ferro Alloys (IMFA), are among the world’s most cost-efficient producers of ferro chrome. This is facilitated by factors such as access to captive chrome ore mines and availability of captive power.

Domestic stainless steel industry The demand for stainless steel was traditionally driven by applications in kitchenware, medical equipment, consumer durables and aesthetic usage.

However, India’s huge capital investments in infrastructure, transportation and greenfield industries will drive demand for stainless steel over and above the traditional applications. India is geared for increased infrastructure spending in the coming years that will more than likely enhance demand for stainless steel. Evolving lifestyles and increasing purchasing power are expected to further raise demand for automobiles and white goods, thus driving demand for stainless steel.

The consumption of stainless steel in a country is linked to its GDP growth rate.

Considering India’s current low per capita consumption of stainless steel at about 2kg as compared to the world average of about 6 kg, there is a huge potential for growth in demand for stainless steel in the country.

With rising per capita income and stainless steel being used in newer applications, demand is poised for an upward trend.

As a result, the domestic market for ferro chrome is going to grow in the coming years as typically for steel to be stainless, it has to contain more than 10.5% chrome content.

While stainless steel production in India is estimated at 3.74Mt in 2018, the domestic installed capacity is more than 5Mt, which signals that Indian stainless steel manufacturers are optimistic about demand for the metal in the domestic market. With the ‘Make in India’ initiative and stainless steel being used in newer applications, demand for the metal is certainly expected to grow further. www.steeltimesint.com

Digital Edition - December 2019

14

LEADERS IN CUSTOMISED HANDLING SOLUTIONS

METALS & FERRO ALLOYS

Challenges The production cost of ferro chrome is largely determined by three major factors: chrome ore, electricity prices and reductants such as low ash, low phos coke. Since low ash coke is not available in India, demand is fulfilled through imports; and because of this, both international availability and the price trend of low ash, low phos coke have a significant bearing on production costs. India has imposed anti-dumping duty on coke imported from Australia and China, which further pushes prices up.

Ferro chrome production is power-intensive and requires about 4,000 units of electricity to manufacture one ton of ferro chrome. Hence, electricity costs play a key role in this industry.

The cost of power in India is high when compared with other major ferro chrome producing countries like South Africa, Kazakhstan and China. However, producers like IMFA, who have captive power generation capability, have an edge over others.

With the ability to use low-grade coal at its power plants, the company has, to a large extent, been able to manage power costs to a reasonable level. Additionally, IMFA’s captive power generation backed by an integrated business model from mining to power generation to ferro chrome production puts the company at an advantage.

Moreover, both the floor and ceiling for ferro chrome prices are now linked to the Chinese market and the price determined

by China, based on its relatively high cost of production, is followed by others, including India. India’s domestic market price also follows the spot price in China with a certain lead or lag time.

However, Indian integrated producers are always in a better position to confront challenges due to being comparatively lower in the cost curve.

Way Forward Higher electricity rates in India combined with dependency on imported coke leads to a higher cost curve for ferro chrome production. The Indian ferro chrome industry is on the cusp of significant consolidation as several producers, including established ones with backward integration, are undergoing insolvency proceedings on account of stressed balance sheets.

The fragmented nature of the industry, which has been an impediment in the past, is thus on the verge of major change.

+353 47 80500

combilift.com

An upright growth trend New policy initiatives, like implementation of Bharat Stage-VI emission norms by April, 2020 for the domestic automobile sector has compelled use of stainless steel for exhaust systems and other applications. Outside of automotive, demand for stainless steel from various sectors, such as food processing, railways, metro rail and pharmaceuticals, has contributed towards making stainless steel the fastest growing value-added metal in the country. While annual stainless steel consumption in India was 3.4Mt in FY18, registering a growth of 9% yearon-year, the country’s per capita stainless steel consumption of about 2 kg is far behind the global average of 6 kg and an astounding 14 kg in China. India’s low stainless steel market penetration offers opportunity for an upright growth trend for the sector, which will ultimately keep the growth momentum for an efficient producer of ferro chrome in India in the future. � www.steeltimesint.com

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00 16

Danieli hard at work across the globe Italian plant builder Danieli has been kept extremely busy of late by a range of global steelmakers.

The company was taken on by Chinese steelmaker Shougang Jingtang of Tanghshan, China, to refurbish the company’s hot-rolling line 2250 and has been hard at work in Vietnam working on the Pomina 2 rolling mill.

Closer to home in France, a four-strand caster supplied by Danieli in 2007 was revamped, while in Russia, Severstal contracted Danieli Corus to supply three sublance systems for three 350t converters at the Cherepovets BOF Shop. There has also been work across the Atlantic for North American electric steelmaker Steel Dynamics Inc. The Shougang contract was awarded in May and the equipment being refurbished had been in operation since 2008, according to Danieli.

The job was completed in six days, and delivery to the customer was 36 hours ahead of schedule, Danieli claims.

In Vietnam, the company supplied electrical and automation equipment for a rolling mill at the Pomina 2 Works in Phu My Ba Ria Province.

Pomina, one of the largest steel producers in Vietnam, chose Danieli Automation, it is claimed, because of the ‘quality technical solution the company offered and its capability of finishing the job in a short period of time’.

Contracts were signed in 20 May and completed five months later in October.

This contract was the first time Pomina and Danieli had worked together.

Meanwhile, in France, a four-strand caster supplied to Ascoval Saint Saulve

back in 2007 was in need of a revamp. It was being used to produce 180-325mm rounds, but will have its production range extended to include square billets of 150mm to 240mm and rectangular blooms of 300 x 365mm.

The plant will also be producing high-grade rail steel as well as engineering steel grades for industrial applications as Danieli is also installing Rotelec Final Electromagnetic Stirrers and product handling equipment for slow cooling, which, it is claimed, will expand the range of the quality steel grades being produced.

High-grade rail steel as well as engineering steel grades for industrial applications will also be produced thanks to the installation of Danieli Rotelec Final Electromagnetic Stirrers, and product handling for slow cooling which will further expand the range of the quality steel grades.

According to Danieli, the specialised design of the equipment being installed will minimise the impact of installation.

Hot tests are scheduled for August 2020.

Russian steel producer Severstal contracted Danieli Corus to design and supply three sublance systems for three 350t converters at the BOF Shop at Cherepovets.

Danieli Corus is a market leader in sublance-based BOF process control and the implementation of this technology, says the company, will contribute to Severstal’s objective of achieving lower steel production costs while maintaining efficiency and quality.

Sublance technology, in combination

with a state-of-the-art process model, enables shorter tap-to-tap times, higher hit rates and reduced consumption of oxygen, energy and flux materials, while improving operating conditions.

In the USA, Danieli has been working on a new billet welder and spooler line producing spooled coils of up to 5 tons, in endless mode, at a Steel Dynamics plant in Columbia City, Indiana.

Among the main equipment being supplied is a 70m conveyor connecting the existing medium section mill to the new spooler line; a 3-MW induction furnace to heat the stock coming from the existing mill, six housing-less SHS 180 roller stands, complete with quick stand-changing table, a 6-pass Delta-type finishing block driven by a low-voltage 2.5-MW motor and finishing services.

For Steel Dynamics, the main benefits include: higher efficiency, productivity and better material yield in downstream cold processing, high mechanical characteristics and good weldability, not to mention a reduction in coil handling and cost-savings through a more efficient operation, thanks to the spooler process being combined with the EWR endless rolling process (saving up to $20-22/ton).

Danieli claims that special attention was paid to minimise foundation costs, erection time and production stoppages.

The mill started up 17 months after the contract award date and was, a resounding success, according to Danieli. There were no major delays during the project execution and start-up of operations.

For further information, log on to www.danieli.com Digital Edition - December 2019

www.steeltimesint.com

INNOVATIONS

17

North American Stainless happy with SMS torque converter SMS group has commissioned a torque retainer for the 160-ton AOD converter number one at North American Stainless (NAS) in Ghent, Kentucky, USA. The steelmaker has issued a final acceptance certificate.

The aim of the revamp, claims SMS group, was to reduce the torque that had previously been causing uncontrolled vibrations and damage to the bull gear, bearings, and foundations of the converter drive during AOD converter operation.

The end result was that uncontrolled vibrations in the gear unit and converter vessel were substantially reduced and target values were achieved under production conditions shortly after commissioning.

SMS group supplied the torque retainer as a compact electro-hydraulic unit. The scope of supply also included the engineering, supervision of the erection and installation work, and technical assistance during commissioning. Cold and hot commissioning were completed in collaboration with the customer, and the latter was performed

during production.

SMS group claims that NAS is ‘very satisfied with the results’ and that the availability and operational reliability of the AOD converter have been significantly improved. Gear unit maintenance will also be drastically reduced and NAS is now able to utilise larger tuyeres and thus increase the blowing rate.

Duncan Bassett, head of mechanical maintenance at NAS, commented: "What impresses us is just how quiet the AOD converter and its entire sur-

roundings are. The integration of the torque retainer in the existing converter went without a hitch, and the electrical and automation systems were adapted especially for us. From a technical and economic perspective, this torque retainer from SMS group is just the right solution."

