Steel Times International Digital Edition February 2016

TESTING & ANALYSIS

AUTOMATION

ROLLING

NEW PRODUCTS

Measuring oil film thickness is crucial to avoid production delays

Analysis of intelligent automation and process optimisation systems

Predicting the effects of bearing failure in rolling mill gearboxes

Eight full pages of new products and new technology contracts

www.steeltimesint.com Digital Edition - February 2016 - No.2

ALL SYSTEMS GO FOR STEEL IN IRAN STI Feb digital.indd 1

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CONTENTS DIGITAL EDITION - FEBRUARY 2016

TESTING & ANALYSIS

AUTOMATION

ROLLING

NEW PRODUCTS

Measuring oil film thickness is crucial to avoid production delays

Analysis of intelligent automation and process optimisation systems

Predicting the effects of bearing failure in rolling mill gearboxes

Eight full pages of new products and new technology contracts

www.steeltimesint.com Digital Edition - February 2016 - No.2

ALL SYSTEMS GO FOR STEEL IN IRAN

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com

Picture courtesy of Friedrich Kocks GmbH & Co Kg KOCKS RSB® 500++/4 currently operating in China The heavy-duty Reducing and Sizing Block is equipped with four stand positions and is designed for controlled rolling at low temperatures.

With a nominal roll diameter of 500 mm this is so far the biggest 3-roll RSB® that KOCKS has designed.

A special feature of this 500 mm heavy-duty RSB® is that every roll has its own drive. The RSB® can produce any desired finished dimension of the complete dimensional range in any desired sequence with a minimum number of roll sets and just a few stand changes.

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2 Leader 4 News focus: Iran All systems go for steel in Iran 11 Product news The latest new technology

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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Managing Director Steve Diprose stevediprose@quartzltd.com Tel: +44 (0) 1737 855164

Testing & analysis 20 Measuring oil film thickness 24 Online quality monitoring 30 Coke production Clean coke production

Chief Executive Officer Paul Michael

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SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com

32 Marketing Marketing technological services 37 Automation Innovative automation packages

Steel Times International is published eight times a year and is available on subscription. Annual subscription: UK £173.00 Other countries: £247.00 2 years subscription: UK £311.00 Other countries: £445.00 ) Single copy (inc postage): £39.00 Email: steel@quartzltd.com Published by: Quartz Business Media Ltd,

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Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, England.

Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034 www.steeltimesint.com

42 Rolling Predicting gearbox bearing failure

Steel Times International (USPS No: 020-958) is published monthly except Feb,

46 Furnaces Unique products for unique solutions

May, July, Dec by Quartz Business Media Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER send address changes to Steel Times International c/o PO Box 437, Emigsville, PA 17318-0437.

Printed in England by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK ©Quartz Business Media Ltd 2016

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49 Perspectives: Redwave Sorting steel from scrap

ISSN0143-7798

www.steeltimesint.com

Contents.indd 1

Digital Edition - February 2016

2/24/16 2:55 PM

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LEADER

“You’re gonna need a bigger boat.”

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

Does anybody remember when Jaws ll was released? I do. And the reason for my memory being so good on the matter is the line, “Just when you thought it was safe to go back in the water...”. The rest is history, as they say.

Ludicrously, I thought I’d use the phrase to start a discussion on Iran’s re-entry into the global steel market, the thinking being that just when the steel industry thought it was safe to...and that’s where it all fell apart. You see, the steel industry has no cause to relax, no reason to assume that everything is rosy and that’s because of our good friends the Chinese.

Now I know I keep bleating on about China and its bid for ‘market economy status’ – something that would be disastrous for the ‘rest-of-the-world’ steel industry – but regardless of what anybody might say about Iran, China is still the big bad wolf.

If anything, the Iranians are a breath of fresh air – certainly for global technology suppliers such as Danieli Group, SMSGroup, Primetals Technologies, Tenova and Fives Group. Although, not for their American counterparts. Why? Because the Americans are holding out on sanctions

against Iran for its links to terrorism and issues surrounding human rights.

My dear old dad, who sadly left this world in 2011, used to say, for some odd reason, “It’s a funny old world we live in, but the world’s not entirely to blame.”

I’ve never truly understood the sentiment behind that statement, but I’m kind of getting there.

It is a funny old world we live in. It wasn’t that long ago when George ‘Dubya’ Bush described Iran – or ‘iRan’ – as the ‘axis of evil’ and yet today the tables are turning.

Many would argue that Bush and Blair are the cause of all the evil goings on in the Middle East today.

But putting international politics aside, the jury is out on whether lifting sanctions against Iran is a good or a bad thing. Good for steel production technology suppliers, maybe (it’s a new market) but perhaps not so good for the steel industry as a whole.

According to the World Steel Association, Iran is the largest steel using country in the Middle East region (18Mt); and with a clear need to invest heavily in its national infrastructure, there’s a lot of excess steel floating around the world and it might well come in handy.

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NEWS FOCUS: IRAN

All systems go for steel in Iran

Now that sanctions imposed upon Iran by the west have been lifted, following a landmark nuclear agreement that was rubber-stamped last month, expect to hear a great deal more about new contracts struck between western steel production technology companies and the MENA region’s largest steel producer. By Matthew Moggridge* IRAN’S re-entry on to the world stage will be cause for concern for the global steel industry, which is already feeling the pinch of an overcapacity situation blamed largely upon the Chinese, although it is a welldocumented global phenomenon.

Iran is showing plenty of promise for western companies. According to the International Monetary Fund (IMF) the Iranian economy will expand 4.3% this year, with growth around 4% over the next two years. Iran’s imports are set to expand 18% in 2016, 14% in 2017 and 7% in 2018.

The big question on many analysts’ lips, however, is whether current oversupply issues will be exacerbated by Iran’s return to the world stage. According to some online media reports, it is difficult to come by accurate figures for just how much demand Iran will add to the equation.

Connor Campbell, senior market analyst at Spreadex, commented, “While talk of Iran’s post-sanctions re-emergence has largely focused on the potential effects it will have on oil, it could spell trouble for another resource: steel. The metal is seeing similar over-supply issues to its slippery commodity cousin, and while cheaper prices may help boost the manufacturing sector, those producing the steel could suffer.”

Worrying signs Gareth Stace, director of UK Steel, said: “With sanctions coming to an end in Iran we have already seen a surge of Iranian HRC in Europe at extremely low prices since mid2015. This is a worrying sign, as according to some commentators the state owns 90% of all mines and related large industries and, therefore, we are likely to see an increase in

dumping of Iranian steel in Europe as supply outstrips demand in the country.”

It seems as if the world and his wife are now focused on currying favour with Iran – once branded the ‘axis of evil’ by former US president George ‘Dubya’ Bush – and it’s not just western companies. The Chinese and the Japanese are also expressing a strong interest – and let’s not forget the Indians.

A recent report from Reuters claims that state-owned KIOCL is considering the construction of a US$59 million iron ore pellet complex in Iran and is in talks to sell over 2Mt of iron ore to the Iranians.

According to Reuters, “the potential Indian investment could offer cheaper supplies of processed iron ore to Iranian steel mills that, like most companies around the world, are having to contend with cut-

* Editor, Steel Times International Digital Edition - February 2016

IRAN.indd 1

www.steeltimesint.com

2/22/16 9:20 AM

NEWS FOCUS: IRAN

President Hassan Rouhani

The Americans still have sanctions in place with Iran concerning the latter’s support of terrorism and human rights abuses

price steel from an over-supplied China.”

KIOCL’s planned investment could be complicated, claims Reuters, by two Iranian companies – Gol-e-Gohar and Sangan Mines – who plan to start their own pellet production in March, adding more than 5Mt in supplies.

In Turkey, however, there is less enthusiasm for Iran’s ‘new kid on the block’ status. It is argued that the Iranian and Turkish steel industries are very similar in terms of product output and that the former might prove to be stiff competition for the latter when it is considered that steel accounted for just 7% of Turkey’s exports last year. The fact that energy is cheap in Iran will also have a bearing on future developments.

Another potential spanner in the works for Rouhani’s centrist government is Iran’s www.steeltimesint.com

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so-called ‘hardliners’ who claim, according to a report in the Financial Times, that Iran’s natural and financial resources are being looted by western companies. The newspaper argues that hardline opposition to Rouhani’s business deals with the west are more to do with Iran’s February elections and won’t endanger the contracts themselves.

The worldsteel perspective According to worldsteel, “Iran is the largest steel using country in the Middle East region with annual steel use of about 18Mt. The socio and economic environment of the country suggests that steel demand is likely to keep growing for a number of years to come.

It has a very young and growing population and ambitious plans to grow

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its industrial base. In 2016, Iran’s steel demand is expected to grow by 6% and it could accelerate in the medium-term with an improved economic environment in the post-sanction era. In the short-term Iran remains a net importer and we do not expect this to change. The impact of the reemergence of Iran is likely to be first felt in the Middle East region before it has global impact.”

Phil Ward, president of the USbased Steel Manufacturers Association, commented, “It remains to be seen what the re-emergence of a post-sanction Iranian steel industry will have on global steel markets. While there are still problems with overcapacity (primarily from China), the steel industry in the Middle East and North Africa is a key potential growth sector.

Domestic infrastructure needs are very high in Iran. Iran’s ability to capitalise on gasbased DRI as part of its raw material mix due to the abundance of natural gas in the region is an important factor to consider.

Additionally, Iran will still have to overcome economic and political instability. In my estimation, if the steelmaking capacity in Iran is used to meet domestic and regional demand, the short-to-intermediate term effects on global steel markets should be minimal.”

Good or bad outcome?

Rafael Rubio, general director of Alacero, the Latin American Steel Association, offered two possible scenarios for the global steel industry. On the one hand, he believes that if new demand from Iran can be satisfied by local production and imports, then it is good news as some of the current overcapacity can be used up.

However, if Iran chooses, over time, to selfsatisfy it’s steel needs – as many developing countries have done in the past – then such a strategy will have a negative effect.

According to Rubio, the capital-intensive nature of steel production might lead to the Iranians relying initially on imported steel, which can only be a good thing.

“It is clear that Iran’s economic situation will start to normalise in the short-tomedium-term with the elimination of sanctions,” Rubio said, adding that the change won’t occur overnight. “As soon as conditions do change, the Iranian economy will enter a growth drive and over the next three-to-six years we will see a normalisation process taking place in Iran,” he said.

Digital Edition - February 2016

2/22/16 9:20 AM

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NEWS FOCUS: IRAN

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Ultimately, said Rubio, only time will tell whether the re-emergence of Iran is a blessing or a curse for the global steel industry.

European technology providers, bolstered by a recent trade visit from Iran’s President, Hassan Rouhani, are readying themselves for some much-welcomed new business.

Oddly, the only nation’s technology providers who might not benefit immediately from Iran’s newfound ‘open for business’ status are those in America.

According to the New York Times, while the Obama administration has promoted the benefits of non-proliferation and global security brought about by the nuclear deal, it is ‘less vocal about the benefits for business’.

Sanctions still in place This is because the Americans still have sanctions in place with Iran concerning the latter’s support of terrorism and human rights abuses. It means that American companies cannot sell oil country tubular goods (OCTG) to the Iranians – although they can trade in Persian rugs and commercial aircraft.

Conversely, the Russians are cock-a-hoop having maintained a good diplomatic relationship with the Iranians over the years and having what the New York Times described as ‘deep military ties’. It all bodes well for Russian steelmaker TMK, a major supplier of pipes to oil and natural gas producers.

It is all good news for steel production technology suppliers too as it means new steel contracts at a time when business is reportedly slow elsewhere in the world.

The Italian Danieli Group, for example, recently signed agreements worth approximately 5.7 billion Euros.

The agreements, signed in Rome by the company’s chairman and CEO, Mr. Gianpietro Benedetti, relate to a joint venture and orders for the supply of machinery and plants to be installed in Iran.

“Persian Metallics” is the name of a joint venture project worth an estimated 2 billion Euros, which will involve a group of international and Iranian investors.

The Persian Metallics venture will use iron ore and energy to produce around 6Mt/ yr of pellets to feed direct reduced iron (DRI) plants for steelmaking using electric arc furnaces – the most environmentally friendly and often most competitive way of making steel today. www.steeltimesint.com

IRAN.indd 3

Top: Rouhani and Putin – the Russians have maintained strong diplomatic ties. Bottom right: Armadinejad – the old guard

Other agreements relating to the supply of machinery and plant to produce steel and aluminium will be signed with several Iranian companies and are worth an estimated 3.7 billion Euros.

South Korean steelmaker POSCO has announced the signing of a preliminary agreement with Iranian steelmaker PKP worth an estimated US$1.6 billion.

Home-grown talent Indigenous steelmakers in Iran are also expanding operations.

The Kish South Kaveh Steel Company (SKS) in Iran claims to be investing heavily in steel production projects that will create around 1,000 direct and indirect jobs in the country.

CEO Ali Dehaqin, says that SKS intends to play an important role in the on-going development of the Iranian steel industry.

“Annual [Iranian steel] production of 55Mt has been envisaged until 2025,” he said, adding that phase one of SKS’s steel production project was launched with a capacity of 1.2Mt/yr.

To date, SKS has produced 400 tonnes

of steel using state-of-the-art equipment including an electric arc furnace (EAF/ EBT/170/7500 model). The equipment in question is a CCM/6 strand/120-150-200 foundry machine with a tundish capacity of 30 tonnes and it is predicted to be capable of producing billets at nominal capacity.

Phase two of SKS’s steel production project is currently under way and is expected to come on stream in March 2017, according to project manager Shahram Salmasi. When phases one and two are completed, the company will be producing around 2.4Mt/yr of steel.

Dehaqin says that the establishment of three steel companies in different geographic locations within Iran will contribute heavily to the continuation of steel production by SKS. In the east of Iran, the East Kaveh Company is prioritising mining and the production of pellets and concentrates in addition to the procurement of raw materials, such as iron ore, for steelmaking.

The Kaveh Arvand Steel Company is focused on rolling and the supply of long products and will be a regular customer for SKS steel.

Digital Edition - February 2016

2/22/16 9:20 AM

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SKS is located within the Persian Gulf Special Economic Zone, close to the sea and within easy access of the Shahid Rajaee port where there is unlimited access to seawater for the company’s desalination plants.

The Southeast Saba Power Generation Company (SSPGC) is also within the zone and intends to construct a combined cycle power plant. Phase one, which is currently under construction, will produce 500mW of electricity. On completion of phase one, SSPGC will provide enough electricity to meet the requirements of SKS’s phase two development, according to Salmasi.

In a bid to provide the industrial water required by SKS’s steel production units in phases one and two, plans are underway to build two oxygen units at the South Kish Kaveh Steel Company aimed at producing 55,000 cubic metres of water per day. Supply pipelines are completed.

Three desalination units with capacities of 5,000, 10,000 and 17,000 cubic metres will pump a total of 32,000 cubic metres of water into the production cycle.

Other units will come on line gradually and as required.

Iranian iron ore production is expected to rise to 40Mt next year, up from 38Mt in 2013. Steel output is estimated to reach 55Mt by 2025 (up from 22Mt this year) and the Iranians are seeking US$20 billion to develop its domestic industry.

While steel is high on the agenda, there is also plenty of potential for other industrial sectors, such as aluminium. t www.steeltimesint.com

2/22/16 9:20 AM

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INNOVATIONS

Increased life for bloom, billet and tube moulds

Castolin Eutectic has developed a Compact HVOF Gun, which can apply coatings to the inside of bloom, billet and round mould tubes.

The company believes that this development will revolutionise the durability and longevity of small moulds in extending performance life. Trials have already taken place at Monitor Coatings workshop in South Shields in the UK. It is claimed that the liquid fuel system and its applications are similar to other mould coatings currently supplied into the UK and Europe, but, performance-wise, are more cost effective.

Castolin claims that its Compact HVOF system is compliant with European legislation such as the REACh Directive, providing continuity and a cost effective alternative to coatings that will soon become obsolete under the new regulations.

According to Dr. Bryan Allock, CEO of Monitor Group: “We have been developing the Compact HVOF Gun for a number of years, and we have now perfected the patented application process. We are now looking forward to sharing this exciting technology with new and existing customers.” www.castolin.com

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Calderys’ new ‘brand platform’ At the recent GIFA 2015 exhibition in Germany, Calderys unveiled a new brand identity platform, reflecting its capability as a provider of global end-to-end refractory solutions.

The new brand positioning and imagery, claims Calderys, better reflects the company’s ability to combine its refractory product portfolio with its ability to deliver project management services – from planning and installation through to turnkey delivery and commissioning.

It is claimed that the new brand platform ‘better showcases the company’s established presence in most developed and developing markets across all industries’ and that includes iron and steel.

The company’s new identity has departed from the qualifier ‘Refractory Solutions’ and instead uses ‘Together for More’, the motto of Calderys.