The torque retainer has already been successfully installed in Acerinox's plants in Columbus Stainless, Middelburg, South Africa (two AOD converters), and at Acerinox Europe SAU., Los Barrios (Cádiz), Spain.

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

Driving digital transformation The name of Voith Group’s new e-learning platform is DRIVE, which stands for Digital Readiness Ideation Velocity Engagement and it is designed, claims the company, to ‘future-proof manufacturing companies and to support them in harnessing the potential of digitalisation to its fullest’.

The e-learning platform’s programmes, claims the Voith Group, are comprised of a wide range of webbased courses whose industry-specific and customisable contents offer a tool set for upskilling employees at every stage of a company’s digital transformation.

DRIVE is claimed to help to create an

initial awareness for the steps necessary to foster a culture of true innovation and provide deeper insights into dozens of different subjects, such as the Industrial Internet of Things (IIoT), automation or artificial intelligence (AI). More advanced programmes within DRIVE are geared towards improving digital dexterity and for this, more than 600 digital skills can be acquired to help manufacturing companies meet both current and future challenges.

It is claimed that DRIVE users can create their own training videos for internal distribution, thus generating customised content for specific

requirements. Message boards allow for an exchange on all things digital, enabling users to discuss opportunities and challenges in implementing digital technologies. Initial assistance is provided by ‘chatbots’ while various games offer a playful way to showcase the impact of digitalisation on the organization and its customers.

DRIVE is available in English, German, Portugese and Chinese and can be used on virtually all devices, including smartphones, tablets, PCs and augmented reality glasses for use in the field.

For further information, log on to www.voith.com/DRIVE

00 18

INNOVATIONS

Fives go big in China

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

Fives presented its latest innovation – NeoKoil® SmartLine – at the China International Import Expo (CIIE) hosted

by China’s President Xi Jinping and attended by France’s President Emmanuel Macron. CIIE, held on 5-8 November in Shanghai, is a top-level national event inspired by the concept “New Era – Shared Future” and focused on economic and trade co-operation.

Fives claims it developed the technology to help steelmakers meet increased demand for high value-added steel grades. NeoKoil Smartline is a fully automatic strip processing line based on predictive modelling to enable the best quality yield and optimal productivity.

“NeoKoil SmartLine completely changes the way the operation and process of continuous annealing or galvanising lines are controlled,” said Digital Edition - December 2019

Guillaume Mehlman, deputy general manager and president of Fives’ steel and glass division. “For the first time, predictive metallurgical models combining physical laws and artificial intelligence are used with the appropriate IT architecture and machine learning algorithms to automatically achieve the best quality and productivity of the line, as well as flexibility of operation.”

Key Chinese steelmakers were present to see the launch of the new equipment, which was also presented during the ‘Smart Manufacturing’ session of China’s Baowu Iron & Steel Ecosphere Forum at CIIE. According to Fives, predictive metallurgical models are a key feature of the line. They are developed by Fives to take into account the entire processing history of the product; upstream to

downstream. These models consider the effects of upstream slab production, annealing, cooling, galvanising, and the skin-pass reduction process.

The NeoKoil SmartLine enables a shift from pre-defined setpoint management for each steel grade to achieve optimal set points for the entire process, automatically achieving the steelmakers’ desired steel grade properties.

“NeoKoil SmartLine gives Fives a great competitive advantage in our business.

The enthusiastic reaction of our clients during the CIIE confirms how well the solution meets their needs. We have been approached by many steelmakers who want to reap the yield and productivity benefits from fully automatic line control – consistently, every time,” said Frédéric Sanchez, chairman and CEO of Fives. www.steeltimesint.com

As a Global Supplier of Automation & Drive Systems to the Metals Industry, TMEIC manufactures a range of medium and low-voltage variable frequency drives, motors and advanced automation systems encompassing all levels of mill operation from Level 0 to Level 3.

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Our high-power main mill motors and coordinated TMdrive-70e2 medium voltage drives are designed for special demands and environments found in the metals industry

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Our TMEIC Advanced Control Solutions (TMACS) provides complete automation functions, including mathematical models to achieve superior product quality and web-based manufacturing data gathering to monitor and improve mill performance.

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00 20

INNOVATIONS

Primetals’ Arvedi ESP for Hebei steelmaker An un-named Chinese steel producer in Hebei Province has placed an order with Primetals Technologies for the supply of an Arvedi ESP (Endless Strip Production) line.

The casting-rolling facility will form part of a new steelmaking facility with one BOF currently under construction.

Compared to conventional casting and rolling processes, energy consumption and related costs are reduced by up to 45%, Primetals claims. This also results in a major reduction in CO2 and NOx emissions, minimising environmental impact. The plant is scheduled to go into operation in 2021.

The Chinese steel producer is described by Primetals as ‘a comprehensive group company integrating steel rolling, natural gas comprehensive development and utilisation, real estate development, social talent training and modern logistics’. The company operates integrated steelmaking plants in two provinces and cities in China, and can produce more than six million metric tons of steel each year.

The Arvedi ESP plant, claims Primetals, will allow the steel producer to better serve the highly attractive local

and export markets for high-quality, thin-gauge strip products. “The 180-metre-long plant is far more compact than conventional casting and rolling mills and is designed for the production of high-quality, ultra-thin, hot-rolled strip products with widths of up to 1,600 mm and thicknesses down to 0.7 mm. Carbon steels, highstrength low-alloyed (HSLA) grades and dual-phase steels will be produced,” Primetals claims.

In the Arvedi ESP process, hot-rolled coils are produced in a linked casting and rolling plant directly from liquid steel in a continuous and uninterrupted manufacturing process. The line commences with the casting of a thin strand that is subsequently rolled to an intermediate thickness of 10 to 20 mm in a 3-stand high-reduction mill positioned at the end of the caster. After reheating in an induction heater, rolling of the transfer bar to the targeted end thickness is performed in a 5-stand finishing mill followed by laminar strip cooling. Strip cutting is then carried out by means of a high-speed shear immediately prior to coiling to coil weights of up to 32 metric tons. The full range

of steel grades can be flexibly produced on Arvedi ESP plants, says Primetals.

As a result of the endless strip-production mode of Arvedi ESP lines, repeated threading into the individual rolling stands is not necessary. This is the basis for the production of ultra-thin strip gauges down to 0.7 mm thicknesses. The tolerance values for the required strip geometry are fully met along the entire length of the rolled product. Endless production assures the homogeneity of the steel microstructure, grain size, yield strength and tensile strength and because the strip is continually under tension, the cobble rate is below 0.1%, even when producing more than 50% below 1.2 mm thickness.

Primetals Technologies is responsible for the engineering of the Arvedi ESP plant and will supply mechanical equipment, media-control systems, technological packages and automation systems. The entire line is controlled by a completely integrated basic (Level 1) and process optimisation (Level 2) automation, which fully controls all casting and rolling operations.

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

INNOVATIONS

21

Hoa Sen Group happy with regeneration plant Vietnamese steel producer Hoa Sen Group has issued a Final Acceptance Certificate (FAC) for the latest state-of-the-art acid regeneration plant (ARP) at its new facility in Binh Dinh, Vietnam, which will operate in accordance with stringent European environmental regulatory standards.

This is the fourth project undertaken by Italian plant builder Tenova for Hoa Sen Group.

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

The incorporated BLUEdriven© Flex Capacity provides the Vietnamese steelmaker with high production flexibility. The plant can operate in a range of +50% to -20% of design capacity, allowing the client to increase pickling capacity without further investment in the acid regeneration.

Tenova’s BLUEdriven Emission Control & ZEROWaste process reduces operational costs while simultaneously optimising emissions to achieve international standards.

A pelletising hardening system offers the client the possibility of supplying the hardened oxide pellets to steelmakers while the high grade oxide powder can, in parallel, be supplied to the market on a demand basis.

According to Tenova, the availability of the ARP is optimised thanks to the new secured remote platform for predictive maintenance as well as a locally implemented wireless HMI system for operators and maintenance staff in the field.

“Tenova has once more shown their high grade performance and client orientated execution of their projects,” said Hoa Sen Group.

00 22

INNOVATIONS

Konecranes’ lifetime achievement Konecranes has launched Lifetime Advantage, a long-term commitment to improving the safety, productivity and endurance of lift trucks around the globe.

According to the company, ongoing support across each truck’s lifecycle benefits customers with consulting, training, spare parts, upgrades and much more – everything needed to keep lift trucks running efficiently in the unique conditions of each customer’s world.

Konecranes believes that its Lifetime Advantage shows its dedication to outstanding quality, uptime and productivity, so that each customer can advance its own business in the ways that matter most. “It means continuous support, from the initial offer throughout the entire lifecycle of one lift truck or a whole fleet, with the aim of achieving a higher level of performance,” the

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

company explained.

Maximising uptime, says Konecranes, is the result of decisions already made at the offering stage. “This means making smart choices when it comes to such options as energy-efficient Ecolifting, safety enhancement and Smart Connected Lift Trucks digital services,” the company added, saying that what is decided together with customers will shape their experience in terms of equipment performance. Konecranes believes that the pace of digitalisation promises to revolutionise maintenance practices and create exciting new advances for operational efficiency.