John Maxwell, Calderys’ CEO, said that the new motto expresses the company’s purpose of delivering incremental value through continuous improvement. www.calderys.com

Variable-speed drive cuts stoppages at Tata Steel, says ABB Less blade wear and greater uptime for a billet mill saw are among the benefits from retrofitting a motor and variable-speed drive (VSD) at Tata Steel’s Stocksbridge plant, claims ABB. The motor and drive improves control of the saw and prevents trips and stoppages that can damage the blade, says ABB. Stocksbridge-based Tata Steel Speciality Steels produces high-value special steels for the aerospace and oil and gas industries. Hot rolled steel is presented to the billet saw from the No.2 finishing mill, in sizes ranging from 180mm to 300mm at a temperature of about 800deg C. The steel is run to a stop and measure system, which allows the operator to position each piece to achieve the required size of finished billet.

However, the original system would frequently trip, requiring the mill electrician to reset the saw protection, leading to delays and lost production.

A trip occurs when the traverse speed feed rate was incorrect, or if the loading increased rapidly.

In both cases the saw jams in the hot steel, in some instances becoming welded to the billet.

The saw has an 1,800 mm circular blade, which was driven by a 185 kW 6-pole motor started by an autotransformer, providing a soft start facility. Originally, the saw ran at the fixed pole speed and the cutting cross traverse was manually controlled with a joystick, connected through a proportional valve in the hydraulic system. The operator checked the motor load via an ammeter monitoring the load on the saw motor, increasing or decreasing the traverse speed to maintain optimum load on the motor.

Tata Steel approached Halcyon Drives and asked the company to look at the application and design and install a solution that would solve the tripping problems.

“We were asked to provide better remote conwww.steeltimesint.com

products.indd 1

trol of speed for the circular saw, by monitoring the motor load and so providing a more accurate rate of traverse speed,” said Tata Steel’s electrical development engineer Bernard Sidway.

This would prevent the motor being stalled or overloaded, which could damage the saw.

Halcyon Drives supplied, installed and commissioned a new ABB 250 kW high efficiency IE2 cast iron, 6-pole motor fitted with an insulated non-drive end bearing. This is controlled by a 200 kW ABB industrial drive, ACS880, housed in an IP54 enclosure.

The VSD is programmed to run at an energy saving speed or full speed, either of which can be selected remotely. When a cut has been completed, the saw motor speed is reduced to 75% and initiates a timer. If no further cutting has started for two minutes, the speed is reduced to 50%.

The VSD is equipped with a braking system, in-

cluding a brake chopper and resistors to dissipate heat from the drive while slowing the circular saw. The drive is programmed to monitor overcurrent, with torque monitoring giving a 4-20 mA analogue signal to allow automatic control.

The control system is modified to incorporate this monitoring – although the operator can still control the saw manually, the torque and current monitoring prevent an action that would trip or stall the motor.

To reduce waiting time, an automatic one time overload reset is incorporated into the new drive.

Should a trip occur, a second trip within 10 minutes requires an electrician to reset the system.

In the two months since the system was introduced, there have been no reported instances of motor trips. Trials are under way to find the optimum traverse speed to optimise blade life. www.abb.com Digital Edition - February 2016

2/22/16 12:50 PM

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INNOVATIONS

Danieli Group signs big Iranian contracts

Tenova DRI plant exceeds expectations A direct reduction plant installed by EZZ Rolling Mills (ERM) in Al Ain Sukhna in Egypt has passed its first trial one month after start-up, according to the Italian production technology company Tenova.

The plant, which has an annual capacity of 2Mt, produced its first DRI (direct reduced iron) last November. But while it was ready to increase productivity, it was forced to work at a reduced rate due to natural gas supply limitations emanating from the national network.

From mid-December onwards, however, the supply problems were rectified and the plant has since been ramped up to full productivity.

Performance tests were passed with flying colours.

Productivity was 112% of the guaranteed value, according to Tenova, showing a metallisation higher >94% and a carbon content higher >3% and this, claims the company, is only achievable

using ENERGIRON technology.

“A natural gas specific consumption of 2.57 Gcal/t and electric energy of 30kWh/t complete the picture of an optimised technology with respect to the overall energy consumption,” said Tenova, adding that one of the most peculiar characteristics of ENERGIRON technology is raw material yield.

According to Tenova, the ERM plant showed ‘an impressive ratio of 1.37 tonne of oxide per tonne of DRI and can process oxide pellets or lumps screened at 3.2mm, minimising the rejected portion. “All these results represent the lowest OPEX nowadays achievable in the DR technology panorama,” said the company.

In under one month, total plant production already exceeded 110kt while hourly production reached 262 tonnes/hr – or 2.1Mt/yr, 10% above the guaranteed value of 1.9Mt/yr www.tenova.com

Following the lifting of sanctions on Iran, the Italian Danieli Group has signed agreements worth approximately 5.7 billion Euros.

The agreements, signed in Rome by the chairman and CEO of the Danieli Group, Mr. Gianpietro Benedetti, relate to a joint venture and orders for the supply of machinery and plants to be installed in Iran.

“Persian Metallics” is the name of a joint venture worth an estimated 2 billion Euros, which will involve a group of international and Iranian investors.

The Persian Metallics project will use iron ore and energy to produce around 6Mt/yr of pellets to feed direct reduced iron (DRI) for steelmaking using electric arc furnaces – the most environmentally friendly and often more competitive way of making steel today.

Other agreements relating to the supply of machines and plants to produce steel and aluminium will be signed with several Iranian companies and worth an estimated 3.7 billion Euros.

Danieli’s plant-making division, based in Buttrio, employs 10,000 people and consists of various product lines active in the design, construction and start-up of plants for the production of steel and non-ferrous metals, from the treatment of ore and scrap to the melting, casting, rolling and finishing of a wide variety of finished, flat, long, forged and tubular products. www.danieli.com

SMS Group – big presence at Tube & Wire The German SMS Group will be attending the Tube & Wire trade fair in Dusseldorf where it will present a number of concepts for efficient tube, pipe and wire production.

The 15th Tube & Wire trade fair takes in Dusseldorf, Germany, from 4-6 April.

SMS specialists will be on hand to demonstrate the company’s latest automation solutions designed to give an additional boost to the efficiency of tube, pipe and wire production plants.

SMS offers a wide range of process automation solutions designed to improve product quality, increase production and cut transformation costs.

SMS claims to offer a portfolio comprising all types of tube and pipe production processes along with associated finishing lines.

According to SMS, increasing production is no longer top priority for most mill operators. “Their focus is rather on optimising production,” the company said.

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“SMS group offers economically efficient technology for the production of high- and premium-grade tube and pipe products. Our customers are perfectly positioned in a market environment that calls for ever higher quality and safety standards for tube and pipe products,” the company said.

SMS claims that its customers have benefitted from the integration of the Schumag brand into the SMS Group in 2008, explaining how that deal ‘bridged the gap’ in the process chain for bar and wire rod production. The deal paved the way for SMS to get involved in the drawing, peeling, straightening and grinding processes and offer ‘truly comprehensive’ expert advice.

Last year, SMS brought together the business areas of SMS Siemag and SMS Meer providing for ‘a perfectly harmonised range of plants and machinery along the entire metallurgical process chain’. www.sms-group.com www.steeltimesint.com

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INNOVATIONS

European Heathyards announces BS EN 1090 Part 2 – Execution of Steel Structures accreditation European Heathyards, which claims to be one of the UK’s leading tube manipulation, fabrication and high integrity welding companies, has started the new year in buoyant mood after announcing it has achieved BS EN 1090 Pt 2 – Execution of Steel Structures accreditation.

West Midlands-based European Heathyards fabricates tube, plate and steel structures for the oil and gas, power generation, petro-chemical and nuclear sectors, started the initial accreditation process in early 2015 and achieved BS EN 1090 Pt 2 accreditation in December 2015.

According to technical director Arran Nash, attaining BS EN 1090 part 2 – Execution of steel structures, forms part of an ongoing drive to maintain the highest possible standards as European Heathyards seeks to expand its market share in the construction industry.

“Achieving BS EN 1090 accreditation was a natural progression in our quality process as we already had most of the systems, procedures and qualified staff in place to absorb the stringent demands of the manufacturing and audit process,” said Nash.

“The move towards BS EN 1090 Pt 2 will play a key part in positioning European Heathyards as a key supplier of safety critical steel structures to the construction industry. The accreditation is now a legal requirement for all structural steelwork products,” explained Nash.

European Heathyards is currently accredited to the globally recognised ISO 9001, ISO 14001 and BS OHSAS 18001 quality and environmental management systems and manufacture heat exchangers and pressure vessels under PED and ASME U-Stamp.

The company also has an ASME audit planned this year to enable it to achieve accreditation for the S-stamp (power boiler) PP-stamp (Pressure piping) R-stamp (Repairs & Alterations). www.europeanheathyards.com

13

AUMUND for world’s largest HDRI plant In August this year Tosyali, an Algerian steelmaker, will take delivery of a 116-metre BZB-H-I 900 conveyor from Aumund.

The equipment has been configured to convey 323 tonnes/hr of hot DRI at a material temperature of 750 deg C, and Aumund is counting on using a patented pan conveyor with buckets.

Improved sealing protects the material to be transported from any environmental influences and thus the inert system prevents the re-oxidation of what is highly reactive bulk material, making the transport of sponge iron possible without losing the high degree of metallisation.

Frank Reddeman, Aumund’s project leader, commented: “To produce the same amount of steel, a significantly lower input of energy into the electric arc furnace is needed this way, the tap cycles are reduced and productivity rises by up to 20%.” He added that the special conveyor will be used as the link between the MIDREX shaft furnace and an electric arc furnace for the transport of HDRI. Tosyali is building the largest plant for the production of DRI

worldwide at Bethioua in Algeria. The new MIDREX-Direct Reduction plant will feature a production capacity of 2.5Mt/yr of DRI and production will commence at the end of year.

HDRI or CDRI will be produced alternatively without constraints to ongoing production, it is claimed. www.aumund.com

Wuppermann Staal installs seven-roller flattener and side trimmer from SMS Group SMS Group recently supplied a seven-roller flattener and side trimmer to Wuppermann Staal in Moerdijk, the Netherlands. The two machines were installed at the entry point of a hot-dip galvanising line for hot strip, which has been in operation since 2001.

Wuppermann made the deal with SMS official in December 2015. The new line configuration at the entry allows the steelmaker to hot-dip galvanise the hot strip face sides and edges in one pass.

In order to ensure that the sides of the strip are accurately trimmed, the strip is first levelled in the flattener. The side trimmer, which is equipped with Automatic Setting Control (ASC), features

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an integrated burr masher and scrap chopper unit.

SMS also supplied special strip processing equipment along with automation and control systems.

The new heat-to-coat hot-dip galvanising line for hot strip, which SMS is building at Wuppermann in Hungary, will have the same entry configuration as the Moerdijk line. The line in Hungary – which starts up in mid-2016 – will

produce hot-dip galvanised strip with hot-dip galvanised edges in a single pass. The material produced is frequently used in silos for the storage of bulk material and is often referred to as ‘silo sheet’.

With its new side-trimming unit installed at the line entry point, Wuppermann can now hot-dip galvanise the face sides and the edges of hot strip in a single pass. www.sms-group.com

Digital Edition - September 2015

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14

INNOVATIONS

POSCO relies upon ISRA PARSYTEC’s Surface Master inspection system Korean steelmaker POSCO is replacing its proven inspection system with a Surface Master Advanced surface inspection system from ISRA PARSYTEC. Pickling and annealing lines for stainless steel bands operate in harsh conditions, according to ISRA VISION PARSYTEC. For this reason a robust inspection system is important.

The system installed by POSCO is claimed to offer the highest inspection performance and can fully satisfy current and future requirements. It is based on multi-dimensional inspection with a single compact sensor for various viewing angles, a

decisive factor in the contract world, claims ISRA VISION. According to the company, a new matrix sensor and sophisticated classification technology ‘offers a high level of robustness’.

The smallest topographical defects can be detected thanks to MultiView technology and multi level classifiers, arranged hierarchically, ensure reliable detection and clear classification of all surface defects.

A Surface Master inspection system means that POSCO can make 100% reliable assessments of surface quality produced on its pickling line. www.isravision.com

Primetals extends TK intensive cooling section at Duisburg steel mill Primetals Technologies has expanded the intensive cooling section of a ThyssenKrupp hot strip mill in Duisberg-Beeckerwerth.

The "Power Cooling" system from Primetals Technologies, operational since December 2010 – and substantially enlarged in 2014 – has passed its acceptance test.

The system cools all steel grades including high strength steel (HSS) ‘quickly and reliably’ in a wide range of thicknesses.

According to Primetals, the aim of the expansion work is to develop new materials that require higher cooling rates and thus helps ThyssenKrupp to gain a technological edge over their competitors.

ThyssenKrupp Steel Europe now runs its hot strip mill to produce materials that could only previously be made on plate rolling mills. It uses Primetals’ intensive cooling system for many grades that used to be cooled only in laminar mode. High cooling rates and precise temperature control, claims the company, allow exact adjustment of the microstructure. As a consequence, smaller quantities of alloying elements are needed to produce certain steel products.

Primetals installed and commissioned phase one of the Power Cooling system on hot strip mill 2 in December 2010. A total of 16 cooling headers were installed above and another 16 below an eight-metre section of the run-out roller table.

In intensive mode, height-adjustable headers

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provide around 6,200 cubic metres of cooling water per hour at a pressure of about three bar.

The 2014 extension doubled the maximum water flow rate. A second group of headers was installed directly downstream of the existing intensive cooling section. The resulting Power Cooling system now features a total of 32 headers above and below an 18.5 metre section of the run-out roller table.

Four 375kW booster pumps feed the cooling system and can raise the laminar pressure to a maximum of three bar to achieve the full water flow rate. The capacity of an associated water management system was increased to a continuous output of 9,000 cubic metres per hour. This means that the first 18.5 metres of the cooling section can achieve cooling rates five times higher than those of the original laminar cooling section. The conversion work was completed on time during a 14-day plant shutdown.

Depending on the thickness of the strip, Power Cooling technology from Primetals Technologies can achieve cooling rates of up to 400 Kelvin per second. Such high rates are required, in particular, for the production of higher and highstrength steels in the upper thickness range of up to 25.4 mm. Cooling intensity can be regulated in the cooling section to achieve the desired microstructure of the rolled material with high precision. www.primetals.com

Name change reflects diversification Clifford Welding Systems (CWS), a leading machinery supplier to the wire and steel industry, has changed its name to Clifford Machines & Technology (CMT).

The reason for the name change is to better reflect the diversified range of machinery being delivered to customers and express the capabilities and ambitions of the company to produce machinery in the ‘industrial equipment space’.

“We increasingly find ourselves receiving enquires to build capital equipment for customers not in our traditional wire and steel industries,” said CMT CEO Craig Markham.

Technical director Iain Ambler said the Clifford name has been linked to the wire and steel industries for the last 50 years. “Our new name reflects all the history and experience we have in the machine building space and speaks to our capabilities to produce equipment, incorporating cutting edge technologies,” he said. www.cliffeng.com

Riva Group orders Sund Birsta Sirius compactor Riva Group has ordered an advanced coil compactor from Sund Birsta AB, a Danieli Group company.

Riva’s mill in Sam Montereau, France, already has experience of Sund Birsta compactors and coil handing systems and has used earlier versions of the equipment over the past 30 years.

The latest piece of equipment – the Sirius – relies mainly on electro-mechanical drives for its functions and only limited hydraulic power.

The Sirius consumes approximately 20% of the energy consumed by conventional compactors on the market, claims Danieli.

“Carriages travel with electrical gear motors quickly and with low force. Final compacting is done by hydraulic cylinders with short stroke and high force,” explained the company.

The press forces will be kept within the framework of the two press carriages since they are locked together before final compacting.

Wire feeding is electrically driven using frequency converters to control speed, according to the Riva Group.

The new fully electrical binding unit KNBe has also been introduced and will use servo motors to operate. “With servo drives, a vast range of analysing tools are available and these can be used for generating feedback for preventive maintenance. The electrical binding units also avoid any risk of getting hydraulic oil on the coils,” it is claimed.

The Sirius will help mills save energy while simultaneously optimising speed and efficiency.

Machine dimensions are smaller than traditional compactors. www.sundbirsta.com www.steeltimesint.com

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INNOVATIONS 15

Witt’s improved PA 7.0 gas analyser – more hygienic?

Monitoring protective and shielding gases is extremely important in the metal processing industry, claims Witt. This is why the company has further optimised its gas analyser PA 7.0 for measuring oxygen and carbon dioxide concentrations.

According to Witt, the compact analyser now sports an even better hygienic design.

Where performance enhancement is concerned, some versions of the PA can perform a random sample analysis using a sample needle to check the protective gas atmosphere. This is done in parallel with the PA’s permanent inline gas monitoring capability, claims Witt.

Three different measuring cells are available for

the analyser: chemical, zirconium and infra-red. All three measure from 0% to 100%. If the individually adjustable limit value is reached, the PA will emit an alarm or switch a floating contact, for example, to interrupt the gas supply. It will also emit an alarm if the needle is clogged.

A USB interface is available for data transmission. There are additional interfaces, such as digital inputs and outputs, 24V inputs and outputs as well as relays with which to integrate the analyser with an existing system.

A data memory stores the last 500 measure-

ments and, thanks to data export and specially-developed OBCC software, the user can document and analyse all measured results digitally. www.wittgas.com

Increasing energy efficiency

Kasto introduces new saws range

Combustion analyser app

Magnetek Inc has added the IMPULSE R to its high performance series of AC Line Regenerative Systems.

The digital power and motion control systems specialist describes the new equipment as an effective solution to increase the energy efficiency of overhead cranes.

The new equipment is available with ratings from 5-400 horsepower and is claimed to be easy to operate and network connectable via Ethernet and a PLC for real-time status monitoring.

Magnetek claims that the new system can be retrofitted with ease to replace dynamic braking units and resistors on existing controls. Wiring and maintenance associated with dynamic braking resistors is eliminated, says the company.

According to Magnetek, it’s AC Line Regenerative units capture surplus regenerative energy from the motor that would normally be expended by resistors and return it to the AC power source, reducing total energy consumption and creating industry-leading gains in energy efficiency. “Initial investment ‘payback’ can be realised in as little as one year,” the company claims.

Also on offer from Magnetek is a high-performance Active Front End Regenerative Unit known as IMPULSE D +. The unit offers a chassis drive layout with ratings of up to 830HP. Magnetek’s IMPULSE D + HHP is a modular, regenerative inverter platform suitable for applications up to 2,000HP. Magnetek claims that all three regenerative units can be easily integrated with the company’s IMPULSE G+ or VG+ Series 3 or Series 4 adjustable frequency drives and sized to fit the expected regenerative need.

Dan Beilfuss, director of sales for the company, said that Magnetek was committed to being the leader in energy savings solutions for the materials handling industry. www.magnetek. com

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Sawing technology specialist KASTO has introduced what it describes as a “flexible, universal solution for serial and production sawing of solid materials, tubes and profiles”.

The new KASTOwin range consists of five fully automatic band saws covering a cutting range from 330mm to 1,060mm and is claimed to be suitable for use with different steels. According to Kasto, they offer a flexible solution for numerous sectors – from mechanical engineering and toolmaking, via the steel and automotive industries to aerospace engineering. A comprehensive range of standard equipment makes them particularly efficient, the company claims.

Hilmar Gehrmann, KASTOwin’s product manager, said: “Our objective was to develop an all-round saw which would enable us to fulfil the majority of our customers’ normal requirements.

Many companies do not want expensive special designs, but a cost-effective and economical standard solution,” The five KASTOwin models (A 3.3, A 4.6, A 5.6, A 8.6 and A 10.6) are manufactured in Germany to the same design and use the same components in order to reduce material procurement costs and manufacturing and assembly effort. As a result, the company claims that its new saws cost significantly less than comparable products on the market. www.kasto.com

E Instruments has released a combustion analyser app, which can be found on the Google Play store.

The app enables users to interact wirelessly with the company’s combustion analyser models 1500 or 4500 through Bluetooth communications.

Users can pair their analyser with a compatible Android Smartphone and/or tablet via Bluetooth in order to: • Remotely display data on their Android device • Remotely save an analysis on the instrument • Generate reports (csv, pdf, or xml format) and send them by e-mail from their device • Load/email a previously saved combustion analysis www.e-inst.com

Thermo’s new spectrometer ThermoFisher Scientific’s new SDD1000 detector for the ARL QUANT’X EDXRF spectrometer is claimed to dramatically improve elemental analysis capabilities for a broad range of applications.

The system utilises a 1,000-micron silicon crystal, which is more than double the thickness of most silicon drift detectors on the market.

The SDD1000 detector is claimed to provide a four times higher count rate and better resolution than the instrument’s previous detector and, therefore, improved limits of detection and three times faster measurement.

According to ThermoFisher Scientific, “the thickness of the state-of-the-art silicon crystal provides enhanced sensitivity for the detection of heavy elements. Its larger active area provides better performance for lighter to heavier elements,” said the company. www.thermofisher.com

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16

INNOVATIONS

Midrex Technologies has been commissioned by Société Internationale Métallique (SIM) to supply the equipment and oversee the technological aspects of a 2Mt/yr hot briquetted iron (HBI) plant in the Bécancour Waterfront Industrial Park, a public-owned facility on the shores of the Saint-Lawrence River in Quebec, Canada; the site is a year-round deep water port and connected to major North American rail and road infrastructure.

Daubeny B. Cooper III, president of Société Internationale Métallique, commented: ‘‘The MIDREX process is the technology responsible for nearly two thirds of the world’s annual DRI production and the primary technology behind most HBI produced today, thus it was a logical choice for us.”

He said that SIM will produce the best HBI in the world by merging state-of-the-art technology with high quality and strategically located iron ore. “Coupled with a friendly business environment and historically-proven performance, SIM’s new plant is positioned to be a leader in clean iron-reducing and in the secondary transformation processing of iron ore in the province of Quebec,” he added.

Midrex and Primetals will provide the principal equipment of the plant, in co-ordination with a construction and engineering firm that remains to be selected. Using the MIDREX NG™ Process, Midrex and Primetals Technologies are designing the plant to have a rated capacity of 2Mt (metric tonnes) per year of HBI, making it one of the largest HBI modules in the world.

MIDREX Technology is also being used in a similar plant currently under construction in Texas in the USA. ‘‘Midrex built two of its first ironmaking plants in Quebec nearly 40 years ago, so it is a pleasure for us to come back to Canada with our latest technology advances,” said James D. McClaskey, president and CEO of Midrex Technologies. “HBI is a raw material that allows a clean, efficient way for many steelmakers to augment their steel production. HBI demand continues to grow, and with this new plant SIM will be in a prime position to supply various steelmakers worldwide by capitalising on the expertise and natural resources of the local region.”

Heiner Röhrl, CEO of Primetals Technologies Austria, said that Primetals Technologies has been a MIDREX licensee for the Direct Reduction Pro-

Midrex Technologies and Primetals

cess for more than 30 years and in co-operation with MIDREX has built more than 20 MIDREX Plants worldwide. “From the development of the first HBI plant in Malaysia in the 1980s up to the HBI plants currently under construction in Russia and the world’s largest HBI plant in Texas, USA, Primetals Technologies played a major role in building most of the HBI plants and contributed with its expertise in the iron and steel industry to the development of this technology.”

Iron ores are first ground and concentrated and then processed to direct reduction (DR) grade pellets. These pellets are then fed into a MIDREX Shaft Furnace where they are reduced to metallic iron. The hot pellets are malleable and

Nokra claims new flatness and contour measuring system is ‘a success’ Alpha.fi 2.0 is the name of a new flatness and contour measuring system, which Nokra managing director Michael Trunkhardt is already calling ‘a complete success’.

According to Nokra, it’s new system, which features high precision laser sensors, ‘measures significantly more precisely than its predecessor’.

The new equipment is described as slim, which means it can be used in narrow spaces – ideal for use with conveyor systems.

With optimised evaluation software, customers can optionally and individually decide on European, American or Japanese standards and norms, Digital Edition - February 2016

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claims Nokra, and they can evaluate according to individual specification.

Nokra says that the new Alpha system requires less maintenance than previous models and that the improved ‘live-time’ of precision sensors and shorter commissioning times, enabled by the new software, offers users a higher return on investment.

With these advantages, claims the company, the Alpha system is perfect for quality steel production lines, an industry which, so far, the company hasn’t served, claims Trunkhardt. www.nokra.de

are fed into briquetting machines, producing hot briquetted iron (HBI) with a metallisation degree exceeding 93%. The briquettes have an apparent density exceeding 5.0g/cm3 and are well-suited for safe waterborne and rail transport due to the density and the low amount of fines generated during handling.

HBI is used to supplement EAF charge material and the physical and chemical characteristics of HBI also make the metallic easier to charge to blast furnaces.

Construction begins in 2017 for a two-year period, enabling the plant to start operations in 2019. www.midrex.com

Kemper announces sales boost Kemper reports increased sales with incoming orders growing over the past year by 5%. CEO Björn Kemper said that the company remains ‘cautiously optimistic’ because of the prevailing political and economic crises, but is counting on the fact that there are opportunities to open new markets for its products.

Kemper plans to focus on Eastern Europe and this year will be represented at three metals industry trade fairs. The company specialises in extraction and filter systems for the metals processing industries. www.kemper.eu www.steeltimesint.com

2/22/16 12:50 PM

Steel Times Buyers Guide Add 2013_MetalCourierAdd 05/02/2016 14:30 Page 1

www.dysontc.com

DYSON TECHNICAL CERAMICS - ZPZ METERING NOZZLES

Manufacturers of High Performance Zirconia Ceramics ZPZTM Tundish Metering Nozzles.

Dyson Technical Ceramics ultra-high density Zirconia ZPZTM series of products is widely considered to be at the forefront of Zirconia Ceramics technology, currently used in the continuous casting of steel billets.

Dyson Technical Ceramics manufactures a comprehensive range of zirconia material nozzles used in the continuous casting of steel.

Benefits of Dyson Zirconia ZPZTM Nozzles: • • • •

Controlled and Consistent Casting Speeds Extended Casting Sequences Excellent Erosion Resistance High Resistance to Oxygen Lancing

Dyson Technical Ceramics Ltd. Baslow Road, Totley, Sheffield.

S17 3BL. United Kingdom

Web: www.dysontc.com Email: enq@dysontc.com

Dyson Technical Ceramics produces an extensive range of Products for the Steel, Foundry, Powder Metallurgy and the Investment Casting industries. Our product range includes: • Composite Stationary and Exchangeable Metering Nozzles • Horizontal Casting Zirconia and Alumina Nozzles • Zirconia Atomising Nozzles • Isostatically Pressed Crucibles • Zirconia Sliding Gate Plate Inserts • Alumina Foundry Nozzles With over 200 years' experience manufacturing cutting edge refractory ceramics we possess the expertise to continuously develop our ideas and products through our Research and Development Laboratory (RDL). We aim to meet the challenges of the future and ensure our materials remain the highest quality materials available within the market place.

Tel: +44 (0) 114 235 6060 Fax: +44 (0) 114 235 6010

18

INNOVATIONS

MTAG’s ‘plug and run’ pumping solution addresses spatial efficiency Vacuum technologies applied to vacuum steel degassing are constantly evolving. As a technology mostly used in clean processes, a great number of challenges require optimisation in applications for steel mills, says MTAG Switzerland.

The most difficult points to address, claims the company, are directly or indirectly linked to reliability and spatial efficiency and with this in mind, MTAG has developed the Ventus Plug & Run pumping solution.

According to MTAG, the development of the Ventus Plug & Run pumping solution shows how the company has understood the importance of continuous development towards increased

Roll polishing perfection from Danieli-Fröhling DANIELI-FRÖHLING’s new generation of roll polishing devices are designed as continuously working cleaning heads, with concave formed fitting surfaces to the roll, containing slotted felt pads for vacuum dust removal. Each unit is pressed to the work rolls by two separately controlled pneumatic cylinders with proportional valve control providing constant and high accuracy pressure adjustment. An oscillation motion of the complete unit is synchronised with the rolling speed.

These features, claims Danieli-Fröhling, ensure a highly uniform roll cleaning result for constant and repeatable strip quality. Cleaning is applied during the rolling operation, work roll changes can be minimised, and hence productivity can be significantly increased. The roll polishing unit is considered as a technological modernisation package for existing skin pass mills, with a return on investment expected in less than two years.

Skin pass rolling for a high-gloss surface finish of the strip is one of the final production operations for stainless steel. A main objective is to keep the work rolls perfectly clean to avoid imprints or dirt particle contamination. Disadvantages of actual practices are non-uniform cleaning results and loss of productivity due to manual roll cleaning between coils.

The most recent installation starts up at AKSteel in Ohio, USA, by end of this year. www.danieli-frohling.com

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performance.

The Ventus Plug & Run module boasts the highest modular pumping capacity at this time, with over 50.000 m3/h capacity on its high vacuum module. MTAG claims that this will save space, a resource of great importance in any steel mill.

With an integrated filtration system, automation and electrical equipment, IIoT (Industrial Internet of Things) capabilities and a monitoring centre manned by experts in steel degassing, the system ensures reliability, predictive maintenance and optimum performance. www.mtag-switzerland.com

Baosteel installs SMS Group hot strip mill

Baosteel Zhanjiang Iron & Steel Co has commissioned a high-performance hot strip mill supplied

by German steel production technology specialist SMS Group.

The new mill in Zhanjiang has an annual capacity of 5.5Mt and has been designed to produce hot strip with final thicknesses between 1.2mm and 25.4mm and strip widths from 800mm to 2,100mm.

SMS Group reports that the Chinese steelmaker’s product portfolio ranges from soft deep-drawing grades to high-strength construc-

tion steels and tube and pipe grades.

The mill offers a slab-sizing press, one twohigh and one four-high reversing roughing stand, each with a flanged-on edger, seven CVC plus four-high finishing stands, a laminar strip cooling system and two hydraulically operated coilers.

According to SMS Group, the mill sets a new benchmark in terms of economic efficiency thanks to Ecoplant technology incorporated into the plant design. www.sms-group.com

New induction motors from TMEIC Corporation Toshiba Mitsubishi-Electric Industrial Systems Corporation (TMEIC) has introduced the TM21-G family of induction motors that it claims are designed for ‘superior reliability in a range of industrial applications.

The motors are manufactured in both Japan and India by TMEIC and the motors themselves are the result of over 100 years of experience supplying motors in Japan to the metal, oil and gas, paper, materials handling, mining, chemicals, and cement industries.

According to TMEIC, typical applications include driving pumps, compressors, fans, conveyors and mine hoists.

Frame sizes range from 315mm to 900mm

with a maximum output of 30,800 HP (23,000 kW). Rated voltages range up to 11kV. The maximum speed, operating from a variable frequency drive, is 3,600 rpm.

A variety of enclosures and cooling systems are available including totally enclosed fan cooling (frame sizes from 315mm to 560mm); weather protected type ll cooling (400mm to 630mm); totally enclosed Air-to-air cooling (400mm to 900mm); and totally enclosed water-to-air cooling (400mm to 900mm).

Anti-friction or sleeve bearings are available and the motors are available in the USA through TMEIC Corporation. www.tmeic.com www.steeltimesint.com

2/22/16 12:50 PM

INNOVATIONS 19

Updated multi-roll levellers from Redex

Combustion and safety analyser E Instruments’ new E900-C combustion gas and emissions analyser is claimed to be ideal for emissions compliance testing for engines, boilers and other combustion applications.

The product is now available with field replaceable sensors for easy replacement to eliminate down time and costly repair charges, claims E Instruments, and comes with memory and software at no extra charge.

The unit includes replaceable sensors, CO sensor (0-8000 ppm), CxHy Hydrocarbon (LEL) safety sensor, memory and software and Bluetooth wireless communication, plus many other features. www.e-inst.com

Gerdau Ouro Branco issues final acceptance order for Steckel mill

With its updated design of multi-roll tension levellers, Redex claims to provide the smoothest and the most progressive ‘alternative bending’ and the most stable process on the market. The company claims to offer a 50% improvement in overall flatness quality in comparison to conventional solutions.

Extreme compactness means easy integration with existing lines while optimised ‘high stiffness’ makes the equipment fully suitable with highspeed tinning lines.

The REDEX PMR multi-roll tension leveller has been chosen by major tinplate producers, such as Arcelor Mittal, Tata Steel, US Steel, UPI, AHMSA, ILVA and Erdemir. www.redex-group.com

Brazilian steelmaker Gerdau has issued a final acceptance order (FAC) for a new Steckel mill supplied by Primetals Technologies.

The equipment is destined for Minas Gerais and the Gerdau’s Ouro Branco production site.

According to Primetals, the new mill has an annual capacity of 800kt of hot-rolled coil and was part of an order placed by Gerdau in 2010.

The Ouro Branco Steel Works is designed to establish Gerdau as a flat carbon steel producer in Brazil, claims Primetals.

Gerdau has industrial operations in 14 countries in Latin America, Europe and Asia. The steelmaker has a combined installed production capacity of over 25Mt/yr and is the largest recycler of steel in Latin America.

A plate mill and a two-strand continuous slab caster have also been ordered by Gerdau.

Primetals supplied all the mechanical equipment for the new mill, including the rolling stand with coiler furnaces, a crop shear, laminar

flow cooling section, downcoiler and associated coil handling devices as well as complete electrical and automation equipment. www.primetals.com

Paul Wurth seals top charging deal with Chinese steelmaker Shandong Rizhao Chinese steelmaker Shandong Rizhao Iron & Steel has commissioned German steel production technology specialist Paul Wurth – part of the SMS-Group – to supply top charging systems for the plant.

Paul Wurth will supply Shandong Rizhao with an 8.5Mt/yr ironmaking plant. A contract was signed towards the end of last year for the delivery of two Bell Less Top (BLT) charging systems for two blast furnaces at Shandong’s

new ironmaking plant. Each blast furnace will have an inner volume of 5,100m3, designed for a daily production of more than 11.5kt of hot metal. These furnaces will be some of the largest ever equipped with a Central Feed BLT, claims Paul Wurth.