The company’s after delivery Lifetime Advantage continues through upgrades and retrofits, Konecranes’ genuine spare parts, business services, digital solutions and education, and is designed to make upkeep of the trucks easier, supporting a longer lifetime and

more efficient maintenance.

Konecranes is launching the first of several upgrade packages, containing themed solutions that can be retrofitted to customers’ existing lift trucks; these are not meant to service the trucks, but improve them with updated technology.

Johan Kårhammer, global spare parts operations manager at Konecranes Lift Trucks, commented: “We’ve always cared deeply about improving safety in the workplace, and we believe that these additional features will be of great use to customers who want to address safety risks in their operations, but are not sure where to start. In the near future, we’ll be releasing more types of upgrade packages and solutions to advance existing trucks and fleets.”

So far, six safety upgrades have been developed to address common operational risks, such as blind spots, yard staff working in the same space as moving trucks, engine overheating, impaired drivers and more. Typical upgrades include: reverse camera, reverse warning alarm, fire suppression system and ignition alcolock. Each one is claimed to be a simple addition to existing trucks, greatly improving everyday work safety to ensure that everyone returns home safely at the end of every shift.

Konecranes’ global distributor network will play a key role in implementing the Lifetime Advantage scheme.

Patrik Lundbäck, director and head of sales and distribution at Konecranes Lift Trucks, commented: “Located in over 100 countries around the world, our distributors are local faces who can be there to help customers address their daily challenges, improve current operations and provide support whenever and wherever something unexpected happens.”

“They play a big part in the Konecranes Lifetime Advantage. This commitment is full of initiatives in very different service areas, but they all have one unique aim: to support customers to maximise their uptime and extend the lifecycle of their lift trucks as much as possible,” Lundbäck added.

www.steeltimesint.com

Eradicate inclusion problems in steel The comprehensive OES inclusion analysis solution: ARL iSpark with Spark-DAT Software Suite For many steel grades, controlling non-metallic inclusions is crucial for the smooth running of production process, and to guarantee targeted steel properties. The Thermo Scientific™ ARL iSpark™ OES Metals Analyzer performs inclusion analysis simultaneously with elemental analysis, enabling real-time control of inclusions for hundreds of samples analyzed every day in a steel production.

ARL iSpark can be automated with ARL SMS-2500 system for unattended operation.

The Spark-DAT Software Suite includes all the on- and off-line software modules and features needed for inclusion analysis, analytical method development and set-up, as well as in-depth investigation, control and reporting of inclusions. The ARL iSpark with Spark-DAT Software Suite is the perfect solution to prevent cost and quality problems caused by inclusions.

Thermo Scientific™ ARL iSpark™ OES

Thermo Scientific™ ARL™ SMS-2500 automation

Discover more at www.thermofisher.com/sparkdat © 2019 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified.

00 24

INNOVATIONS

Oil-free claw pump from Atlas Copco A new air-cooled, oil-free claw pump designed for harsh applications has been introduced by Atlas Copco.

The company claims that its ‘robust pump’ increases productivity in conveying, clamping, drying processes or environmental applications, thanks to its low energy consumption and space requirement as well as its handling of pollutants.

There is also a new VSD app, which enables users to set and access the relevant parameters of the vacuum pump quickly and in real time via iOS or Android devices, claims the company.

According to Atlas Copco, there are three different pump models, the DZS 100, 200 and 400 VSD and they are all equipped with corrosion-resistant materials for those aforementioned harsh applications. They also have a durable internal coating and according to Alexander Frerichs, product manager for the company’s dry vacuum pumps, this means the company has designed its vacuum pumps specifically for long service and reliable, efficient operation, ‘even under robust process conditions’.

Frerichs says that cleaning or replacing the pump claws doesn’t require complex gearbox stripping and retiming, which means quick access to the inside of the pump by Atlas Copco service technicians or end users.

A VSD inverter drive is integrated in the motors to control the pumps, says Atlas Copco. “This allows the optimum performance points of the claw pump to be specifically controlled and power consumption to be reduced,” the company explained, adding that energy is saved and the CO2 footprint reduced.

The pumps are certified to ISO 85731 Class 0 and are claimed to be completely harmless to the quality of the ambient air during operation, eliminating the risk of oil-induced contamination and damage to sensitive applications and products in the environment.

Frerichs commented, “This also

includes the guarantee that neither man nor the environment will be harmed by the use of the pumps.

Lastly, parameters such as inlet pressure, rotor speed, running hours and service intervals can be monitored in real time using the newly developed VSD app. It also makes it easier, claims Atlas-Copco, to commission the pumps via the three parameters: target pressure; start/ stop delay and stop level.

Once started, the app automatically connects via Bluetooth and once the desired values have been entered, the pumps will operate immediately.

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

Digital Edition - August 2019

INNOVATIONS

25

New steel grades for cutting tools

For further information, log on to www.uddeholm.com Uddeholm, a leading manufacturer of tool steel for industrial tools, has introduced new grades for cutting tools and grinding kits used in the food industry.

According to the company, cleaner cuts, less friction, extended lifetime with less maintenance of the knives and parts are only some of the benefits.

Tests carried out within production at meat processing companies support the results.

The most commonly used steel grades for the production of cutting tools in the food industry are not sufficiently durable in order to maintain a sharp edge, claims Uddeholm. Cutting tools and grinding kits must remain stable within the desired tolerance to enable the increase in production and support improved capacity utilisation.

Yield losses generally occur in the last part of the production process near to a scheduled stop. This is because the equipment is overloaded and pushed to the maximum, in order to avoid costly interruptions, due to down time through the replacement of tools.

Within the product portfolio, Uddeholm offers steel grades that are ap-

proved for food processing by Normpac certification and can be hardened to a high hardness. In many cases, for optimum performance, the steel grades have to show a combination of properties such as wear and corrosion resistance as well as toughness. Uddeholm Vanax Super Clean, which is a powder metallurgical produced steel grade, fulfills all of those expectations, it is claimed.

The main advantages found within the properties of Uddeholm Vanax SuperClean are:• High hardness 60 HRC results in a high wear resistance • Low friction makes an easier cut • Stainless properties in line with AISI 316 L • High toughness for a 60 HRC hardness steel grade In a modern food processing facility many slaughterhouses with automatic production lines require the cutting tools to remain sharp during an entire production of one day. With a blade made of Uddeholm Vanax SuperClean,

end users will obtain a tool life that is at least three times longer than comparable blades made of standard steel W. 1.4112, according to Uddeholm. In addition to a much longer running blade life, the total service life of the blade is also extended considerably due to the edge retention and durability properties of Vanax SuperClean material, which does not need to be re-sharpened as often as other knife materials.

Uddeholm offers steel grades that it claims are perfect to use as holeplates and knives within meat grinding machines for sausage production.

The problem often encountered in the production departments of meat processing companies is that the holeplates and knives don’t remain sharp throughout the day, and this will have a negative effect on product quality if the knives are not replaced. By using an Uddeholm grinding kit consisting of knives in Uddeholm Unimax and hole-plates manufactured using Uddeholm Vanax SuperClean, the grinding machines were able to remain sharp for 10 production days, or longer, without intermediate re-sharpening. Consequently, many meat-processing companies have achieved a consistently high product quality during the production week and a decrease in energy consumption. The huge reduction in the need to re-sharpen knives as well as hole-plates means that the life cycle of the tools has been extended considerably.

The main advantages for meat processing companies are claimed to be: higher hourly output; lower energy consumption; and higher meat quality.

Digital Edition - December 2019

00 26

INNOVATIONS

New analyser from Hi

For more information, log on to www.hitachi-hightech.com/hha

Hitachi High-Tech Analytical Science Corporation has introduced the OE750 high-performance OES analyser for complete metals analysis control.

The OE750 is described as ‘a ground-breaking new optical emission spectrometer for verifying demanding metals specifications in foundries and metal production’.

According to Hitachi, complex supply chains and increased use of scrap metal as a base material put foundries and metals manufacturers under increasing pressure to control tramp and trace elements within the melt. The OE750 is an optical emission spectrometer that offers a level of performance never previously seen in an analyser in this class. “It covers the entire spectrum of elements in metal and has some of the lowest detection limits possible,” claims the company, adding that the equipment has the capability of much more expensive instruments, bringing high

Rockwell security capabilities certified Rockwell Automation recently received ISA/IEC 62443-2-4 certification, which defines security requirements for service providers.

The certification shows that the security capabilities Rockwell Automation uses when quoting, designing, integrating and maintaining automation systems meet the standard’s requirements. ISA/IEC 62443 is the world’s only consensus-based cyber-

security standard for industrial control applications.

Rockwell Automation also received a maturity-level increase in the ISA/IEC 62443-4-1 certification it obtained last year for its security development lifecycle, showing that the company meets the standard’s security requirements in the way products are produced and supported. In addition, this shows the company has mature processes to

handle vulnerability disclosures and work transparently with customers to help manage their risk.

The new certifications were independently performed by TÜV Rheinland and add to a list of ongoing Rockwell Automation achievements as the company helps customers strengthen cybersecurity.

“Industry needs partners that can help them use technology to expand

27

itachi quality analysis within reach for many foundries and metals manufacturers.

Hitachi claims that revolutionary new optical concepts, with four patents pending, using superior CMOS detector technology are behind the high level of optical resolution and the large dynamic range of the OE750. As a result, it is said that this new analyser has a very large wavelength range, meaning it can measure the entire range of elements within metals at ppm levels, which is essential for meeting today’s tight metals specifications.

The OE750 can meet the requirements of the new ASTM E415 test method for carbon and low-alloy steel.

Hitachi says that the OE750 has other technical features that support high volume metals analysis; these include a new sealed spark stand with optimised laminar flow to reduce argon consumption and the likelihood of contamination as well as reducing maintenance

requirements. A mid-pressure system with low-pressure argon purge cuts down pump usage and reduces power consumption by 90% enabling an oilfree design to be used while increasing reliability and instrument uptime.

There is also performance-enhancing software such as the Hitachi GRADE Database that includes more than 12 million records for over 339,000 materials from 69 countries and standards, reducing time and potential errors from manually consulting grade catalogues.

Optional charge correction software

automatically calculates the right quantity of material to add to a melt to bring it into spec.

Wilhelm Sanders, Hitachi’s OES product business development manager, commented: “In the past, foundries and metal processing businesses had to choose between high performance analysis and instrumentation that was in their price range. Thanks to the new OE750 they no longer have to make that compromise. The OE750 offers comprehensive metals analysis in one accessible package.”

Timken acquires BEKA Lubrication

what’s possible in their operations while protecting what matters most to them,” said Blake Moret, CEO, Rockwell Automation. “When companies work with us, they can take comfort knowing we provide products and services built with security in mind. The security requirements in ISA/IEC 62443 aren’t a mere checklist for us, they’re embedded in our everyday work.”

Earlier this year, the company introduced the first industrial controller certified to ISA/IEC 624434-2, with more products to follow.

Rockwell is also a founding member of the ISA Global Cybersecurity Alliance, a coalition of industry, government agencies and others working to help secure manufacturing and critical-infrastructure operations.

The company is also working to expand the use of the ODVA CIP security protocol, which helps make sure that only authorised devices are connected in industrial operations.

It also helps prevent tampering or interference with For more information, log on to www.rockwell.com

The Timken Company, a leading manufacturer and supplier of engineering bearings and power transmission products, has completed its acquistion of BEKA Lubrication (BEKA) an equally accomplished global player in the field of automatic lubrication systems.

Timken paid $165 million for BEKA, a company serving a diverse range of industrial products sectors including rail, on-and-off highway and other process industries.

According to Timken, the acquisition positions the company as the world’s second largest producer of industrial automatic lubrication systems, which extend equipment life and improve reliability over manual lubrication methods, reduce environmental impact caused by over-lubricating and lower total costs for equipment and machine owners.

For further information, log on to www.timken.com Digital Edition - December 2019

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Cutting edge temperature measurement Ametek Land, a leading industrial temperature measurement specialist, has developed two new short-wavelength radiometric infrared borescope imaging cameras for a range of continuous industrial furnace process monitoring and control applications requiring highly accurate temperature measurement.

The NIR-B-2K is claimed to provide a cutting-edge thermal image with an

outstanding definition of nearly 3 million pixels (1968 x 1472), unaffected by the hot atmosphere and gases of the furnace, and allows operators to measure from any of three full radiometric-calibrated megapixels, providing data to optimise furnace temperature.

According to Ametek, this helps to save energy, increase efficiency and reduce emissions.

The NIR-B-2K was designed specifically to produce high-definition thermal images in a temperature range from 600 to 1800 deg C (1112 to 3272 °F).

It delivers continuous process monitoring and control for large furnaces, says Ametek, and only needs a narrow opening in the furnace wall as the wide-angle lens provides a 95° x 71° field of view, ensuring an extensive

For further information, log on to www.ametek-land.com

INNOVATIONS

measurement area covering stock, refractories and burner/heating zones in a single image.

Advanced spectral filtering is employed, unaffected by furnace temperature and gases, to deliver real temperature readings and clear monitoring of the interior. Combined with the advanced thermal imaging monitoring and process software, IMAGEPro, the patented background

compensation corrects for background reflection, enabling continuous, correct stock temperature readings.

Continuous coverage via Gigabit Ethernet connection and automated alarm outputs, makes the NIR-B-2K ideal for use in rotary furnaces, reformer tube furnaces, coal-fired power boilers, glass melt furnaces, cement kilns and biomass boilers, says AMETEK. The second release from AMETEK Land, the NIR-B-640, is a short wavelength radiometric infrared borescope imaging camera for continuous temperature measurement in furnace applications with a higher differential temperature in the field of view.

Measuring in a range from 600 to 2000 deg C (1112 to 3632 °F), the NIR-B-640 provides a high-resolution thermal image with real-time, continuous, high-accuracy temperature readings and uses the latest wide dynamic range imaging technology, providing the highest available temperature reading accuracy over the entire wide temperature range, it is claimed.

AMETEK Land says that the NIR-B-640 can accurately measure “cold” and “hot” areas in one frame or image. This allows the entire process to be monitored without switching to

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different temperature ranges during operation.

Ametek claims that the high-resolution image, combined with the wide-angle (90° x 67.5°) field of view, allows multiple areas in the lane to be imaged and measured simultaneously.

The image and data can be viewed in real-time in a safe area control room.

The NIR-B-640 is said to be ideal for applications in reheat furnaces, continuous casting (zone 1), heat treatment and annealing furnaces.

Both new models are available with IMAGEPro, an advanced thermal image processing software for controlling, monitoring, analysing and capturing imager data. The software enables a plant to optimise the performance of the furnace, identifying “hot” and “cold” areas. Any uneven heating can be visualised with corrections viewed in real-time.

As with all AMETEK Land NIR-B imagers, an optional auto-retract system safeguards the thermal imager against damage from overheating in the event of a loss of water flow, air pressure or electricity supply, or if a borescope tip high-temperature alarm is activated.

Digital Edition - December 2019

FUTURE

STEEL FORUM 2019

REVIEW

The Future Steel Forum 2020 has landed!

Early speaker confirmations include: • Dave Stickler, CEO of Big River Steel, Osceola, Arkansas USA • Sergey Detyuk, CEO, Metinvest Digital To register, visit https://www.futuresteelforum.com

There is still time to submit an abstract.

For further details, email the programme director on matthewmoggridge@quartzltd.com

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FUTURE

STEEL FORUM 2020

The Future Steel Forum has always been well ahead of the curve, offering the steel industry a high-tech steel conference focused 100% on the subject of Industry 4.0 and its relevance to the steelmaking process. As I write this, the development process has already started for the 2020 event in Prague (Grandior Hotel, 2-3 June) and you will probably find an ad somewhere in this issue inviting potential speakers to submit an abstract for next year’s programme.

If you are a steelmaker and think you have a story to tell our 2020 attendees, then do get in touch as our growing community of high-tech steel industry executives (our delegates) would love to hear about the challenges you face and share with you their experiences of artificial intelligence, cyber security and other facets of digital manufacturing.

If you’re a plant builder, the best way to find yourself on the 2020 programme is to involve a steelmaker, either as a copresenter or, if persuading them to speak is a bridge too far, why not consider a case study based on an Industry 4.0 project your company has undertaken in the primary steel industry?

As you will notice if you check out the following six pages, this year’s Forum in Budapest – like all of them – was jam-packed with interesting people and presentations. Steelmakers, plant builders, AI specialists, academics, consultants, they were all in the Sofitel Hotel (Chain Bridge) at the heart of the Hungarian capital to learn more about the most exciting, challenging and fast-moving aspect of modern steel manufacturing.

Beyond the following 14 pages lies the future and the 2020 event at the Grandior Hotel, Prague, in the Czech Republic next June. If you wish to present a paper, contact me direct on matthewmoggridge@quartzltd.com. If you want to be a delegate, register online at https://www.futuresteelforum.com

www.steeltimesint.com

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“The amount of information and knowledge makes the event valuable.”

Hidenori Nagao, TMEIC. “It’s an exceptional opportunity to assess the evolution of the steel industry and to meet relevant people.”

Diego Diaz, ArcelorMittal “See the direction the industry is going and what the trends are.”

Thomas Eens, OMP

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1. Manfred Hayk, Ametek Land; 2. Andrew Zoryk, Deloitte; 6. Daniel Middleton, Klaveness; 7. Diego Diaz, ArcelorMitta University of Oklahoma, USA. www.steeltimesint.com

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; 3. Giovanni Bavestrelli, Tenova; 4. Hans Diehl, Buderus Steel; 5. Costanzo Pietrosanti, ESTEP; al; 8. Dr. Falk-Florian Henrich; 9. Enrico Plazzogna, Danieli Automation; 10. Farrokh Mistree,

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55 “I would recommend this event to others because it is very helpful to understand how big players are moving with new technologies.”