The order comprises all the BLT’s mechanical equipment (including 100m3 volume material hoppers), the cooling systems, parts of the hydraulic system, field-mounted electrical and lu-

brication equipment and site supervision services for erection and commissioning. The tops feature some of Paul Wurth’s latest developments, such as its pressurised cooling concept for the main gearbox and spherical maintenance valves.

Equipment supply and services will be provided from Luxembourg and China.

The steel plant’s two blast furnaces will be commissioned in 2017 and 2018 respectively. www.paulwurth.com

Bob Scheuer (front left) president of Paul Wurth Metal Technology in Beijing.

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20

TESTING & ANALYSIS

Measuring oil film thickness Lubrication oils are commonly used to ensure that the surface of sheet steel behaves consistently during stamping and punching operations. When the oils are applied in excess, they can pool in the die and cause problems in the stamping operation. If they are not present, the steel may tear, heat up too much, or cause the punch press to jam. Each of these scenarios is undesirable and can lead to production delays. Measurement of the oil, therefore, becomes critical to the process.

By Christopher Burnett* STEEL is truly one of the most versatile materials available to modern designers.

It is used in nearly every aspect of our world, all manner of engineers across transportation, housing, communication, food and beverage, medical, defense and recreation use steel in their products. From rod and bar, to sheet and plate, steel has become an essential building block for progress. As the applications for steel increase, the forming, bending and shaping of raw steel products expands as well. For example, a flat sheet of steel could literally end up in over a million end uses and, when recycled, a million more.

Component manufacturing lines that produce hundreds of thousands of steel parts per day rely on uniform distribution of oil across the strip. The presses and stamping operations that transform the flat sheet would overheat and bind up without the benefit of a thin layer of lubricant on the steel. To prevent unplanned line stoppages, lubricants are often applied in excess, reducing profitability, creating slip hazards in the coil storage areas and generating an additional waste stream to manage. Traditional methods developed to measure the amount of oil require cutting samples, punching out coupons of exact diameters and precisely weighing the sample before and after stripping the oil from the surface. While generally accepted, this process reduces yield by taking from the finished coil and takes place after the components have been made, too late to make any changes.

A robust sensor that employs infrared

100%

CH- absorption More oil

Less oil Clean surface

Wavelength Measurement channels

Fig 1. Schematic of IR absorbance by CH molecules

light to determine the amount of oil online is essential, thereby allowing sheet steel suppliers to provide assurances to component manufacturers that the critical oil layer is thick enough to guarantee consistent production, but not excessively thick to cause waste or pooling in their dies.

Oil weight measurements Oil is applied in very thin coatings ranging from 50 to 1,500 mg per square metre, or 0.055 to 1.65 microns in thickness assuming an oil density near 0.9. Traditional destructive techniques based on the WeighStrip-Weigh (W-S-W) process described in ASTM A90 or ISO 1460 to verify coating thickness require hyper-precise scales to achieve accurate results. Sample coupons that are roughly 75cm in diameter will have less than 1 mg of coating on them. If a scale is accurate to +/-0.1 mg this could result in an error that is 20 % or more

of the coating amount. To counter this dilemma, larger coupons can be used, but this too has its drawbacks.

Infrared sensor overview: Two-wavelength infrared sensors Infrared (IR) light is ideal for measuring hydrocarbon-based lubricants. Just below the energy of visible light, IR light is defined as light with wavelengths between 0.7 and 1000 microns. Sub-divided into three sections based on wavelength, IR light has many practical applications outside of the coil coating line. The sensor presented in this paper primarily uses light in the Near IR range to take advantage of the fact that the molecular bonds of most hydrocarbons absorb specific wavelengths of infrared light in that range. (See Fig. 1). By positioning an IR light source and detector on the same side of the coated product, a system of optics can be used to measure

* Thermo Fisher Scientific, 200 Research Drive, Wilmington, MA 01887 USA christopher.burnett@thermofisher.com Digital Edition - February 2016

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IR lamp IR detector

IR lamp

Intensity

Full spectrum

Ref filter Absorption filter Spinning filter wheel

Wavelength

Fig 2. General arrangement of two-wavelength IR sensor

the intensity of a specific wavelength of reflected light relative to a reference wavelength. By comparing the ratio of the two intensities, a relative measurement of the coating thickness can be made. In general terms, the thicker the coating, the more absorption will occur at the measured wavelength in relation to the reference wavelength and the larger the observed ratio.

Two methods were originally developed into on-line IR sensors. The first is interferometry, which provides a tight window for the measured and reference wavelengths, but tends to be expensive and sensitive to light-scattering pigments as well as mechanical shock. The second is to use a spinning filter wheel that exposes a single detector to alternating wavelengths of light (see Fig. 2). The primary filter on the wheel is selected based on the coating type to be measured, while the second filter passes the reference wavelength.

Both methods have the benefit of reduced sensitivity to passline and both are virtually unaffected by changes in air pressure or temperature. There are limitations to their effectiveness as the measurement can be

influenced by spectral changes coming from variations in the surface finish of the substrate or moisture in the air or the coating. Additionally, in the case of the filter wheel, the operator must physically change it to measure coating compositions that are dramatically different from the standard filter.

These standard IR sensors can be a practical on-line oil measuring instrument for sheet producers that manufacture the identical product repeatedly in their production schedule. However, for those operations that coat their products with different oils onto different substrate chemistries, there are unaccounted variables that can result in measurement errors.

IR spectrum-based sensors For those production situations that involve multiple coating/substrate compositions, the most appropriate sensor is one that measures a wide spectrum of IR light. When configured to measure wavelengths associated with an entire range of hydrocarbon bonds, an IR sensor can accurately measure coating weights for nearly every type of coating

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(Fig.3). Additionally, by using optical light, the sensor is immune to background interference due to air temperature changes between sensor and strip. By synchronising source lamp emissions with detector sampling, the sensor will eliminate background light variations and sheet flutter.

The IR Spectrum sensor also overcomes a fundamental design limitation with the two-wavelength filter wheel design. As the coated strip is moving, and the filter wheel sensor spins, the sampling location for the first and second filter are different.

The spectrum-based detector, as compared to the two-wavelength IR approach, can measure the coating without the influence of naturally occurring localised variations in zinc coatings, for example. As the light intensity varies across the spangle, the two-wavelength IR sensor would falsely interpret that as a coating change, whereas the spectrum-based detector monitors the influence on the entire spectrum in one single measurement location and is thereby immune to any variation.

As an added benefit over the filter wheel design, there are no moving parts, therefore increasing overall reliability (See Fig. 4).

Technical performance Statistical noise As with all measurements, there is a base level of sensitivity or ultimate limit to the precision of any single measurement. In the case of IR light, the detector signal is proportional to the number of light photons collected in a unit time. For any consecutive measurements on a single sample, the number of photons detected will vary in a statistical distribution and result in slightly different measurements even though the

Spectra normalised to reference spectrum 0.00 1.58 1.05

Absorbance

0.70 0.45 0.32 0.21 0.13 0.01

Wavelength

Fig 3. Typical IR spectrum for different coating thicknesses of the same oil

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Fig 4. The Thermo Scientific PROSIS measuring head

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TESTING & ANALYSIS

Noise in coating weight measurement (averaging time: 0.1s) Mean: -006, Std-Dev: 0.008

Coating profile with oil gap Scanning left to right 2 Second integration time:

Scanning right to left

Scanning left to right Scanning right to left

0.1 Second integration time

Measurement deviation from mean value

0.06 0.04 0.02 0 -0.02 -0.04 -0.06 0

Fig 5. Impact of integration time on determining the location of a clogged nozzle

sample is exactly the same. This variation is called statistical noise. To minimise the noise, the unit time over which the data is collected can be increased, reducing the percentage of variation and resulting in more precise measurement. However, when considering an on-line sensor, it is preferable to collect the data as quickly as possible to allow for process control actions as changes are observed. In Fig. 5, the impact of increasing the averaging time is seen. As a sensor is scanning across an area on the sheet where a spray nozzle might be clogged, the location of the gap will erroneously be skewed depending on the direction of scan.

As an alternative to increasing the averaging time, the number of photons for the same unit time can be increased.

This can be accomplished by using a higher power IR lamp, or optimising the geometry between the source and detector to capture the most light. While using a higher power lamp seems to be an obvious solution, there are limitations due to heat build-up and thermal stability. IR lamps, like incandescent light bulbs, convert the majority of the

Passline variation As discussed above, well-designed optics can decrease statistical noise on the measurement and can be positioned and focused to direct the light in a manner that minimises sensitivity to passline. The sensor response can be virtually immune to typical variations in passline, maintaining accurate measurements over a span of +/8 mm (Figs. 7a and 7b). The intensity of the detected IR light will vary by a factor of three across this range, but by considering the relative absorption of wavelengths across the whole spectrum, the system is still able to provide accurate measurements.

energy consumed into heat, so often less than 5% is converted to light. Additionally, higher power lamps cost more and have a reduced lifetime.

The use of reflectors, lenses and light guides are more effective at reducing signal noise. Again, like the incandescent light bulb, the source of the IR light emits in all directions. For the IR spectrum sensor, the IR light is only needed on the strip side, so a parabolic reflector can be used to direct all the light forward on to the coated strip.

The net result will significantly multiply the number of photons used in the measurement without the need for temperature control and complex cooling circuits.

For the IR spectrum sensor, typical noise observed on the oil measurement over an averaging time of 100 milliseconds is less than +/- 0.02 grams per square metre (Fig. 6). When compared to the W-S-W coupon this is less than 0.09 mg of oil mass on the sample, which is only possible with expensive high-precision scales mounted on special vibration limiting tables with enclosed measuring environments.

Observed accuracy of oil coatings The accuracy of any non-contact sensor will depend heavily on the accuracy and precision of the laboratory method used.

In order to minimise the random errors of the W-S-W process, multiple samples are required. As the number of samples used in the calibration increases, the overall error of a least squares multiple regression fit through the samples decreases. As stated earlier, the laboratory method directly Correlation of measurement to LabValue for model 2

14

0.9

12

0.8

10

0.7 Measured value

Relative light intensity

8000 9000 10000

Fig 6. Typical statistical noise observed for IR sensor measurement of oil coatings

Light intensity change with distance

1

1000 2000 3000 4000 5000 6000 7000 No of measurement

0.6 0.5 0.4 0.3

8 6 4

0.2 2

0.1 0 0

5

10

15 20 25 Distance to sensor in mm

Fig 7a. IR light intensity as a function of sample position

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30

35

40

0

dist. 45mm dist. 29mm 0

2

4

6

8 Lab value

10

12

14

Fig 7b. Accuracy at 29mm and 45mm of height

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1.8 1.6

23

Regression: RV=(-0.0011) *MV2+(1.0019)*MV+(-00004) Correlation: R=0.99954; R2=0.99907

Measured and connected value

1.4 1.2 1 0.8 0.6 0.4 0.2 0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

Lab value

Fig 8. Predicted versus actual lab measurement

measures the oil weight using a scale. The list of possible error sources in this process extends well beyond the precision of the scale. Oil coatings can be accidentally wiped off during handling, or residual oil can stick to the balance surface. Determining a repeatability and reproducibility test is difficult as samples are destroyed during the process and sample-to-sample consistency is not guaranteed. With care and disciplined laboratory practices, adequate samples can be collected. The process will take time, but the time investment will be rewarded with an accurate and reliable calibration that will last the lifetime of the sensor and beyond. Additionally, in order to cover the full production range of minimum to maximum oil thickness, samples should be provided from at least 10% below the minimum coating to 10% above the maximum coating. Extending the calibrated measuring range beyond the normal production range will prevent extrapolation and assure meaningful measured values that will guide out-of-control situations back to normal production processes.

Nine measurements Typical IR spectrum-based sensor accuracy is depicted in Fig. 8. This data was collected on seven oil-coated samples, plus one sample of the bare substrate, ranging from 0.13 to 1.6 gsm (0.14 micron to 1.8 micron at a density of 0.9). Nine measurements were made on each sample, over an area of 100 square centimetres. A simple least squares multiple fit through the data resulted in a two-sigma accuracy of less than +/- 0.03 gsm.

Summary Online measurement of oil coatings is becoming essential as metals component manufacturers work to eliminate costly delays in their process, save raw materials, reduce re-work and improve product quality. The infrared spectrum technology described in this article addresses the typical influences present in a rolling mill and provides reliable measurements for oil coating thickness in realtime. This method results in significant benefits associated with improved coating uniformity, reduced re-work and elimination of delays while destructive tests are made by sheet suppliers. t Further information, www.thermoscientific.com

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TESTING & ANALYSIS

Online quality monitoring of a CGL With demand for flat sheet steel from the automotive market at an all-time high, we look at the process improvement of continuous galvanising lines (CGL) and quality management across a wide range of steels. It also examines the revamping of a Furnace Mathematical Model on an existing automotive galvanising line at Tata Steel’s Segal plant in Belgium, which has been implemented along with an online quality measurement device based on the determination of magnetic ‘remanence’.

By Matthias Bärwald*

HIGH Strength Steel (HSS) is driving progress in the flat sheet industry. High demand from the automotive market has led to increased challenges for steelmakers.

Without a doubt, one key element is product quality, accentuating the need for continuous improvement and necessitating the introduction of online quality monitoring.

The continuous galvanising line of Segal (Tata Steel), Belgium, was built in the mideighties as the first line in Europe designed specifically for automotive products. At a time when direct fire furnaces combined with a radiant tube section were common, the Segal line relied on full radiant tube technology from Drever. This dedicated production line called for different sections in the annealing process, commonly found today on high-end production units. The full radiant tube furnace, for example, is followed by a slow cooling section, then a rapid cooling section and later a long ‘galvannealing’ section.

The Segal line has always been regarded as state-of-the-art technology for the increasingly popular HSS. Continuous investment led to the introduction of up-to-date process equipment. Where the annealing process was concerned, there is a new high hydrogen management system in the rapid cooling section, a new reheating section and, most recently, a new high

performance after-pot cooling section.

As part of a process of continuous improvement, Drever revamped the Furnace Mathematical Model in 2014. It now integrates the latest self-adaptation technique, known along an advanced transition management technology, both dedicated to annealing process optimisation. It is designed to allow synchronous control of the annealing furnace and process line speed.

In addition to the implementation of a new mathematical model, an online quality measurement device – the EMG IMPOCpro

Fig 1. Resulting peak metal temperatures and quality measurements over various products, when the annealing furnace and the line are fully controlled by Mathematical Model.

– has been installed. Its output and other parameters, such as material thickness, are continuously recorded. Regression analysis of the destructive tests and the recorded data provide a model for the online determination of tensile and yield strength.

This article reveals the benefits of a new generation mathematical model to control the galvanising line; the online determination of the mechanical properties of the steel; and quantitative explanations of the effects of the different process parameters on the mechanical properties.

Mathematical model revamping Over the lifespan of a line, the product mix steadily shifts from relatively simple steels to increasingly complex grades. This shift follows on from the implementation of standard practices; the response to higher customer demands; the increased market share of AHSS grades; and the introduction of next generation steels. With such a changing portfolio, galvanisers face a growing variability of parameters in their production schedule.

A mathematical model already drove Segal’s annealing furnace. The increasing complexity of the process and the high quality requirement, however, have led to the introduction of the latest mathematical model and quality monitoring technologies as keys to further developments.

* Matthias Bärwald, EMG Automation GmbH, Industriestr. 1, 57482 Wenden, Germany, Phone: +49 2762 612 407, Fax: +49 2762 612 384, Email: Matthias.baerwald@emg-automation.com Co-authors U. Sommers, M. Biglari, SMS Group GmbH, Germany; E. Montagna, Tata Steel SEGAL S.A., Belgium; W. Beugeling, Tata Steel IJmuiden BV, The Netherlands; A. Lhoest, Drever International S.A., Belgium Digital Edition - February 2016

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Magnetic field probe

Magnetising coil Fig 2. Schematic diagram of the IMPOC operating principle

St ri

p

di

re c

tio n

Idle roles

Strip

At production level, operators face a high variability of the parameters that need to be integrated and these include: steel type, strip dimension, heat cycles and their limits, cooling rate, target speed and so on. These factors are taken into consideration to create a production schedule that includes constraints, which in turn induce parameter changes that need to be managed during production. Drever responded to these day-to-day situations with an advanced transition management system, which was integrated in its mathematical model and allowed fully automatic furnace and process line speed control.

For each scheduled coil, set points are calculated, which lead coil after coil to recurring changes of furnace working points and thus the strip temperature profile. Cascading of transitions, as well as collision of transitions, are common among producers and are managed within the model. The advanced transition management system integrates the dynamic behaviour of the furnace and thereby enables optimised control.

Fig. 1 offers an example of transition management using the new mathematical model. The furnace and line speed are controlled and the model forecasts the process behaviour. Irrespective of a change in grade, heat cycle and/or strip size, the goal of optimising quality remains.