Antonio Ambra, AIC “A good gathering of industry leaders.”

D. Egner, Materials Processing Institute “Good networking and some very good presentations.”

Luc Van Nerom, PSI “Highly recommended for knowing the industry trends and the latest innovations in the field.”

Adity Ganguly, Tata Steel

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n, Tata Steel; 55. Stephen Pratt, noodle.ai;

Andrew Zoryk; 59. Dr. Eiji (Eddy) Takahashi;

“I would highly recommend the Future Steel Forum to my colleagues involved with Industry 4.0 and digitalisation.”

L. Morsus, Danieli “Interesting to see what others are doing and a great opportunity to share experiences.”

Giovanni Bavestrelli, Tenova

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FOG COMPUTING

How fog is good for smart factories So-called Fog Computing moves cloud-type resources closer to ‘the edge’ where ‘things’ and the Network of Things can use more advanced computation resources with much smaller network delays.

By Lane Thames* DIGITAL technologies have been transforming our world for the past few decades. Within the industrial realm, we are only beginning to see the impacts of this transformation. The Internet of Things (IoT) and cloud computing have induced an evolution in the way we as society live our everyday lives, as well as how many enterprises conduct business.

This evolution has started to enter the industrial realm, most notably seen by those involved with ideas such as the Industrial Internet of Things (IIoT) and Industry 4.0.

The IIoT and the cloud are major driving forces behind other innovative ideas such as smart factories. Smart factories can achieve significant advancements with IIoT and cloud technologies. For example, predictive analytics using data from the IIoT and processed in the cloud enable optimizations of various processes for smart factories. However, many industrial organizations, including those in the steel industry, have systems with more stringent requirements such as realtime computational and communication constraints that cannot be offered by the cloud. To address these limitations, fog computing has emerged. Fog Computing is a new paradigm of computing that will provide significant benefits to industry. This paper will discuss these interconnected ideas and the relationships between the

IIoT, cloud computing, and fog computing, review some of the benefits and problems being solved, describe how the steel industry will be able to take advantage of this new paradigm in the near future, and discuss the importance of cybersecurity and how it must be viewed as a fundamental component of this entire ecosystem of technology.

Concepts In this section, we will seek to understand the concepts related to smart factories so that we can understand its connection to the fog and the cloud. Let us start by asking: What is a smart factory? A smart factory can be viewed as a highly digitized and networked production environment containing numerous devices (things) with computing and communication capabilities.

Some of these devices only communicate locally with other devices or legacy backend Information Technology systems.

Some, however, such as cyber-physical systems, can even communicate with other systems via the global Internet. Smart factories enable smart manufacturing.

Smart manufacturing generally seeks the utilization of smart factory resources to provide benefits such as robust, reliable, and safe manufacturing operations, to enable manufacturing automation, to optimize processes by reducing waste or

reducing downtime, and much more.

The next question to consider is: How can we achieve the vision of smart factories? There are numerous technological paradigms being studied and developed to achieve the vision of smart factories as well as other smart entities such as smart cities and smart homes. These technological paradigms include the Internet of Everything (IoE), the Internet of Things (IoT), the Industrial Internet of Things, and Industry 4.0. Essentially, all of the paradigms are highly related. For example, the IIoT is a subset of the of the IoT, and the IoT is a subset of the IoE. Let us explore these related paradigms further.

The IoE was introduced by Cisco Systems, Inc. [Cisco, 2013] as a system that “brings together people, process, data, and things to make networked connections more relevant and valuable than ever before — turning information into actions that create new capabilities, richer experiences, and unprecedented economic opportunity for businesses, individuals, and countries.” The IoT, however, is a technological paradigm based on things – objects with computing and communication capabilities embedded within it. These objects are networked together to form Networks of Things (NoT) potentially using numerous different communication protocols. These objects can be accessed via the Internet, currently

* Senior Security Researcher, Tripwire Inc’s Vulnerability and Exposure Research Team (VERT) Digital Edition - December 2019

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FOG COMPUTING

Artificial intelligence (Advanced)

Cloud

Big data

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Big data Artificial intelligence (Intermediate)

Fog

Edge

Edge

Network of things Network of things

enabled via connectivity protocols executed in cloud computing infrastructure. These objects often provide value-added features to things, such as being able to view a surveillance camera video feed over the Internet or turning a light off in a kitchen while on vacation.

The primary difference between the IoE and the IoT is that of people and process.

The IIoT is similar to the IoT, the main difference is that, by definition, the IIoT utilizes technologies and things that are based on industry needs and resources whereas the IoT goes beyond industry and contains things of any nature. Indeed, using the term IIoT is really just to emphasize that one is focused on an industrial perspective.

Finally, let’s consider Industry 4.0 and how it fits into this picture. German Chancellor Angela Merkel [European Parliament Briefing, 2015] states that Industry 4.0 is “the comprehensive transformation of the whole sphere of industrial production through the merging of digital technology and the internet with conventional industry”. This implies that with Industry 4.0, all entities associated with an industrial system such as manufacturing are digitally connected.

Forbes and Schaefer [Forbes and Schaefer, 2017] describe Industry 4.0 as a tight interconnection between the Internet of Things and the Internet of Services. All of these ideas reveal a type of equivalence between Industry 4.0 and the Internet of Everything, but with a main difference being that the IoE can, by definition, encompass all things, whereas Industry 4.0 has an industrial focus.

Foundations and State of the Art The goal of the previous section was to provide an understanding of the various www.steeltimesint.com

concepts, technologies, and paradigms that are being used as foundations for smart factory technology. One particular technology that is at the core of all the aforementioned ideas is the Internet of Things. The IoT is a paradigm, but it is also a reality – a highly complex system that exists worldwide. IoT research and development is advancing at a very rapid pace, and its adoption is growing exponentially. Numerous problems have been solved via the development of IoT technologies. For example, 10 years ago it would take a very crafty technical person to install a video surveillance camera in one’s home that was accessible via the Internet.

Nowadays, this is a trivial task, which is a result of IoT technological advancements.

Cloud computing plays a very important role for the IoT – without the cloud, we would not have an IoT as we know it today.

Fig 1 is a simplistic view of the current state of the art for IoT architecture. To be brief, the IoT’s current architecture is composed of things that live at the edge of the Internet. These things are often referred to as edge devices. These things form Networks of Things (NoT) and they have the ability, generally speaking, to communicate with other devices or humans either directly using various types of specialized IoT communication protocols or via the Internet. As seen in the figure, IoT devices communicate to the cloud via the Internet. State of the art IoT technologies use the cloud for data processing, intelligence, and communication fabrics.

For example, when one uses a smartphone to turn on a connected light in one’s home, the application on the smart phone communicates with an endpoint in the cloud, and the cloud then uses a preestablished, always-on connection back

to the device with the given command.

This is a type of command-and-control architecture very commonly found with IoT products.

Future Advancements with Fog Computing The IoT’s current architecture works well for many application domains, especially within the consumer market space.

However, there are various shortcomings of the architecture, especially for smart factories and the IIoT. One of the most crucial shortcomings is that of time. Smart factories as well as other IIoT systems have many components (things) that are sensitive to time delays, meaning there are real-time constraints for many of the components in a smart factory (the same real-time constraints that exist in legacy, non-smart factories).

Industrial systems utilize what is known as operational technology. Operational Technology (OT) is “the hardware and software dedicated to detecting or causing changes in physical processes through direct monitoring and/or control of physical devices such as valves, pumps, etc.” [Wikipedia, Operations Technology].

OT is comprised of systems such as programmable logic controllers (PLC), supervisory control and data acquisition (SCADA), distributed control systems (DCS), and computer numerical control systems (CNC) and, generally speaking, industrial control systems (ICS). Many of these technologies along with the many sensors and actuators that are used by them have real-time constraints. For example, a PLC in certain environments might fail if a signal is not received and processed within an order of milliseconds. This real-time constraint poses a significant challenge for smart Digital Edition - December 2019

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FOG COMPUTING

factories that need to send data to the cloud for processing – the amount of time between sending and receiving data from the cloud is too large for real-time control systems.

A solution to this problem, as well as various others, is Fog Computing. Fig 2 illustrates how fog computing fits into the IoT/IIoT architecture.

In essence, the fog moves cloud-type resources closer to the edge where things and NoTs can use more advanced computation resources with much smaller network delays. With this architecture, smart factories can be achieved even for control system operations.

There are several definitions of fog computing in the literature. According to the OpenFog Consortium [OpenFog, 2018], fog computing “is a system-level horizontal architecture that distributes resources and services of computing, storage, control and networking anywhere along the continuum from Cloud to Things. It is a: • Horizontal architecture: Support multiple industry verticals and application domains, delivering intelligence and services to users and business • Cloud-to-Thing continuum of services: Enable services and applications to be distributed closer to Things, and anywhere along the continuum between Cloud and Things System-level: Extend from the Things, over the network edges, through the Cloud, and across multiple protocol layers – not just radio systems, not just a specific protocol layer, not just at one part of an end-to-end system, but a system spanning between the Things and the Cloud”.

Fig 2 illustrates this definition where the “fog computing layer” of the figure encompasses Internet connected systems between the edge and the cloud that can be used as a fog computing resource.

Examples of these resources include switches and routers near the edge, on premise data centers, and even dedicated www.steeltimesint.com

fog computing nodes living at the edge with the networks of things.

Benefits and Problems Solved Fog computing will be a key technology to enable the full benefits that can be achieved with the IIoT and smart factories.

These benefits are galore such as increased productivity, increased product quality, and increased safety. The IIoT will provide a technological path for clean and green manufacturing.

Manufacturing industries will achieve customer level collaboration like we’ve never seen where will be able to implement the ideas of mass customization and individual customization at scale. The potential opportunities to optimize every aspect of the smart factory are endless.

Challenges Ahead Although many benefits are achievable with the IIoT and smart factories, there are some notable challenges that lie ahead. Cybersecurity will be one of the most – if not the most – critical obstacles to overcome, if we are to see the full potential and benefits of the IIoT. System complexity and countless new cyberattack vectors will arise as more advanced IIoT systems come online. This brave new world will require some evolution within all parties involved – including those who build IIoT technology, those who use IIoT technology, and those who secure IIoT technology. Cybersecurity for the IIoT will require strong interdisciplinary collaboration between all of these associated parties. In other words, cybersecurity will no longer be siloed, and everyone will need to play some role. We will also need to move towards the core of the problem – education. Our educational ecosystem has failed miserably with cybersecurity. Every single Science, Technology, Engineering, and Mathematics (STEM) based student should be required to learn the fundamentals of cybersecurity.

Nowadays, all of the technological things we design and build must be viewed with a

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cyber perspective, as the goal is to “connect all the things”. As such, every person who studies the design and implementation of technological things should be well versed in cybersecurity fundamentals, with an importance akin to the requirement of having to study calculus, i.e., no engineering student on this planet can get by without knowing calculus. In summary, a key to success for securing the IIoT is collaboration and appropriate cybersecurity education highly coupled with cybersecurity technologies.

Closing Remarks This paper discussed the technological foundations required for smart factory technologies and other paradigms such as the Internet of Things, the Industrial Internet of Things, and Industry 4.0.

Technologies such as cloud and fog computing where discussed to show how all of these ideas and technologies are interrelated. The Fog is a newer technology that is evolving and will be a critical component to fully achieve the potential for the IIoT and smart factories. One of the main obstacles for the IIoT and smart factories is cybersecurity. Collaboration and appropriate cybersecurity education highly coupled with cybersecurity technologies will be necessary for achieving our goals and visions for a future world where everything is smart. � References Cisco, 2013: https://www.cisco.com/c/dam/ en_us/about/business-insights/docs/ioe-economyfaq.pdf European Parliament Briefing, 2015: http:// www.europarl.europa.eu/RegData/etudes/ BRIE/2015/568337/EPRS_BRI(2015)568337_ EN.pdf Forbes and Schaefer, 2017: “Social Product Development: The Democratization of Design, Manufacture and Innovation,” Procedia CIRP, vol.

60, pp. 404-409.

Wikipedia, Operations Technology: https:// en.wikipedia.org/wiki/Operational_Technology Digital Edition - December 2019

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INFRASTRUCTURE

Floating towards the future Like a net frozen in midair, a striking footbridge in southern Germany is making a statement about minimalism.

This gossamer structure is only possible thanks to the unique characteristics of 2205 duplex stainless steel.

AT first glance, it resembles a giant piece of metallic silk. But this airy bridge offers more than just good looks; it represents new possibilities for sustainability and efficiency in structural design. The footbridge connects two production areas of the TRUMPF campus in Ditzingen near Stuttgart, Germany. International success and growth meant the only way to expand was to the other side of a busy country road. With the campus divided in two, getting from one part to the other was cumbersome. Besides crossing the road, checking in and out of security gates increased the amount of time taken. The new bridge not only provides employees and visitors with a way to move around their campus, but also serves as a showcase for what is now possible in laser-cutting technology – one of the main products of the company.

An elegant reduction The 28-metre long and 10-metre wide footbridge was designed by schlaich bergermann partner. It consists of double curved stainless steel sheets just 20 millimetres thick. To reinforce the lightweight structure, all edges are folded downwards and twist towards the four base points to form triangular bearing points. No further bracing was required in the shell to support the 21-tonne bridge.

To create the ethereal feel of the structure, holes corresponding to the flow of forces were cut into the shell with laser machines.

Their size and placement were calculated to maximise airiness while maintaining structural integrity.

Pedestrians walk directly on the stainless steel shell, which is treated with a slipDigital Edition - December 2019

resistant coating. The holes in this area are smaller but more numerous and filled with glass plugs. These bundle the daylight and increase the transparent appearance.

During the night, the effect inverts; light from LED spotlights under the bridge shines through the glass fillings in the walking area and the lateral areas of the structure.

Additionally, the lightness of the bridge is accented by anti-reflective, all-glass railings.

The culmination of these effects is a bridge that appears not only to float, but also to softly glow as it hovers over the country road.

2205 Duplex: less is more To realise the unique design of the bridge, 2205 duplex stainless steel was an ideal choice. With its 3% molybdenum content, it resists the corrosive environment created

by deicing salts used both on, and under, the bridge. While a similar design may have been possible in carbon steel, it would not have been practical given the many perforations. Sealing all these surfaces with a protective coating would have been intricate work and, therefore, expensive.

Additionally, this process would have had to be repeated regularly as the coatings deteriorated, resulting in enormous maintenance costs. Finally, the bare stainless steel surface also affords the bridge a crisp and modern look.

Innovation meets tradition The duplex stainless steel sheets were cut to shape and holed by modern laser technology. Nevertheless, forming the high-strength duplex stainless steel into double-curved shapes was not easy. Turning www.steeltimesint.com

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1. Due to the optimised design, the bridge is so light, it appears to float over the road. © sbp/Andreas Schnubel 2. At night, LED lights illuminate the bridge on both sides of the walkway and from underneath. © sbp/Andreas Schnubel

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3. The lasered stainless steel sheets are formed three dimensionally on a heavy press (left).

Afterwards these sheets are welded together into four quarters. The ‘folded’ edges that reinforce the lightweight shell construction are actually attached by welding. © Wilfried Dechau

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INFRASTRUCTURE

the 20-millimetre-thick flat sheets into the three-dimensional structures prescribed by the data model, required operator experience as well as a heavy press at a traditional shipbuilding firm.

There they were also welded into seven larger pieces of the bridge. These parts were then transported to a field factory adjacent to the installation site and welded together. Lastly, a heavy-duty crane lifted the entire bridge into its final position. Due to the bridge’s strength and light weight, the crane was able to lift it quickly and with minimal disruption to traffic.

With its striking design and innovative use of material, the bridge sets new standards.

The interplay between high strength, work hardening rate, and elongation means that duplex grades are particularly well suited to lightweight and cost-efficient applications with complex shapes. Due to the excellent weldability, structural components can be prefabricated in large sections and installed on-site very quickly. The possibilities are endless. This beautiful, almost weightless bridge shows that sustainable, efficient architecture can also be high art.

(Martina Helzel) �

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4. The bridge being lowered into its final position by crane; it is only self-supporting once placed in this exact position. © schlaich bergermann partner

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LUBRICATION

Experts at the extreme Choosing the right oil is crucial for so many reasons. Sarp Degirmenci* offers some guidance for steel mills

STEEL mills are among some of the most hostile manufacturing environments imaginable. The unavoidable combination of extreme heat and high loads is the enemy of effective lubrication, which risks costly and unplanned equipment downtime, a situation that steel mills are not well equipped to handle due to the continuous nature of their operation.

Although extreme temperatures and heavy loads can have an adverse effect on the in-service oils and greases, it is the high levels of external contaminants that pose some of the biggest problems. And the most taxing contaminant is water – essential as a coolant, but a major challenge for lubricants.

The presence of water is especially

hazardous as it can result in a number of problems. It can lead to premature oxidation, which can produce corrosive acidity, trigger sludge formation and increase viscosity. It is linked to hydrogen embrittlement, which can cause premature bearings failure, and give rise to rust. There is also the risk of additive depletion and reduced film strength, which decreases

* EAME offer advisor, ExxonMobil Digital Edition - December 2019

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lubricant to consider, it is easy to monitor.

However, circulation systems have their limitations. The oil choice is a compromise as one type is rarely optimal, and when contamination and degradation require the oil to be replaced, the whole system needs to be shutdown. Moreover, water contaminated and degraded oil will affect all components serviced by the circulating system, and oil replacement costs are high, especially for large installations.

It is essential for mills to select high performance, long-life circulating oil with good demulsibility.

wear protection.