In an apparently smooth production schedule – varying from thin coils driven at high line speeds to thick coils driven at lower line speeds – Fig. 1 nonetheless shows plenty of fluctuations. Here we see cascading transitions, some with opposing changing factors: going to a higher heat cycle (red) and at the same time going to thicker (violet) material. The coil width is represented by a darker purple colour.

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Testing & Analysis EMG.indd 2

Coil

Speed Speed scheduled [mpm]

driven

Ratio

[mpm] [%]

240QDY 79

90 13.9

240QBI 65

74 13.8

240QBE 65

74 13.8

240QBH 65

74 13.8

240QBM 73

84

240QBN 73

84 15.1

240P98 79

90 13.9

240P99 79

90 13.9

15.1

240QBG 79

90 13.9

240QBF 89

101 13.5

240QB2 89

101 13.5

Table 1. Productivity increase by mathematical model control

automatic control is released. At this stage, a more complex situation needs to be managed, i.e. a big change in thickness and restricted quality limits (+/-10 °C). Online quality measurement is plotted at the bottom (cyan).

The new mathematical model (Table 1) is designed to aim for maximum productivity, while managing the quality of the products.

Here, out of a production campaign of wide coils (up to 1760 mm), an overspeed of up to 15.1 % has been reached.

Online quality measurement Online quality measurement is performed by the EMG IMPOC device, a magnetic inductive measuring system for the nondestructive determination of mechanical properties.

The material spectrum, with proven results, covers IF steels, dual phase steels and martensite steels up to tensile strength values of 1,600 MPa. The system can be applied at production speeds of up to 900 m/min (600 m/min using the Power IMPOC version) and material gauges of up to 3 mm (6 mm using the Power IMPOC version), which allows a broad application on various production lines.

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Online material properties measurement has established itself as an important tool for optimising the quality of flatrolled steel products. Increasing demand from the automotive industry for more reliable product quality has led to a search for measuring instruments that overcome the drawbacks of standard mechanical properties testing methods.

To optimise product quality and achieve narrow production tolerances, continuous monitoring of mechanical properties during production is mandatory. Only online measurements of these properties provide fast and immediate feedback and enable the producer to react during processing.

The online material properties measurement system (IMPOC) allows automatic non-destructive testing of ferromagnetic steel strips. The system periodically magnetises the steel strip and measures the residual magnetic field. Based on mathematical models the mechanical properties of tensile and yield strength are calculated online along the coil length.

The system developed by the Institute of Applied Physics (IAP), Minsk 1-3, has been further optimised for industrial applications in close co-operation with ThyssenKrupp Steel4 and is now applied in various steel producing plants worldwide. IMPOCpro is the second generation of the IMPOC product family and has been optimised with regard to fast and easy production integration and optimal data handling.

Principle of operation The basic underlying physical operating principle is magnetic induction. Based on the fact that there are well-known physical relations between the mechanical and magnetic properties of ferromagnetic strip steel,5, 6 the IMPOC system periodically magnetises the strip and subsequently measures the residual magnetic field strength of the material. In order to operate at the high speed of typical steel production lines, such as hot-dip galvanising or continuous annealing, a pulsed magnetic field is used.

The amplitude of the magnetic field pulse is fixed and is chosen to magnetically saturate the strip steel material locally.

After the external magnetic field pulse has decayed, only the remanent magnetic induction (remanence) of the magnetised strip remains and this is measured by a highly sensitive fluxgate magnetic field probe. The mechanical properties of Digital Edition - February 2016

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TESTING & ANALYSIS

the steel strip (tensile and yield strength) can then be assigned to this gradient via correlations.

System components and operation The IMPOC measuring system is designed for automatic, non-destructive, online testing of ferromagnetic steel strips with thicknesses from 0.15 mm to 6 mm. This system is based on two identically constructed sensors, which are arranged on the upper and underside of the strip.

Each sensor consists of a magnetising coil, as well as a magnetic field probe for recording the remanent magnetic induction (Fig. 2).

Data modelling/system performance Data modelling is essential for deriving the mechanical properties from the magnetic field measurements. All variables are

measured online and the calculation is performed during strip production. Steel grades are classified into different material classes and analysed using multiple linear regression. Linear functions of the following type are calculated: Rx=c0+c1∙IM+c2∙TH+c3∙SKD+c4∙TLD (1) where Rx: Results of destructive test [MPa] Rp0.2 (Yield strength) or Rm (Tensile

strength) [MPa] ci: Regression co-efficients IM: Measured IMPOC value [A/m²] TH: Sheet thickness [mm] SKD: Skin pass degree (ratio of

changes in strip length before

and after skin pass mill, similar to

skin pass elongation) TLD: Tension leveller degree (ratio of

changes in strip length before and

after tension leveller)

Different material classes are grouped together based on similar chemical composition and similar processing conditions and several groups – such as low carbon steel, IF steel, high strength low alloy steel, dual phase steel and bake hardening steel – are formed. Typical standard deviations of tensile and yield strength for these models are approximately 6 to10 MPa. Tool-supported model development By introducing IMPOC, the development of appropriate models became fully supported by graphical oriented software tools (IMPOC Data Analyser) on a Lab View base, (Fig. 3).

Tensile and yield strength are calculated by multiple regressions on measured IMPOC values by comparison with the mechanical characteristics emanating from destructive material testing. To obtain stable statistics, Experiment

685

IMPOC value 15000

Blue lines show typical “camel” shape curve of IMPOC value.

Red lines shows temperature at exit of slow cooling section

680

14800

675

14600

670

14400

665

14200

660

14000

655

0

200

400

600

800

1000 1200

1400

1600

IMPOC value in A/m2

Strip temperature after slow cooling in °C

Strip temperature after slow cooling

13800 1800

Coil length in mm Experiment IMPOC value

685

15000

680

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675

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665

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14000

655 0

200

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800 1000 1200 Coil length in mm

1400

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IMPOC value in A/m2

Strip temperature after slow cooling in °C

Strip temperature after slow cooling

13800 1800

Fig 3. (above) IMPOC Data Analyser – typical screen for model development

685

IMPOC value

15000

680

14800

675

14600

670

14400 14200

665

IMPOC value in A/m2

Strip temperature after slow cooling in °C

Experiment Strip temperature after slow cooling

14000

660

13800

655 0

200

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600

800 1000 1200 Coil length in mm

1400

1600

1800

Fig 4. DP600: typical “camel” shape, up and down with SC temperature, compensation

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1.8

x104

Actual value Model value

1.7 IMPOC value in A/m2

Example

4200

IMPOC value - actual and model

1.6

27

4150 4100 4050

1.5

4000

1.4

3950

1.3

3900

1.2

3850 3800

1.1 0

0.5

1

1.5 Index

Fig 5. Example for a model applied on 70 coils

approximately 300 data records are required.

The validation is good when the co-efficient of determination R² is at least 70 %.

Fig. 3 shows different views on the underlying data sets and the results of the regression analysis. With little effort, this allows validation and rating of the models and the quality of underlying datasets.

The software is further equipped with the following functions: • Import of destructive testing results in Excel® format • Automatic plausibility checks and coil assignment • Possibility of averaging several IMPOC values over certain coil sectors for accurate length allocation of destructive testing results • Various filter functions • Building of new models and automatic data update at the press of a button • Ease of administration of models (for different material classes) and a menubased formula editor • Menu-based formula editor for setting alarm levels or system warnings based on thresholds • Export of IMPOC co-efficients in Excel® format Overall, the software allows for the introduction of an IMPOC system and regular surveillance of system performance with very low additional efforts. Users report that following the installation of the system, basic model building can be completed in less than a month. Regular checks and model development for new steel grades take 1-2 days per quarter.

Installation IMPOC system installation does not differ when applied to AHSS production. It can be www.steeltimesint.com

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2

2.5

3 x104

3750 0

500

1000 Coil length in m

1500

2000

Fig 6. Example of slight changes from hot rolling

installed vertically or horizontally or at an angle in the exit region of the line, typically after the looper.

At Segal, the IMPOC system, in this case an IMPOCpro, is installed as close as possible to the annealing furnace – at the exit of the cooling tower. In this way the skin pass mill or the tension leveller does not affect the raw IMPOC measurement.

Since destructive tests are influenced to a certain extent by the skin pass mill and the tension leveller, the calculation of the mechanical properties from formula1 needs to include the skin pass and the tension leveller degree where necessary. The IMPOC system can set up material limits, which are used for coil release during production.

IMPOCpro and Power IMPOC are applied in more than 40 applications worldwide.

Optimising steel quality Data analysis presented below revealed the following results for dual phase steels: • Steel quality after annealing can be improved by changing the furnace parameters in order to compensate for systematic behaviour • Steel quality is determined by previous processes and by the processes in the galvanising line. When furnace operation is stable, it is presumed that quality variations are mainly determined in the hot rolling stage. This is currently being explored by Tata Steel • This presumption is based upon: 1) data analysis of steel quality data and the process parameters in the hot rolling mill, 2) implementing quantitative recommendations and 3) subsequently improving steel quality • The effect of relatively big changes of furnace parameters on steel quality can be

described with linear models • The IMPOC device can detect even slight changes in steel quality Overall, steel quality improvement is enabled by collecting position-specific quality data, comparing it to the parameters of all relevant processes, implementing subsequent recommendations and compensating with specific furnace parameters during annealing.

The main method used to determine the mechanical properties of a coil is the destructive test with samples taken from the coil. Typically, three different positions for one coil are analysed by this method. The IMPOC device determines the quality of the coil over its whole length every 2 m. Such position-specific data can be directly linked to position-specific furnace parameters or others along the production line.

Improving steel quality Changes in mechanical properties over the coil length showed systematic behaviour.

In order to improve steel quality we looked for parameters that can be changed fairly quickly and can change the IMPOC value.

From the metallurgical analysis and the linear models, the temperature after slow cooling was identified as a good way to improve steel quality. Changing the slow cooling strip temperature is quicker and, therefore, better than changing the annealing temperature. By using the temperature at the exit of the slow cooling (SC) section it is possible to compensate the profile (see Fig.4 on the top in blue) of the DP600 coils. The higher temperature after slow cooling retains more austenite prior to rapid cooling. The austenite transforms into martensite. Higher temperatures lead to a higher martensite fraction, which gives a higher tensile strength.

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TESTING & ANALYSIS

A continuous galvanising line. Photo credit: Voestalpine

‘camel’ shape curve of the IMPOC value in blue. The curve in red gives the strip temperature at the exit of the slow cooling section. In the middle part of Fig. 4 after going up and down with the temperature at the exit of slow cooling, the IMPOC value shows the effect. On the bottom of Fig. 4 we used the temperature after slow cooling to compensate the ‘camel’ shape.

This method can also be applied to Segal’s DP800.

In the Furnace Mathematical Model, data from the furnace and the IMPOC device are available. The data for the IMPOC device is given for every 4 m of the coil and the date from the furnace is time-based. In post-processing, data from the furnace is recalculated for the position over the coil length. From different sources extra information (strip data including chemistry and, if possible, hot rolling mill parameters) is collected.

On the right hand side of the formula1 the only parameter that changes over the coil length is the IMPOC value, which is used to describe the behaviour of the tensile strength over the coil length.

Case DP600 We compared the shape of the IMPOC value over the coil length for several coils of the same grade. For DP600, based on quality measurement for operations under stable furnace conditions, the most common shape is a ‘camel’ shape (see top of Fig. 4). The most likely reason for this is the cooling conditions of the coil after hot rolling. First attempts to describe the behaviour entirely by furnace parameters were not successful. In these first attempts the emissivity calculated by the pyrometers in the furnace showed the same ‘camel’ behaviour as the IMPOC value. There were some examples where this behaviour didn’t

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match. When the furnace was stable, it was mainly processes prior to the CGL that influenced the quality of annealed steel. For coils with big changes in furnace parameters we could also formulate linear models that describe the behaviour of the IMPOC value very well.

Fig. 5 shows the striking correspondence between modelled IMPOC values (with linear and interaction terms, see formula2) and measured IMPOC values for a sequence of 70 DP600 coils. The model has the following form: n n

∑

∑

IMModel=k0+ ki ∙xi+ ci,j∙xi∙xj (2) (i=1) (i,j=1) where: IMmodel: modelled IMPOC values which are

the result of regression analysis ki, ci,j: regression constants xi: parameters that vary over coil length n: number of regression parameters The main parameters – xi in the model – include strip thickness, furnace temperature, strip annealing temperature, line speed and steel composition.

Case DP800 With DP800 we identified two influences when the furnace conditions were stable: one causes a general rise of the signal from head to tail (for hot rolled coil) which is related to temperature conditions in the hot rolling mill, and the other causes a dip and a rise at the head of the hot rolled coil as a result of changing coiling temperature. This result was obtained by including coiling temperature in the analysis for some DP800 coils. We showed that the dip and rise at the end matched the behaviour of the coiling temperature. This was used by Tata Steel IJmuiden to improve the setting of the coiling temperature in the hot rolling

mill. Substantial work is being done at Tata Steel to improve the settings of the process parameters in the hot rolling mill. Regarding influences from the annealing furnace and strip data, the main parameters include peak metal temperature, temperature after slow cooling, temperature after rapid cooling, thickness and line speed.

The next step is to include all relevant data from the hot rolling mill in the data analysis. It should then be possible to have a full description of the behaviour of the mechanical properties over the coil length.

Later, compensation of the remaining deviation can be done for individual coils.

IMPOC measures slight changes There was a systematic pattern of changes in mechanical properties. To understand this a qualitative explanation was given on the basis of metallurgical understanding and then validated by the quantitative data obtained from the process. This way the influences from the reheating furnace and hot rolling could be used to explain slight changes in the IMPOC signal. Normally these changes correspond to variations in the tensile strength of a few megapascals.

From the shape of the curve and the data for several coils it was possible to identify root causes.

The influences we observed originated from the skid marks of the reheating furnace and from cooling conditions after hot rolling.

Even signals that seem, at first sight, to be an oscillation on the IMPOC value (Fig. 6) turned out to be closely related to the cooling conditions of the hot rolled coil after coiling. Again a qualitative analysis on the Abbreviations Used Explanation abbrevations AHSS

Advanced High Strength Steels

ci, ci,j, ki

Regression coefficients

CGL

Continuous Galvanising Line

DP

Dual Phase

IAP

Institute of Applied Physics

IF Steel

Interstitial Free Steel

IM

Measured IMPOC value [A/m²]

IMModel

Modelled IMPOC value [A/m²]

IMPOC

Impulse Magnetic Process Online

Controller Rp0.2

Yield strength [MPa]

Rm

Tensile strength [MPa]

Rx

Results of destructive test [MPa]

SC

Slow cooling

SKD

Skin pass degree [%]

TH

Sheet thickness [mm]

TLD

Tension leveller degree [%]

xi

Parameters for modelling IMPOC value

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TESTING & ANALYSIS

basis of metallurgical understanding enabled an appropriate recalculation. Here the amplitude diminished with length, while the frequency increased. It could be recalculated that the rate of frequency change corresponded with the coiling position. This means that the oscillation represents the actual characteristic of the steel.

Conclusion For Tata Steel there are numerous benefits of combining the new Furnace Mathematical Model, the IMPOC device and the data analysis as follows: • The new mathematical model increases line production by up to 15% • The new mathematical model opens the door to the optimisation of dual phase steel quality in general • The IMPOC device enables a faster release procedure, and also enables online steel quality monitoring • Data analysis indicates parameters along the production line that can be improved

• All relevant data from the hot rolling stage will soon be utilised to enable direct optimisation of steel quality for the individual coil Tata Steel sees a high potential to further improve the quality of galvanised steel over the coming months. SMS Group GmbH is working on a metallurgical model for the annealing furnace, namely the annealing microstructure model. For the coming years the combination of the IMPOC device, the Furnace Mathematical Model, the metallurgical model and data-driven models for steel quality opens up new ways to ensure optimised quality for annealed steel.

The introduction of an online quality measurement device and a Furnace Mathematical Model makes it possible to adjust the annealing peak metal temperature. One main benefit is the reduction of energy costs. As a side effect, line speed can be increased several per cent.

Pinchukov D.A., Institute of Applied Physics of

References

Further information, www.emg-automation.com

[1]

Matyuk V.F., Delendikh M.N., Osipov A.A.,

NEW ACCUSPEED LASER ASDC VELOCIMETER

29

National Academy of Sciences of Belarus, Minsk, Republic Belarus, Hartmann H., Reichelt H., Schmidt R., Forschungs- und Qualitätszentrum, Eisenhüttenstadt, Germany: The Plant for Pulse Magnetic On-Line Testing of Mechanical properties of Rolled Products. Paper presented at the ECNDT 2006 [2]

Matyuk V.F.: Pulsed magnetic testing of

strengthening characteristics of ferromagnetic articles, Vestsi Nat. Akad. Navuk Belarusi, Ser. Fiz.Tekhn. Navuk, 1998, no.4, pp. 114-118 [3]

Matyuk V.F., Osipov A.A.: Pulsed magnetic

testing of separately moving sheets in the production line, Defektoskopiya, 1995, no.6, pp. 56-62 [4]

Dürr W. and Irle M.: Stahl & Eisen 123 (2003)

No. 10, pp. 73-77 [5]

Kneller E.: Ferromagnetismus, Berlin,

Heidelberg, New York: Springer Verlag 1962 [6]

Seeger A: Moderne Probleme der etallphysik.