If left unchecked, over time the presence of water can result in the growth of microbial contamination, such as fungi and bacteria, which can block filters and impede oil flow. Mill managers, therefore, need to select grades that are specifically formulated to not only offer reliable equipment protection under harsh conditions, but also ones with excellent demulsibility, given the high levels of water present in a steel mill. www.steeltimesint.com

Circulating systems The beating heart of a steel mill is its oil circulating system, which will require large volumes to fill – the biggest installations may be greater than 100 cubic metres in capacity. There are a number of benefits to using a circulating system, not least that the oil is not subjected to continuous high thermal stresses. Also, due to high flow rate, it can be constantly filtered to remove contaminants and as there is only one

Bearing failures Russia’s Severstal Cherepovets steel mill, one of the largest facilities of its type in the world, was experiencing water-related issues in the oil circulation system of its hot rolling mill, which were resulting in excessive bearing wear, emulsion issues and deposit formation. These factors combined to increase bearing temperatures, which required a reduction in rolling speed to minimise the risk of bearing failure. This, in turn, was hampering productivity.

ExxonMobil’s field engineering services (FES) team was called on to investigate the problem and hopefully provide a solution. What was immediately apparent was that the existing oil was failing in a number of areas. A lack of demulsibility was contributing to the formation of an emulsion, while thermal degradation was reducing its overall ability to lubricate the bearings and protect them against rust and corrosion.

The FES team recommended that the Severstal Cherepovets steel mill switch over to Mobil Vacuoline 525, a circulating oil with excellent water separation performance and anti-wear properties.

The lubricant is part of a range of highperformance, heavy-duty circulating oils designed for no-twist rod steel mills.

Following the switch, ExxonMobil monitored the performance of the product over a three-year period during which time the Russian plant reduced lubricant consumption by 50%. It also eliminated lubricant-related bearing failures and emulsion problems, oil deposit formation and equipment corrosion.

The Vacuoline family ExxonMobil’s offer for steel mills also includes the Mobil Vacuoline 100 Series as well as the Mobil Vacuoline 500 Series.

Digital Edition - December 2019

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LUBRICATION

ensure long service life and reduced oil consumption.

A blood test for machinery Once the most appropriate circulating oil has been selected, it is important to monitor its in-service performance. The most effective way to do this is to employ a used oil analysis service, which is a key part of a fully-featured maintenance programme.

Used oil analysis is best described as a blood test for machinery, providing insights into the condition and performance of the lubricants that are being used. This information can help users detect potential problems such as contamination, deposit build-up and wear, helping to improve equipment reliability.

These lubricants are formulated from high quality base stocks and a proprietary additive system to provide superior wettability, extra oil retention and thin film protection against rust and corrosion.

The lubricants offer excellent resistance to oxidation and thermal degradation, and a high level of protection against wear. They also possess excellent demulsibility, which enables water and other contaminants to separate readily from the oil in the system reservoir.

Meeting critical requirements The Vacuoline 500 Series meets the critical requirements of Primetals’ high speed ‘NoTwist Rod Mills’, as well as the circulation oil requirements of Danieli rod mills. The Vacuoline 100 Series consists of heavy duty circulating oils specifically designed for the lubrication of plain bearings in metal rolling Digital Edition - December 2019

mills. The series also meets the Morgan ‘super demulsibility’ advanced lubricant specification.

Both ranges are available in multiple viscosity grades, offer enhanced equipment reliability, a reduction in avoidable maintenance costs and cuts in oil consumption. This not only helps protect a plant’s bottom line, but also increases its competitive advantage.

All Vacuoline lubricants offer globally consistent formulation, irrespective of location, and high levels of property retention, including demulsibility. This is achieved through the use of an advanced demulsifier additive system, which concentrates small water droplets (<150um) into larger ones that are more easily separated from the oil.

Vacuoline oils are formulated using high quality base stocks and additives, helping

Lubricant analysis However, not all oil analysis services are the same. For example, Mobil Serv Lubricant Analysis offers features such as a mobile app, scan-and-go bottles and flexible analysis capabilities, all designed to provide a platform that is fast, convenient and easy to use.

The service uses QR-coded bottles that eliminate the need for labels and the manual completion of paperwork.

Users simply register a lubricant sample by scanning its bottle’s QR code, which identifies the container when it arrives at the lab. Results and bespoke equipment recommendations can be accessed via a range of devices including mobile phones and tablets using a cloud-based app.

This means that lubricant performance at remote locations can be centrally monitored.

Cost benefits Despite accounting for around 1% of a steel mill’s operational costs, high performance oils and greases have the potential to deliver substantial cost benefits.

Improvements in lubricant technology have seen significant breakthroughs in extending equipment life compared with conventional mineral oils, lengthening oil drain intervals.

That’s why mills should always choose the oils and greases that best fit their operations. By working side-by-side with their engineering team, switching the oils in their operation is a small investment that can make a big difference in achieving their productivity goals. � www.steeltimesint.com

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DIGITAL CONTROL

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Improving rail plant reliability Improved automation of the handling system for railway wheel machining at SAIL’s Durgapur steel plant using a programmable logic controller linked to each CNC machine has improved reliability, throughput speed and fault diagnostics; and enabled remote monitoring from a centralised pulpit or from any PC connected to the steel plant’s local area network. By S Singh*, I Banerjee*, D Raj*, S Kumar*, N Gupta** & S K Majumdar**

THE Wheel and Axle Plant (WAP) at SAIL’s Durgapur Steel Plant (DSP) in Durgapur, India, forges wheels for railway rolling stock. Various tests are performed for internal defects, surface defects, hardness and so on. After processing and heat treatment, wheels undergo automated machining using Computer Numeric Control (CNC). The CNC machine finishes wheels by light cutting on both sides. The former wheel handling system was semiautomatic, causing operational constraints and delay in fault diagnostics in case of any problem in the system. A state-ofthe-art Programmable Logic Controller - Remote Input Output (PLC–RIO) based centralised monitoring and control system was introduced in all CNC machines in the wheel handling system to achieve smooth and trouble-free operation. Wheel handling involves various operations – tilting the machine bed, roller table movements, cart and grab movements, transfer trolley movements and wheel positioning at the Vertical Turning & Boring (VTB) table. All these operations have been automated and include a diagnosis feature. Two PLCs and 15 RIOs are connected in ring topology.

Field sensors such as pressure switches, limit switches and various solenoids are integrated with the PLC-RIO system.

The PLC subsystem consists of a General Electric Intelligent Platform (GEIP) Process Automation Controller (PAC) that combines performance, productivity, flexibility and openness.

These centralised monitoring facilities using client-server architecture and a web

Finished railway wheels at the Durgapur wheel and axle plant

accessible interface (HMI) have helped easy fault diagnosis should there be any breakdown. The system has resulted in a significant reduction in breakdowns in the wheel handling system so improving the reliability of handling.

Wheel plant The Wheel and Axle Plant (WAP) of DSP, SAIL, was commissioned in 1961-62. DSP is the bulk supplier of railway wheels to Indian Railways. The wheel machine shop was modernised in 1993 with the introduction of additional facilities such as the ability to machine the web section of the wheels, logistical changes and a greater number of machines to match wheel production

capacity and meet the dynamic specification set by Indian Railways.

The WAP of DSP supplies wheel sets, coach wheels, loco wheels and axles to the customer. Coach wheels include BG coach wheels, BG loco wheels, S profile loco wheels, MG loco wheels and Electro Motive Unit (EMU) wheels. The steel for the wheels is from bottom-poured fluted/round ingots from steel made by DSP. Wheels are produced by forging. All the wheels are ultrasonically tested for internal defects, magnetic particle tests for surface defects and Brinell hardness values, along with several other tests. There are two finishing lines each comprising 15 operator stations for finishing the wheels on both sides.

*RDCIS (Research & Development Centre for Iron & Steel), Steel Authority of India Ltd., Ranchi, India. ** Durgapur Steel Plant, Steel Authority of India Ltd, Durgapur, India Contact: email: shakti@sail-rdcis.com, nilaygupta1@saildsp.co.in, sanjay@sail-rdcis.com www.steeltimesint.com

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DIGITAL CONTROL

Fig 1. Wheel handling mechanism in finishing line and motors used in various mechanisms

Fig 2. Schematic of fully automated wheel handling control

In the former system, wheels were shifted from the heat treatment bay to the CNC machines by a semi-automated system which controlled the next 12 movements.

After side machining, the wheel is moved to a vertical turning and boring machine (VTB).

Once machining is completed, the wheel is taken from the VTB to the next operation.

The former sequential operation is shown in Fig1.

The wheel handling system comprises of: - Roller conveyer, - Cart movement, - Hydraulic actuators.

Roller tables are driven by AC motors and convey each wheel through the entire process of machining and handling. The Digital Edition - December 2019

tilting bed is fed from the heat treatment area by crane. Tilting feeds the wheel onto the charging roller bed which acts as an input tray for machining. A moving cart is responsible for grab up and down movement and forward/reverse movement to place the wheel at the desired location.

Two kinds of hydraulic power packs are used: a stationary power pack for the tilting bed and a mobile power pack for cart movement and up and down movement of the grab. A Transfer trolley is used to move the wheel from the VTB to the discharge bed, which serves as an output tray after all machining is completed.

Correct maintenance of this system was vital for the continuous production of the plant. The introduction of a PLC-controlled

automated handling system to overcome known failures of the semi-automatic system was considered necessary.