Band I und II, Springer Verlag Berlin 1965/1966

24TH BLAST FURNACE IRONMAKING COURSE May 8 - 13, 2016

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TR A INING .M C M A S T ER. CA It is an in-depth, week-long course held every second year. It covers every aspect of blast furnace ironmaking, making it invaluable for managers, operators, engineers, researchers and suppliers of equipment, refractories and raw materials. It is officially recognized by the American Iron and Steel Institute. The lecturers in the course are acknowledged experts in their fields and the delegates come from diversified industrial backgrounds. The week-long course consists of 24 lectures given by experts in the field, supplemented by a computer game, and plant tours.

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kelk.com ©2016 Vishay Precision Group, Inc.

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30

COKE PRODUCTION

Clean coke production Dry quenching of coke was first introduced by Nippon Steel Corporation in 1976 and is now used at a number of plants in other countries. The process uses nitrogen in a closed circuit to avoid environmental emissions. By Fathi Habashi* IT is said that organic chemistry is the chemistry of carbon while metallurgy is the technology of carbon. Carbon in the form of coal is used in metallurgy as a fuel, but the major use is to make coke that is an essential component of the feed to iron blast furnaces. For each ton of iron produced, half a ton of coke is needed. It is estimated that 50Mt of coke are produced annually worldwide.

The present technology for coke manufacturing is based on heating coal in retorts in the absence of air then quenching the product with a limited supply of water shower. This last step is highly polluting due to dust and toxic organic emissions (Fig. 1).

It also consumes appreciable amounts of water.

Dry quenching A technology now used in Japan and at a few plants in Korea and China, known as dry quenching, uses nitrogen in a closed circuit to avoid environmental emissions.

In addition, heat is recovered in the form of steam from the red-hot coke. The technology was first introduced by Nippon Steel Corporation at Kitakyushu in 1976. By 2001 90% of coke production in Japan was using this technology and plans are under way to make it to 100%. Table 1 shows the widespread use of this technology in Asia, Europe, and Brazil – but not yet in North America.

In this process (Fig 2), coke leaving the retorts is charged at the top of a closed reactor that acts as a heat exchanger through which nitrogen at 130oC is introduced at the bottom. The coke is then discharged at 200oC while nitrogen, after passing through a dust removal system, leaves at 900oC to a boiler to generate

Fig 1. Water quenching of coke

111 UNITS

Table 1.Coke dry plants quenching

* Department of Mining, Metallurgical, and Materials Engineering Laval University, Quebec City, Canada. Fathi.Habashi@arul.ulaval.ca Digital Edition - February 2016

COKE PRODUCTION FATHI.indd 1

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COKE PRODUCTION

Fig 2. Dry quenching of coke

coke 1000°C Charging device

Steam 900°C

130°C

Quenching chamber

Dust collector

Boiler

Discharging device

Dust

Water

Blower

Dust collector

Nitrogen Coke 200°C

steam, and is then recycled to quench the coke. In addition to eliminating the pollution in the coke plant and recovering the heat from the hot coke, less coke fines are produced.

Harder and stronger In an integrated steel plant, air is liquefied to produce oxygen for top-and-bottom blowing technology. Nitrogen generated in this operation could be recovered for the dry quenching process. Dry quenched

Dust

coke is harder and stronger, and its moisture content is much lower than that of wet-quenched coke. Furthermore, water is not wasted from the process and not contaminated with toxic pollutants. In North America dry quenching has been repeatedly rejected as unnecessary and costly.

In summary the new technology first introduced by Nippon Steel Corporation at Kitakyushu in Japan in 1976 is now used at a number of plants in other countries

31

and is known as dry quenching of coke. It uses nitrogen in a closed circuit to avoid environmental emissions. In addition, heat is recovered in the form of steam, from the red-hot coke. In steel plants oxygen is used extensively and, therefore, by-product nitrogen from air liquefaction can be effectively utilised in this way.

Suggestions for further readings Y. Ishida and K. Yokote, “Coke Dry Quenching in Connection with Environmental Counter Measures and Energy Savings”, pp. 21-26 in Greenhouse Gases in the Metallurgical Industries: Policies, Abatement, and Treatment, edited

by C.A. Pickles, Canadian Institute of Mining, Metallurgy, and Petroleum, Montreal 2001 F. Habashi, Textbook of Pyrometallurgy, pages 311-319, Metallurgie Extractive Quebec. Quebec City, Canada 2002, Distributed by Laval University Bookstore "Zone", www.zone.ul.ca K. Kishimoto and S. Tashima, “Spread of Coke Dry Quenching System”, METEC Düsseldorf, 15 – 19 June 2015

Liftec Translifters and Cassettes for All Transports in Steel Industry For additional information please contact: Tel. +358 3 3140 1400 | sales@tts-liftec.fi

LIFTEC

www.ttsliftec.com

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MARKETING

Marketing technological services The rapid evolution of technologies means that those that were significant a few years ago may no longer be so important. Things change: the economy shifts; new competitors emerge; organisations modify their strategies and the customer base changes. Suppliers needs to evolve, adapt and align with new technologies to seek competitive advantage. Collaboration with other like-minded organisations is the key to offering new services and technologies as well as the selection of suitable customers who will maintain their loyalty long-term for future supply. By S Kumar*, P K M Kashyap*, R Gopal* and N K Thakur* CUSTOMERS availing themselves of the latest technological services and expertise are well-educated and knowledgeable.

Therefore, a supplier of these should not apply the marketing strategy of ‘brand’ image to market technological services and expertise while in competition with equally talented organisations. However, an advantageous solution is to adopt the essence of ‘brand’ by building partnerships with other research organisations for mutual gain of knowledge and economic benefits by collaboration, so establishing an image to customers as a supplier of innovative technology.

Why technology marketing?

Technology has the inherent attribute of changing the method of working of a business and its production system.

However, what is different today is the unprecedented rate of change in the development of technology, the marketing tools and the escalation of customer expectations for better experiences[1].

New technology is putting into disarray everything we know and believe; consumers are more connected and perplexed than ever before; and promoters of technology are largely under-prepared for the velocity of change driving the industry forward. But with obstacles come opportunities[2].

Technology marketing is not choosing technological solutions to drive marketing performance. That is largely the domain of the marketing technologist. Instead, technology marketing is the ways and

means of rendering technological solutions and specialised services to appropriate customer segments. This generally results in knowledge and monetary gain improving the prosperity of the organisation.

While technology marketing has greater importance during economic downturns, it is also a thrill for technologists to achieve innovative solutions that help businesses adapt and thrive as technologies evolve.

While some market promoters struggle to keep up with this pace of rapidly evolving technology, others are imagining new ways of marketing their products and may even

offer prototype technology (a combination of various technological components) known as amalgamation/hybrids.

It is those with an insatiable appetite for technical industry knowledge, who are constantly testing and integrating new solutions, that gain an edge in efficiency and performance.

The rate of change is accelerating, and shows no signs of slowing down. Highperformance companies constantly adapt as new technologies and opportunities emerge. This agile approach requires a dedicated group of people to drive and ‘own’ the technology marketing efforts of an organisation. In recent years, this approach has been adopted at The Research & Development Centre for Iron and Steel (RDCIS) of The Steel Authority of India Ltd (SAIL).

Technological Services RDCIS has been consistently enhancing its capabilities over the years. This has been possible due to a highly dedicated team of technical and scientific personnel, possessing a high level of expertise and wealth of experience matching the best available elsewhere.[3] Apart from rendering technological services to SAIL plants and units, RDCIS undertakes various activities for customers, outside SAIL, related to: • Rendering specialised technical services and tests; • Contract research/consultancy services;

The authors are with the Research and Development Centre of Iron & Steel, Steel Authority of India Ltd, Ranchi, India Contact: sanjay@sail-rdcis.com Digital Edition - February 2016

MARKETING Kumar.indd 1

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MARKETING

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About SAIL RDCIS Centre has acquired several patents and copyrights during the past few years. The technical accomplishments of the Centre are regularly published in prestigious journals in India and abroad.

The Research & Development Centre for Iron and Steel (RDCIS) is the corporate R&D unit of the Steel Authority of India Ltd (SAIL). It is India‘s premier research organisation in the field of ferrous metallurgy.

The main centre, located in Ranchi, was established in 1972.

Equipped with more than 300 advanced diagnostic tools, five pilot facilities and 15 major laboratories, RDCIS encompasses the entire spectrum of iron and steel – starting from raw materials to finished products. The Centre is continuously engaged in improving process parameters, developing value-added products, energy conservation, improvement in product quality, upgrading of existing technologies and introducing new technologies to the production plants and units of SAIL. The

Innovative systems and procedures While making significant contributions to the overall performance of SAIL, RDCIS has developed and introduced innovative systems and procedures which have enabled quantification of inputs, outputs and the measurement of performance. The highest priority and attention is accorded to customer needs and the Centre aims to deliver specialised services to the full satisfaction of the customers.

RDCIS, SAIL, caters primarily to the needs of SAIL plants and units, it has also

Org. image

been rendering technological services to various public and private sector organisations in India and abroad. RDCIS can transfer some of its proven technologies to other organisations, provide technical consultancy, render specialised testing services, undertake contract research and conduct training programmes.

RDCIS has entered into collaborative agreements with leading research and academic institutes, from time to time, both in India and abroad. Some of the leading collaborating institutes from abroad have been Deakin University Australia; Swerea/ MEFOS Sweden; CSM Italy etc.

The Centre has collaboration with ARAI Pune, IOCL Faridabad, Midhani Hyderabad, CDAC, IITs, NITs, IISc, CSIR laboratories, and other reputed organisations in India.

Manpower Revenue

Technology

Equipment utilisation Value based customer accounting

Technology Marketing Marketing Data Archive Acquisition cost

Customer expectation

Repetitive technological services cost

• Collaborative projects/joint development of products/processes technology; • Transfer of know-how/technology developed by RDCIS; • Sponsored research/consultancy assignments/testing jobs awarded to external organisations.

RDCIS carries out collaborative projects with academia and institutes/organisations, with expertise and state-of-the-art facilities, to carry out research projects for the development and adoption of innovative technologies related to iron and steel production.

This has developed a broad spectrum of expertise which can readily be used to solve complex problems in numerous disciplines.

Major activities extend from developing new products and processes to guiding contract research programmes for specific needs of www.steeltimesint.com

MARKETING Kumar.indd 2

Profit margin

Depreciation of equipment Equipment maintenance

Customer loyalty

Fig 1. Major factors of Technology Marketing and value based customer

Consumable (material, electricity, etc)

Organisation overhead

Fig 2. Repetitive technological services cost

the steel industry. In addition, the Centre also imparts training on multi-faceted technology of iron and steel production.

The areas of expertise have a broad range in various areas of an integrated steel plant and are presented in the blue box above.

RDCIS has targeted specific customers to offer the services it provides and has maintained a close relationship with them. Specific efforts are exercised in this approach and it is recognised that not all potential customers are suitable for the specialist services that RDCIS offers.

Finding the right customer Not all customers are good customers. In fact, some are completely inappropriate for RDCIS. Inappropriate customers have a propensity to change suppliers frequently lured by the cheapest rates and the largest incentives. When these run out, so may they, long before they can ever

be profitable. In marketing technological services the organisation needs to make extraordinary efforts to please suitable customers or else it can stumble badly.

Busy chasing the wrong customers, the organisation strays from what it does best, and is more likely to encounter failure, thereby, alienating its most profitable customers.

For success, one needs to know exactly who the ideal customers are, and focus energy on creating the best services and relationship to please them, and only them.

RDCIS has been concentrating on satisfying a targeted group of customers who place the highest value on the goods or services it offers.

Customer life time value The technology marketing effort of RDCIS has developed more loyal customers and has paid greater attention to them.

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MARKETING

Box 2: Coal & Coke Area − Washability characterisation; − Coal blend formulation; − Coal carbonisation under top and

stamp charging; − Post carbonisation treatment; − Coal and coke characterisation.

Raw Materials − Mineral characterisation; − Iron ore enrichment; − Quality improvement of iron ore.

Sintering − Innovative sinter mix pre-heating; − Sinter-mix permeability optimisation

through moisture control; − Roll feeder and magnetic plate

charging system; − Bulk density optimisation; − Improvement in balling and

segregation of sinter-mix; − Mathematical models (Level-II

control) of heat pattern and burn

raise point control.

Ironmaking − Mathematical and physical model of

blast furnace (BF) operation;

− Optimisation of BF operating parameters; − Alternate fuel injection in BF; − Diagnosis of irregularities in BF and

their control; − BF hearth protection measures.

Energy − Energy audit; − Waste heat recovery; − Heating models for furnaces and BF stoves; − Development and implementation of

various types of burners; − Optimum thermal and combustion

regime for processes and furnaces.

Steelmaking & Casting − Minimisation of cycle time for BOF

and EAF steel making; − Optimisation of ladle metallurgy; − Steel refining for critical steel grades; − Casting technology for stainless steel

and high alloy grades; − Diagnosis of casting defects and

process optimisation; − Mathematical and physical modelling.

Refractory − Design and Application of refractory;

− Improvement in performance of

refractory plant; − Characterisation and Performance

evaluation of refractory.

Development of Steel Products − Development of new products; − Characterisation and structure property; − Process simulation study; − Material characterisation; − Weldability evaluation; − High temperature materials,

creep and stress rupture studies.

Rolling Technology − Development of technology for flat

and long products; − Controlled rolling and

thermo-mechanical processing; − Mathematical modelling – mill set

up, control of micro structure; − Process technology for rails,

structural and wheels; − Roll bite lubrication system;

Pollution control and waste management − Assessment and control of air, water

and noise pollution; − Solid waste characterisation.

Quantified benefit of RDCIS Repetitive technology service cost

300

400

Know-how transfer/ opportunity cost

Interaction/ knowledge cost

Travel and accommodation cost

0

100

200

Innovative R&D/ consultancy cost

2010-2011

Fig 3. Cost elements of marketing technology

Calculating the lifetime value of customers had been an eye-opening experience. Top management supports customer retention initiatives to the extent that, if needed, the strategy of altering the service/product offered is adopted, rather than thinking of changing the customer.

Only focused efforts of service and technology pay off in the long run.[4] The approach of determining who the target customers are, and then doing everything possible to please and retain them, has been a success story. The well-defined target customer has become the guiding beacon for RDCIS. Digital Edition - February 2016

MARKETING Kumar.indd 3

2011-2012

2012-2013

2013-2014

2014-2015

Fig 4. Benefits accrued from R&D efforts

Association with customers Close association with the customer provides the opportunity to observe and see how customers use the services/products offered in real life. It reveals what they like, what they do not like, and ways that would improve the services or technology offered.

Customers view the services provided from a different reference frame, prompting RDCIS to make a paradigm shift on learn things that it had never even thought of.

Expectation of the customer Every target customer is a moving target – their expectations shift and evolve over

time. Thus, service quality is not absolute because it is determined by the customer, not by the service provider. And it varies from customer to customer. Consequently, excellence in the quality of service provided

by RDCIS is on account of it adapting its services to meet and exceed changing customer expectations.

Customer feedback The successful organisation should meet and exceed the expectations of its target customers. For this reason, organisations need as many opportunities to hear and respond to customer feedback as they www.steeltimesint.com

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100

200

300

400

RDCIS effort for collaboration

2011-2012

2012-2013

2013-2014

2014-2015

0

2010-2011 2010-2011

2011-2012

2012-2013

2013-2014

2014-2015

Fig 5. Number of collaboration agreements between RDCIS and other organisations

can find. To accomplish this, RDCIS listens continually to its target customers to find out what services and technology customers want to meet their needs with, and the way in which RDCIS can deliver these services.

With each service delivered by RDCIS a feedback form is sent to the customer to collect views and ideas for improvement.

Valuation of services The desired results and outcomes are dependent on the perception of customers about the product offering and the efforts involved in delivering them. The two important facets are a well-educated customer and the organisation that renders specialised services. Mutual interaction and the techno-economic balance between the two determines the boundary of the technology marketing result..[5] This broadly comprises of the following six significant factors of technology marketing (Fig 1).

Customer • Customer Expectations: Customers expect to receive a highly valuable bespoke experience all of the time.

Differentiating customer relationships on the basis of account-specific insights and responsiveness has a tendency to raise customer expectations and create a competitive advantage. Expectations are set very early in the buyer’s journey, long before they interact for associated cost, so technology marketing plays a crucial role in demonstrating a value-added service from the very first touch.

• Customer Loyalty: Personal and professional brand relationships, a long association with a customer, provides distinction over competitors. www.steeltimesint.com

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Quantified R&D output

Collaborative effort

Fig 6. Enhanced collaboration and benefits accrued by RDCIS

• Customer acquisition costs: The scale efficiencies of marketing versus sales are critical and subject to accomplishing customer objectives cost-effectively.

Supplier • Technology: Cutting-edge technology enables steel companies to gain additional margins and raise customer expectations.

These are the tools that must leverage by delivering value to the account. At the same time, transfer of know-how should be limited to the extent that the supplying organisation maintains the competitive advantage of expertise in cutting-edge technology.

• Image Building: Association with prestigious customers builds the image of the supplier. It opens new prospects of marketing. While it is subjective in nature, it transforms into significant confidence over time.

• Subscription revenue: The supplier needs to recoup the cost of sales. Ideally, revenue and profit increase over time, but that is dependent upon retention and expansion of the relationship which requires constant care and nurturing.

Technology marketing is part of a large programme that co-ordinates all customer oriented resources (from marketing, sales, finance, fulfilment, product/technology development, service, support and partner organisations). Regardless of the stages of various activities, the ultimate goal remains the same: to deliver a highly differentiated, deeply customised, supremely successful experience for every account. When executed well this results in increased customer lifetime value and raising the bar for competitors.

Cost of services/expertise The price line plays a vital role in deciding the customer relationship. The costing of repetitive technological services can be standardised within the organisation. In general it includes the cost of equipment, consumables (material and electricity), depreciation charges, manpower costs to carry out the service, maintenance cost of the equipment, the cost of organisational overheads and profit margin. This is shown in Fig 2. Maintaining a uniform cost policy irrespective of the customer has built an impartial authentic organisation image of RDCIS. Costing of one-time customised technological services for any customer that encompasses the essence of knowledge or know-how is considerably out-sized compared to technological services costs.

Costing of such cases is complex. It varies from case to case, as well as depending upon the nature of the customer. To handle such cases a committee is formed comprising the technology group of RDCIS providing the service, technology marketing, finance, technical experts and management representative. Deriving the cost is depicted in Fig 3 which also includes the cost of repetitive technology services.

Challenges and constraints The challenge for technology marketing is to figure out the right solutions for customer requirements, and deliver it by integrating the necessary technologies by all means available. Large and important assignments always have challenging technical issues and need the involvement of experts who may not be fully available for the assignment if they are catering to the needs of SAIL plants at the time.[6] Digital Edition - February 2016

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MARKETING

• Marketing automation: Marketing automation should be the starting point when building a marketing technology approach, as many companies bundle core technologies into all-in-one suites.

Unfortunately it is difficult to accomplish this task for specialised and customised technological services where the majority of tasks are non-repetitive in nature. Data related to repetitive services can only be analysed or compared with others. • Customer Relationship Management (CRM): A CRM system is required to manage one-to-one relationships with leads, prospects, customers, employees, partners and other priority audiences. In the absence of such an integrated system it is managed by means of e-mail and discussions by telephone.

Collaboration to retain organisation talent Collaboration has a positive impact on the human resource of the organisation.

As often acknowledged, the human resource is the most important resource for good performance in an organisation.

The supplier organisation needs to put in the appropriate effort to manage this talent. Ability is of little relevance without the provision of proper opportunity. It is worthwhile for an organisation to take additional steps to help manage the talent pool. It becomes more important when the yield of the organisation is primarily drawn from its talent pool. People of worth often stay in organisations because they enjoy the company of like-minded colleagues. Organisations must invest in bringing talented people together and strive to enhance collaboration among talented people within the organisation. This can be done informally through social networking opportunities, or more formally through special task forces or work groups through collaborative projects/efforts.

The technological contribution of RDCIS to SAIL plants and units is reflected by qualitative and quantitative benefits accrued by these plants. This is documented by means of Certified Annual Benefit (CAB).

The quantification of benefit is substantiated by the respective SAIL Plant and Units where the work has been carried out.

RDCIS has also rendered technological services to various public and private sector organisations. This effort generates external earning apart from tacitly contributing to the prosperity of the organisation. Table Digital Edition - February 2016

MARKETING Kumar.indd 5

Financial Year 2010-2011 2011-2012 2012-2013 2013-2014 2014-2015

External CAB Earnings 71.00 139.27 195.43 137.51 135.80

Total Earnings

Collaborations signed

260.17 331.17 269.30 408.57 230.80 426.23 150.12 287.63 153.39 289.19

3 3 4 7 13

Table 1. Benefits accrued due to R&D effort and collaboration (normalised values)

1 lists recent collaborative efforts, external earning and CAB of RDCIS.[7][8] Benefits accrued by SAIL plant and units on account of R&D efforts and external earning from technological services and expertise are plotted in Fig. 4. A downward trend is observed from financial year 20132014 due to RDCIS’ efforts in pursuit of new technology and its application to steel plant by collaborative efforts as shown in Fig 5. There is a marked increase in the number of collaborative efforts from 2013-2014 onwards. The combination of these two trends is shown in Fig 6.

It is obvious that remarkable effort has been put into collaboration with reputed academia and research institutes as solo benefits have declining probably due to fading technological impact. Also when an organisation is struggling to get its footing, collaboration is the key to meeting goals. It is expected that this intervention will yield encouraging results in the days to come by building the technological competence of RDCIS and maintaining its prestige by gaining an edge in technical performance and efficiency.

Conclusions Performance objectives need to be relevant to current technology and business conditions, yet we need to be as consistent as possible over time so that one can compare historical performance.

Before this drives or forces us to create new technologies or services one needs innovative technology. To be successful we must not be afraid of new services and innovative technology. This requires regular assessment of changes in the external and internal environment to maintain a balance.

Collaboration with organisations working in similar fields helps to identify technological changes and modifying them only if necessary to reflect changing realities. t Acknowledgements The authors express gratitude and acknowledge support and encouragement received from the management of Research & Development for Iron and Steel, Steel Authority of India Ltd. The initiative of collaboration with reputed academia and leading collaborative institutes was conceived by executive director in-charge RDCIS, SAIL, Dr B K Jha as a step towards competence building at RDCIS, SAIL. Continuous encouragement, critical observations and valuable guidance received from executive director in-charge, RDCIS, kept the work on the right course. The authors express their heartfelt gratitude for the insight imparted.

Close co-ordination and deep involvement of the general managers and technology area head has helped to meet the desired objective.

Further information, www.sail.co.in References 1. http://www.forbes.com/sites/ johnellett/2014/09/30/technology-is-changingthe-future-of-marketing-again/ 2. http://marketingland.com/5-marketingtechnology-challenges-every-business-mustsolve-116308 3.

Technology Marketing Brochure, RDCIS, 2014 4.

Paul F. Nunes, Woodruff W. Driggs, David Herman, Jeffrey F. Rayport, Stephen Dull, and Joe Scafido. "What Serves the Customer Best?"

Harvard Business Review, October 2006.

5. http://techmarketingblog.blogspot.in/ 6. http://marketingland.com/5-marketingtechnology-challenges-every-business-mustsolve-116308 7.

Certified Annual Benefit (CAB) Report RDCIS (2010-2011, 2011-2012, 2012-2013, 2013-2014, 2014-2015) 8.

RDCIS Performance Report (2010-2011, 2011-2012, 2012-2013, 2013-2014, 20142015) www.steeltimesint.com

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AUTOMATION

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Innovative automation packages Intelligent automation and process optimisation systems are essential for achieving excellent product quality, enhanced safety and increased plant performance in the steel industry.

By T Kurzmann*, F. Hartl, A. Rohrhofer, P. Aufreiter SAFE and cost-efficient production has been the driving force behind the introduction of new automation packages from Primetals Technologies.

One of the main consumers of electrical energy in a BOF plant is the electrostatic precipitator of the dry type primary dedusting system. Substantial energy savings have been achieved with the introduction of the Precon (Precipitator Economiser) system.

Leakages often go undetected and can cause heavy damage and costly delays in production. Fluid Guard is a system for detecting leakages.

Inaccurate or delayed measurement data can be the result of limited equipment accessibility or other technical reasons. A wireless, self-organising network facilitates wide-ranging data transmission in previously inaccessible areas and opens up a wide range of new opportunities.

A standard bag filter operates without any dynamic energy optimisation, based on fixed cleaning cycles. To achieve cost reductions, an optimised bag filter control is essential and acoustic monitoring of equipment noise is a new approach to plant and process observation.

Reduced energy consumption Recently developed automation packages from Primetals Technologies are designed to reduce energy consumption, assist operational personnel and enable measurement where accessibility for wired instruments is not given.

The energy consumption of a dry dusting plant’s electrostatic precipitator is a major focus for steelmakers. Following the

installation of Precon by a European steel making plant, substantial energy savings have been achieved.

Iron and steel plant equipment exposed to high temperatures can be problematic.

Water-cooling is the most adequate form of protection available. Water leakages within the cooling circuit, however, can cause heavy damage and result in major production delays due to the reaction between liquid iron or steel and water. Fluid Guard accurately monitors cooling circuits and detects water leakages.

Limited accessibility of equipment or other technical reasons often result in inaccurate or delayed measurement data.

Wireless solutions leave these limitations behind. A wireless, self-organising network facilitates wide-ranging data transmission in previously inaccessible areas and opens up a range of new opportunities. Wiplant uses the industrial WirelessHART standard for communication and data transmission and can be used for retrofitting weighing measurement equipment on scrap transfer cars not equipped with a weighing system.

Bag filters are operating without dynamic-energy optimisation. An optimised bag filter control is a major pre-condition if cost reductions are to be achieved. Acoustic monitoring of specific equipment noise is a new approach to plant and process observation.

Energy optimisation The electrostatic precipitator (ESP) consists of collecting electrodes arranged in parallel, which are earthed jointly with the unit’s circular shaped casing [1].These electrodes form lanes through which

the gas flows. High voltage discharge electrodes are located centrally in the lanes, are poled negatively and supported by insulators. There is a direct voltage of up to 65kV between discharge and collection electrodes. Depending on plant size, energy consumption varies between 1.4 kWh and 2.1 kWh per metric ton of tapped steel.

Electrostatic precipitators are the heart of primary dry-type dedusting in steel plants, but they are also a major cost factor.

Precipitators are usually operated so that dust concentration limits can be reliably maintained. However, as dust emissions at the converter fluctuate widely in time, this operational practice is not in line with demand and simply leads to higher operating costs.

The filter is normally divided into four sections and each filter section is connected to a designated transformer and a highvoltage control unit. For effective gas cleaning operation, the electrostatic precipitator operates with higher power consumption than required due to physical reasons.

A principle configuration of the system is illustrated in Fig. 1.

The used electrical power has a secondary importance and most of the time the energy input for the ESP is at its maximum.

This is a vast waste of energy and has a negative impact on running costs.

Precon was installed in a European pilot plant. The system is designed as either a fully automatic stand-alone unit, as shown in Fig. 2, or as an integrated package of the dry dedusting automation system, which significantly reduces the energy input of an electrostatic precipitator.

* Thomas Kurzmann, Primetals Technologies Austria GmbH, Turmstrasse 44, A-4031 Linz, Austria; Mobile: +43 (0) 664 615 3367; e-mail: thomas.kurzmann@primetals.com www.steeltimesint.com

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Precon

HV control unit

HV transformer

Raw gas

Clean gas

Fig 1. Principle configuration of Precon

Precon controls the level of possible energy reduction under the boundary limit of a zero increase in the dust concentration of clean gas – based on process conditions and the converter phase. The operator can switch on automatic energy reduction or keep the pre-selected settings in the high voltage units. A single Precon unit controls and optimises up to three electrostatic precipitators simultaneously. The system features automatic control of energy reduction parameters, high accurate power monitoring devices for each field of the electrostatic precipitator, touch panel for fast and easy operation and simple switch-over from normal mode to optimisation operation. An implemented energy management module evaluates all relevant information on used power at each converter cycle. On the HMI all relevant energy saving values information as well as filter effectivity is provided to the operator.

Fig. 3 indicates the values for two parallel dry dedusting systems. The first dial instrument (‘Energy’) gives information about saved energy in comparison to energy consumption prior to optimisation, on the second instrument (‘Dust’) the improvement of dust content in the offgas, in percentage terms, is indicated. Furthermore with ‘Energy Heat’, information about used energy per heat in kWh is provided. The last instrument (‘Filter’) gives an estimation of the filter condition by measuring the maximum power to be brought into the electrostatic precipitator. The dial instruments show the average values of one electrostatic precipitator. The actual converter process step as well as the operational status of Precon is indicated. On additional screens individual values and conditions of each filter section are provided.

The package is installed with pre-tested Digital Edition - February 2016

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Fig 2. Precon stand-alone control unit

hardware, an industrial PC with integral PLC that guarantees an independent solution and flexible communication to all suppliers of high voltage units for the electrostatic precipitator.

The first installation demonstrated encouraging results where energy consumption could be reduced by between 30% and 50% compared with the operation without energy optimisation as shown in Fig. 4. Based on a BOF converter plant with two converters, each 300 tons, with 31 heats per day and an overall production of 340 days per year, the resulting saving in energy is about 4.5GWh per annum.

Leakage detection Equipment with high temperature exposure in iron and steel making plants is a major problem that needs to be solved. The equipment needs adequate protection and the most common method is water cooling.

In case of water leakage within the cooling circuit the reaction of liquid iron or steel to a water leakage can lead to catastrophic injuries to operational personnel and heavy damage to the plant resulting in costintensive production delays. Cooling circuit monitoring is state-of-the-art and many producers use industrial instruments that indicate process values on the operating system as shown in Fig. 5.

Fluid Guard is used to monitor cooling circuits and detect water leakages. It provides fully automatic monitoring and control at the highest safety level and detects any variation in process conditions and immediate reactions are performed.

The safety-relevant part of the system is designed in accordance with “safety of machinery” standard EN ISO 13849.

Furthermore the Fluid Guard system provides an automatic self-diagnostic system where – after a pre-defined period

– the system checks itself by detecting selfinflicted virtual water leakages.

Cooling circuit measurement is mainly realised by the use of safety temperature, pressure and flow-measurements, safety shut-off valves, self-diagnostics and a safety control unit as illustrated in Fig. 6.

The software evaluates and compares the measured values from the supply and return line and determines the operating flow.

Defined counter measures are executed in case the system detects deviations of flow.

In addition to detecting leakages, the system can undertake a comprehensive health check in which the process conditions of the cooling circuits are monitored.

Where energy saving is concerned, Fluid Guard provides a function for dynamic control of the water pumps for the cooling circuits. Based on the actual production situation and measurements, the system provides a set point for the drives (VVVF) of the motors for the cooling water pumps which will reduce the energy. According to affinity laws for pumps[2] a 20% reduction of rotational speed leads to a power reduction of approximately 50%.

Process data capture Many areas are more or less inaccessible for installation of new instrumentation or measurement points because cabling is hard to realise or cost-intensive. A wireless, self-organising network with wide-ranging data transmission, therefore, opens up a wide range of new opportunities. With WirelessHART, for example, additional applications can be realised without cabling or installation of new cable trays. WirelessHART is an open wireless communication standard (IEC 62591, EN 62591) based on the foundation of the HART Communication Protocol[3]. www.steeltimesint.com

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Energy consumption per day [%]

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Fig 4. Operational results of the energy consumption with “active” Precon compared to

Fig 3. Visualisation of energy saving and plant performance.

reference consumption (blue line) without energy optimisation

Supply cooling water

*

T

F

*

P

* *

Interface to main PLC M

Safety PLC* F

AC DC

Return cooling water

T

*

* *

AC DC

*) Safety certified components

Fig 5. Visualisation of cooling water circuit for a top blowing lance

Wiplant modular system To ensure a high overall performance, all relevant processes in the steel plant have to be monitored, controlled and co-ordinated.

Limited accessibility or technical reasons often result in inaccurate or delayed measurement data.

The Wiplant modular system leaves those limitations behind as it allows reliable measurement of values, conditions and so on using a combination of sensors with a secure data transmission based on established industrial WirelessHART technology – even in harsh environments.

An interface to automation solutions enables advanced process control.

Wireless weighing system In order to be consistent with the actual trends of customised steel making processes – and effective scrap management – a proper weighing measurement system for used amounts of raw material becomes increasingly important for plant operators.

For this reason a highly integrated circuit www.steeltimesint.com

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Fig 6. Schematic diagram of Fluid Guard

for weighing and temperature measurement has been developed and is shown in Fig.7.

The hardware can handle up to four weighing disks, two thermocouples and one integrated acceleration sensor for inclination compensation or shock detection.

To use the hardware on transfer cars and scrap chutes without a power supply the main focus of the hardware has been given a low power realisation. Thus lifetimes of up to one year without recharging the batteries can be achieved.

Fig. 8 shows the power consumption of the hardware over a one-year test period.

For the pilot test application two 140Ah batteries, parallel-connected, are used.

During the test period the weight of four weighing beams and two thermocouples are measured and evaluated.

The update rate from the WirelessHART network hardware to the central gateway was set to four seconds. Typical fields of application for the wireless weighing systems are continuous ladle weight measurement on transfer cars and slag pots

transfer cars or weight measurement on moving scrap chutes.

Wireless temperature measurement Primetals Technologies recently commissioned a wireless temperature measurement system at a KOBM converter.

The configuration consists of eight thermocouples at the centre pipes of the tuyeres and one for bottom temperature measurement. From the converter bottom the cable route has been laid to the converter shaft (as shown in Fig. 9) where three wireless transmitters have been placed.