Fully automated design The design of the project needed to ensure such functions as monitoring and control of all the signal input/outputs (IOs) in accordance with the process requirements.

Various safety interlocks and sequential operation logics in the PLCs were tested offline and during an actual trial. The two PLCs communicate with 15 Remote Input Outputs (RIOs) in such a manner that a problem in any node of any line does not affect the functioning of the other nodes. The PLCs are thus connected to the RIOs in a ring topology. Various www.steeltimesint.com

DIGITAL CONTROL

Fig 3

61

Fig 4

Fig 3. PLC panel for communication and sequential logic for the wheel handling system. Fig 4. New operator desk for wheel handling

subsystems and their communication involved experimentation for the successful commissioning of the new automation system.

The PLC subsystem consists of a General Electric Intelligent Platform Process Automation Controller (GEIP PAC) environment that combines performance, productivity, flexibility and openness. It uses the GEIP RX3I 7 slot rack to interface between the various modules. The rack is powered by a RX3I 24v supply which supplies all modules and the PAC RX3i CPU which contains a 1.1 GHz processor. The CPU has 5Mb of user memory and 5Mb of flash memory. The rack also has a GEIP RX3I Profinet Controller used for interconnection between RIOs through Profinet scanners (PNS).

The RIO subsystem uses the GEIP Versamax IO carrier into which the input and output modules are mounted. GEIP Profinet Scanner PNS is used for interfacing between Profinet controllers (PNC) and RIOs over an Ethernet ring. A 32-channel Versamax digital input (DI) and digital www.steeltimesint.com

output (DO) modules are used. The system consists of seven RIOs for machining line 1(RIO1-7) and seven for line 2 (RIO8-15).

RIOs 4 and 11 are integrated with the PLC panels of line 1 and line 2 respectively. Each PLC and RIO system is interconnected over Ethernet cables in a ring network.

To interface with operators the HMI subsystem monitors the process by animation and report generation. This subsystem comprises two HMI stations, one is Proficy Cimplicity for process and status monitoring, the other Webaccess HMI, which is browser-based for status monitoring through local mode and remote mode providing access from any authorised PC connected to DSPâ&#x20AC;&#x2122;s intranet. The Proficy machine edition of GEIP is used for software development.

Provided Ethernet communication between the PLC and RIOs is maintained, both ports on either side of the ethernet cable should appear green in colour to indicate its healthiness. An optical fibre cable (OFC) has been laid from each PLC of lines 1 and 2 to the communication panel

in the electrical shift office. The protocol used here is S90 Triplex. This is an open protocol for supervisory control and data acquisition (SCADA).

Features of system The lay-out of the improved system is shown in Fig 2. Features of automation are: â&#x20AC;˘ All wheel handling mechanisms are controlled by the PLC. The first finishing line comprises one PLC panel and six RIO panels. The PLC panel is installed at machine No 4 of the finishing line. This PLC has all the necessary IO modules to take care of input /output signals of operations related to that CNC machine. Each RIO is responsible for input /output signals for one CNC machine requiring IOs to be terminated at local RIO panels located near to the CNC machine. Connection is by the Ethernet ring communication network.

Similarly, the second finishing line comprises one PLC and seven RIO panels. The PLC is installed at machine No 11. The field sensors such as limit switches; pressure Digital Edition - December 2019

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DIGITAL CONTROL

switches and solenoid are interfaced with the new system. One of the PLC panels is shown in Fig 3.

• Centralised monitoring is connected to an engineering station placed in the electrical shift room (ESR).

This engineering station has been used as a programming terminal for developing the software for the PLC. The terminal also acts as a HMI for centralised monitoring.

The HMI has a number of screens for the operator to monitor the wheel handling processes. The web accessible HMI screen server has web accessible HMI screens for monitoring purposes. The screens are accessed by Thin Client through web browser from nodes on the DSP local area network (LAN). Connection is established with DSP’s plant-wide LAN for this purpose and a separate web server used for deployment of web accessible HMI screens.

The web accessible HMI screen server and engineering station are connected to both networks, the PLC network and the DSP LAN as required. The node point for DSP LAN is available in the electrical shift room. A suitable network switch or network interface card (NIC) is used for interconnectivity between PLCs, engineering station and server for web accessible HMI screens.

• Operator Desk: The Operator desk has a number of push buttons, selector switches, indicating display and emergency switch for operation of the wheel handling system from an individual CNC machine location (Fig 4). There are a total of 15 such desks corresponding to every finishing point for the wheels.

Fig 5. HMI screen to display dynamic process flow for wheel handling system

Result and discussion The centralised monitoring and control system for wheel handling ran satisfactorily during the trial period. It has stabilised after tuning-in of the PLC programme as well as in the hardware sections, especially the limit switches, pressure switches and hydraulic actuators. The response is much faster and more reliable than the previous method. It has the facility to provide control from a central location, but is mainly used for centralised monitoring and fault diagnosis. The index page of the HMI as well as dynamic process flow (Fig 5) is provided with tabs for direct navigation to the PLC configuration page, Alarm viewer and 15 pages for wheel handling process automation along with input/ output details. The user can navigate to the welcome screen through a tab provided at the bottom of the screen.

The operator desks are provided at all 15 locations, where there is the provision to

select auto loading/unloading and manual operation. Communication between different nodes of the network is found to be quite satisfactory. The Ethernet ring topology between PLC and RIOs provides inherent redundancy in communication.

The PLCs are connected to the HMI and programming terminal by optical fibre cable via an ethernet switch.

Acknowledgement The authors are grateful to members of the electrical department of WAP, DSP for their continuous help and support during the installation and commissioning. Special thanks to all departments of WAP, DSP for their easy adoption of the new system. The authors are grateful to the management of RDCIS, SAIL for their encouragement and support in implementing centralised monitoring and control for wheel handling at WAP, DSP. �

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HISTORY

THE village of Laxey on the Isle of Man in the Irish Sea, is famous for its 70ft (21.3m) Great Laxey water wheel named Lady Isabella (See STI October p44). The dressing floors of this mine are now the home of the restored 50ft (15.2m) wheel, built for the nearby Snaefell lead-zinc mine. Following the demise of the mine in 1908, after several revivals, the wheel was dismantled and shipped to Cornwall in 1920 where it worked as Gawns wheel for English China Clay (ECC) pumping clay slurry until 1934.

After standing idle for 37 years, ECC gifted the wheel to the Trevithick Society in 1971.

The Society loaned the dismantled wheel to Llywernog Lead Mining Museum near Aberystwyth, Wales. However, the wheel was never re-erected and in 2003, the Laxey Mines Research Group contacted the Trevithick Society requesting that the wheel be returned to Laxey. This they agreed and on 22 September that year the surviving components of the wheel arrived in Laxey, 138 years after its original construction.

L & G Howell of the Hawaeden Iron Works in Flintshire, NE Wales, built the wheel in 1865. It was one of two destined for the Isle of Man – the other, now lost, the Ellan Vannin, a 55 ft (16.7m) diameter wheel built for the East Laxey Mine at Maughold. It was agreed that the wheel should be erected as a working exhibit on the ore dressing floor of Laxey mine rather than the remotely located Snaefell mine. A wheel pit, which formerly housed a 43 ft wheel, was available once cleared of debris and was sufficiently large to house the 50 ft wheel. It took a further three years to raise the £100k required to restore and reerect the wheel. The wheel was re-named Lady Evelyn in honour of the mother of one of the principle fundraisers to restore the wheel.

A number of the cast iron rim segments had to be replaced, which was accomplished by Progress Foundry of Stoke on Trent. Booth Kelley at Ramsey shipyard, Isle of Man, refurbished the axel and hub, and the bearings – lost long ago – and hub end plates that secure the spokes, were remade in the Isle of Man Steam Packet workshops. The timber spokes, buckets and back guard were all replaced from locally donated timber.

On 5th February 2005, the axel and hub were mounted over the wheel pit and by 17 July all the spokes and rim segments were in place. Assembling and fitting the

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Homecoming of a 50’ water wheel In 2003 the Laxey Mines Research Group contacted the Trevithick Society requesting that the Great Laxey water wheel, named the Lady Isabella, be returned to Laxey. By Tim Smith*

Progress Foundry of Stoke on Trent recast many wheel rim

L & G Howell of the Hawaeden Iron Works in Flintshire, NE

segments for the wheel’s refurbishment in 2003-5

Wales, built the wheel in 1865

buckets took a further five months.

On 19 February 2006, the wheel was ready to receive water from a lade (leat) carrying water from a wear on the Laxey river. In August 2006, a grand opening ceremony took place attracting 3,000 members of the public and guests.

Lady Evelyn is accessible throughout the year in the Valley Gardens, free of charge. Along with the Great Laxey Wheel,

it is normally running from Easter to October. For further details, visit https:// manxnationalheritage.im/our-sites/laxeywheel/ �

Acknowledgements Text based on Andrew Scarffe description, a trustee of the Laxey and Lonan Heritage Trust.

*Consultant editor, Steel Times International Digital Edition - December 2019

www.steeltimesint.com

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