The temperature readings are transmitted via WirelessHART technology to a gateway located close to the control room. The gateway provides the network device status.

The reliability of the transmitter increases with the amount of wireless transmitters in the nearby surroundings. For the installed application each transmitter found two or three network participants; the wireless transmitter and the wireless gateway (Fig. 10). The reliability of the measurement Digital Edition - February 2016

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14

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12

Fig 7. WirelessHART network node for multiple fields of application

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Fig 8. Battery lifetime with WirelessHART data transmission

Fig 9. Cable routing and location of wireless transmitters HART Tag

Node state

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Service denied

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wihartgw TOO1 848

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Fig 10. Network device status

system was 100% and there were no interruptions due to closing and opening the doghouse or during the KOBM steel producing process.

Reliable vessel tracking system with wireless data transmission The system is based on UHF-RFID (radiofrequency identification) technology. RFID uses radio-frequency electromagnetic fields to transfer data from or to a tag, for automatic identification and tracking.

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Primetals Technologies developed a new type of passive UHF-RFID tag called ICE-Tag-RFID developed for use in harsh environments (Fig. 11).

Because ICE-Tag-RFID is passive the reader powers it and there is no need for batteries. The Tag has an adequate heat and shock-resistant housing in order to protect it against splashes of liquid metal and mechanical collision.

The operating temperature is up to 200°C and it also endures short-term temperature

peaks of up to 800°C. A tag contains electronically stored information that can be read within a distance of 3m. ICE-Tag-RFID also includes passive damage detection, thus the tracking system recognises if a tag is damaged and the exchange of the tag can be arranged.

Fig. 12 shows the temperature trend in front of a UHF-RFID antenna. Each peak represents a hot vessel passed through the tracking position. Thus a reliable system can be provided to detect a vessel beyond the UHF-RFID tracking system. With this temperature evaluation it is possible to detect if an ICE-Tag-RFID is still mounted on the vessel or if it has broken away, for example, from a crane. In this case the tracking system detects a temperature peak but no ICE-Tag-RFID. A combination of WirelessHART data transmission and the RFID vessel tracking station has tested successfully in a steel plant in Austria.

Bag filter control A standard bag filter operates without any dynamic energy optimisation, based on fixed cleaning cycles where the cleaning valves purge compressed air into the filter bags by means of jet pulse technology. A malfunction of a cleaning valve can only be detected manually through acoustic checks.

These are both time-consuming and costintensive.

Furthermore, a fixed amount of compressed air for filter bag cleaning is used for each cleaning valve. Most of the cost-intensive compressed air is wasted, because the cycle time cannot be adjusted automatically based on actual process parameters. To activate a cleaning valve, electro-mechanical relays switch on the power for the solenoid valve.

In Fig. 13 the pulses of a bag filter with an 8m length and 20 chambers is shown.

The filter is working with a pressure for cleaning at 4.5 bar. With the blue trend line the record of compressed air flow in Nm³/h is provided and on the red trend line the pressure drop of each of a total 20 pulses can be found. An optimised bag filter control is the major pre-condition for cost reductions.

Using a differential pressure measurement between bag filter inlet and outlet, and the actual volume gas flow, an optimal cleaning cycle mode is automatically selected by the Bag Filter Control unit. A fast and reliable electronic module with MOS-FET www.steeltimesint.com

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Fig 11. ICE-Tag-RFID; a high

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technology, which additionally features selfmonitoring functions, controls the cleaning valves. The duration of the open time for each cleaning valve can be adjusted and in combination with diaphragm valves a reduction of 30% in compressed air can be achieved. Furthermore, the reduction of the pulse length has a positive effect on the lifetime of the filter bag inserts so that the average lifetime of three years in operation will increase to four years before replacing the inserts.

An additional feature of the Bag Filter Control unit is built-in condition monitoring featuring continuous supervision of each cleaning valve, which generates a warning at the HMI in case a malfunction is detected.

The Bag Filter Control unit is a completely pre-tested technological package including HMI, software and hardware, which can be easily integrated in to new or existing bag filters within the shortest commissioning time.

The bag filter control unit features automatic control, an ultra-efficient entire bag cleaning process, energy savings due to reduced cleaning air consumption, reduction of filter bag wear and a reduction in maintenance costs.

Acoustic plant monitoring Acoustic Expert is a new system from www.steeltimesint.com

AUTOMATION Primetals.indd 5

Primetals Technologies with high plant monitoring potential. The system checks noises in the surrounding area. Once the system detects an acoustic situation outside of its normal operating limits, the soundscape is recorded and a detailed analysis leads to a statement as to whether the observed equipment works at its proper conditions or not.

The system has been installed in a European steel plant monitoring the cleaning valves at a Jet-Bag filter plant.

Fig. 15 shows a decreasing signal from good to bad condition. The threshold is set to a standardised power limit of 0.6. Over the threshold the valve is in a good condition; below the threshold the system informs the user to change the valve. Fig. 15 also shows that Acoustic Expert analysis is robust and unharmed by disturbing noises in the background. The system is adaptable for nearly every field of application with continuous diagnostics for production and maintenance support.

Records provide reports over the whole equipment utilisation time and can be easily installed and implemented without disrupting ongoing production.

Further possible applications are tuyere monitoring of torch cutting machines on continuous casting equipment, valves for lubrication and other equipment generating

a specific noise during operation.

Intelligent control of electrostatic precipitators with Precon leads to significant energy savings and reduced production costs. With Fluid Guard smallest leakages in water cooling circuits are detected and adequate measures provided.

For retrofitting weighing equipment on transport cars, Wiplant provides the optimum solution and provides the wireless data transmission for automatic ladle tracking. The specific noise during a cleaning cycle in a Bag Filter can be monitored acoustically and the typical operation of a bag filter has a high potential for optimisation. t Further information, www.primetals.com References [1] S. Hofinger, R. Hubmer, S. Schütt, “Steel Expert Takes Command – Optimized Performance on BOF Converter”, Proceedings Aistech 2012, Atlanta M. Hiebler, C. Bruckner, S. Hofinger, G. Wimmer, F. Hartl, [2] Pelikan, Bob, The pump book, Fifth Printing, Affinity Law #3, pg. 116 [3] HART Communication Foundation, WirelesHART Brochure, HCF_LIT-090 Revision 3.1 EN, 2014 Digital Edition - February 2016

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Predicting gearbox bearing failure Gearboxes for rolling mills are complex machines and their reliability is crucial. Condition monitoring systems are useful tools for estimating defects on main gearbox components, but their performance relies upon the training procedure, which often requires a very expensive and experimental set-up. This paper introduces a numerical approach to predict the effects of bearing failure under several working conditions. The generated outputs correspond to different fault conditions and will constitute a useful database to tune up and train the entire apparatus of the condition monitoring system (CMS) of rolling mill gearboxes. By S.Cinquemani1 F.Rosa1, E. Osto2

GEARBOXES for rolling mills are complex machines that cannot be treated as commodities; they are part of a complex drive system that, in case of failure, can seriously affect plant productivity. [1], [2], [3].

From this perspective, early detection of improper operating conditions, as provided by condition monitoring systems (CMS), is a chance to plan extraordinary maintenance to prevent sudden interruptions and identify primary rather than secondary causes of failure.

[4], [5], [6] . It is worth mentioning that preventive maintenance implies negligible costs compared to those related to secondary failure causes, such as bearing replacement versus gear and shaft replacement.

In fact, bearings represent a typical source of gearbox failure or improper operation. [7], [8], [9]. Gradual deterioration of operating behaviour is normally the

first sign of bearing damage. Depending on the operating conditions, a few weeks, or even a few months, may pass from the time damage begins to the moment when the bearing actually fails because of contact fatigue damaging mechanisms. This typical progressive damage evolution makes bearings especially suitable for continuous condition monitoring analysis.

From the perspective of failure detection, bearing damage results when there is an increase in operating temperature, lubricant contamination and vibration. In principle, all these parameters can be measured by CMS, but the techniques based on the analysis of vibration signals are the most efficient, as they can provide an earlier identification of the specific bearing involved and can give more information on the kind of damage.

Spindles

Mathematical model An outline of a rolling mill can be seen in Fig. 1. Hot steel is rolled through a sequence of rolling stands or – with reversible mills – in multiple runs between the stand’s rolling rolls. At each run, the rolled section is reduced and the bar elongated.

To generate “virtual accelerations”

Output: Forces on housing due to defects on bearings speed

Gearbox Rolls

Usually, to properly set up the algorithm, measures associated both with standard operating conditions and malfunctioning are used. This paper investigates the possibility of training a CMS by exploiting numerical analysis based on models of the machine under several operating conditions[10], [11].

This approach would avoid the need for expensive experimental tests and quantitative estimations of bearing damage.

Data: gearbox main mechanical features

Motor Data: main parameters of bearings

Hot steel Input: motor torque and angular speed

Fig 1. Outline of a rolling mill

Data: experimental frequency response of the gearbox

Fig 2. Graphical representation of the mathematical model

1- Department of Mechanical Engineering, Politecnico di Milano, Via La Masa 1, 20156, Milan, Italy 2- Primetals Technologies Italy, Via Pomini 92, Marnate, Italy Digital Edition - February 2016

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related to bearing malfunction in the gearbox, a mathematical model of the system has to be developed. A ‘lumped parameter’ model has been conceived and deployed for rolling mill gearboxes (Fig. 2). It takes into account the main mechanical and geometrical features, main gear parameters and the most important information on the bearings involved.

First the model needs to input the torque (TM) and angular speed (ωM) of the motor. This information is collected from the field (Fig. 3) and is limited to conditions in which the speed is constant. Then the kinetostatic model of the transmission calculates the forces on bearings along the three main directions X, Y, Z and the corresponding displacement of the shaft along the same directions (Δx, Δy, Δz) with respect to the housing.

Bearing defects, like pits on any race, periodically change the stiffness of the bearing itself and how it transfers the forces from the shaft to the housing.

For generic roller bearings, the development of the relationship between load and displacement is based on the following key steps (symbols and conventions are illustrated in Fig. 4 for a double row tapered roller bearing, but can be easily extended to all the www.steeltimesint.com

ROLLING primetals bearings.indd 2

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bearings):1. Define an arbitrary position for each roller.

2. Assign a displacement to the inner ring (Δx, Δy, Δz) as obtained by loads on the bearing 3. Determine overall contact deformation of a generic roller due to these inner ring displacements.

4. Define a relationship between this deformation and the corresponding load (Hertz Theory).

5. Determine how this load is ‘distributed’ among contacting surfaces on the basis of equilibrium equations.

6. Determine the forces acting on each race as resultant of the forces exerted on it by each roller.

Even though more sophisticated models of bearing internal load distribution can be found in literature (see, for example, [12]), a simplified calculation approach has been adopted in this model, to have affordable computational time.

Bearing defect’s fingerprint According to different operating conditions (ie. load and angular speed) each bearing has a distinctive behaviour during malfunctioning that can be used as a fingerprint to detect damages.

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Cage wear model Cage wear was introduced by assuming that its effect on the bearing global model? can be considered by changing the circumferential positions (with respect of their evenly spaced theoretical positions) of the rollers with respect to the rings. From a mathematical perspective, after having defined the maximum circumferential displacement (εWC) of the rollers, there is a need to define the distribution of these displacements in order to locate all of them. If this type of defect is introduced, it implies that the rollers are no longer evenly spaced, as assumed in the model of a healthy bearing.

Race pit model Reducing the contact deformation of a roller when it is ‘on the blocks’ simulates the presence of a pit stop in a race. This condition leads to a reduction of the load that can be transmitted by a simple roller/ball. A regular function Cd is used to describe a generic irregularity of a race (i.e. any deviation from its nominal shape measured along the normal direction).

To reduce the number of variables, a simple relationship between the depth (Cd) and the width (Δd) of the defect has been imposed as shown in Fig .5. To evaluate the effects of bearing damage, Digital Edition - February 2016

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Shaft 2 Shaft 3

Shaft 1

B1

Tapered roller

SKF 31326

B2

Spherical

SKF 22332

B3

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SKF 24148

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SKF 24148

Table 1. Configuration of bearings 0.05 0.045 0.04

Fig 7. Layout of the gearbox

0.035 0.03 m/s2/N

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Fig 8. Frequency response function of the chassis TFX;B1(f) close to bearing B1 along X axis

0.025 0.02 0.015 0.01 0.005 0

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it is possible to set different values of Cd, and Δd.

For each roller, the algorithm evaluates the corresponding deformation due to the displacement of the inner ring and the corresponding transmitted force. When a roller is over a defect, its deformation decreases as the load it is transmitting. By considering all the rollers it is then possible to estimate the total force transmitted to the housing.

According to the geometry of the bearing and its operating conditions (ie. shaft angular speed), the FFT that the forces transmitted is univocal (Fig.6).

The response of each type of defect has its own frequency structure, i.e. the spectra of the responses to a pit on the fixed (outer) race is completely different from the spectra of the responses to a pit on the rotating (inner) race as well as from the spectra of responses to cage wear. Looking at Fig.6, if the pit is on the fixed ring (outer race), the reaction forces spectra exhibits harmonics at the Ball Pass Frequency of the Outer race (BPFO) and at its multiples.

Alternatively, if the pit is on the rotating ring (inner race), the reaction forces spectra is more complicated due to the interactions of bearing elements; in particular, there are harmonics at the Ball Pass Frequency of the Inner race (BPFI), surrounded by side bands, evenly spaced, of the rotating ring speed.

Case study The parametric model described in the paper has been used to simulate failures on the bearing of a real mechanical transmission installed on a rolling mill.

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ROLLING primetals bearings.indd 3

The layout of the transmission to be analysed is depicted in Fig. 7. The transmission is used in a rolling mill plant and it has a speed ratio of 0.072.

Shaft 0 is connected to the motor, while shafts 2 and 3 are linked by spindles to the rolls of the mill. Speed reduction is obtained from the first two stages of the transmission, while the third one (whose ratio is equal to 1) is used to split the power to the two rolling rolls.

Bearings configuration is resumed in Table 1. According to different operating conditions and different kinds of defects, the model can evaluate the forces applied to the chassis along X and Y directions.

Because of the complexity of the system and the wide variation of the frequency response, due to the mounting and assembling operation, as well as to manufacturing tolerances, the relationship between forces applied on the housing, and the corresponding virtual accelerations, is obtained experimentally.

The frequency response function between the force exerted on the chassis and the corresponding acceleration can be obtained with impulsive tests. Fig. 8 shows, as an example, the frequency response function between the force exerted on the chassis along the X axis near the bearing B1, and the acceleration measured along the same direction.

Once the forces transmitted to the chassis, due to a defective bearing, are identified from the mathematical model, the corresponding accelerations can be easily obtained by simply multiplying the forces (in frequency domain) to the frequency response functions of the

system. As an example, let’s consider bearing B1. The acceleration along the X axis x”B1(f) can be computed by multiplying the frequency response function of the chassis, close to bearing B1, TFX;B1(f) and the force (FX;B1(f)) along the same direction estimated by the model for a defect on bearing B1.

Figs. 9, 10 and 11 respectively show the quantitative estimation of the forces applied along X direction and the corresponding accelerations for different kinds of defects. Numerical analysis has been carried out considering motor torque: TM=14kN, motor angular speed ωM=500rpm, Cd = 0.1mm for defect on the outer ring, Cd = 0.1mm for defect on the inner ring, Cd = 3.2mm for defect on the cage.

Remarks The response of each type of defect has its own frequency structure, i.e. the spectra of the responses to a pit on the fixed (outer) race is completely different from the spectra of responses to a pit on a rotating (inner) race as well as from the spectra of the responses to a cage wear. While the entity of the harmonics due to pits are much higher than the harmonics due to cage wear, a cage wear will be more difficult to detect, i.e. when it has reached considerable dimensions.

Coming to the accelerations that may be measured on the chassis, it is worth observing that, even if the frequency structure has not changed, the harmonics distribution has been radically altered by the response of the gear box structure, which amplifies some frequency ranges and hardly smooths others. www.steeltimesint.com

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The usefulness of the presented approach and tools, therefore, appear evident: they allow geared systems and condition monitoring developers to pre-determine system responses to defective bearings, help transmission designers to design systems where the frequency response does not transmit excessively defective bearing-exciting forces, and allows condition monitoring system developers to train and fine-tune systems aimed at detecting bearing faults. Condition monitoring system developers, for instance, may identify more clearly which frequency range has to be more accurately examined, as well as which accelerations magnitude they have to expect. The approach introduced in www.steeltimesint.com

ROLLING primetals bearings.indd 4

Fig 11. Forces applied on the chassis along X direction (up) and corresponding virtual acceleration (bottom) for a defect on the cage

this paper can significantly increase the reliability of condition monitoring systems, by making them capable of more accurately detecting incipient failures and estimating more accurately the residual life of bearings, resulting in an improvement of maintenance efficiency and effectiveness, and a reduction of running costs. t Further information, www.primetals.com References 1.

J. Antoni and R. B. Randall. A Stochastic Model for Simulation and Diagnostics of Rolling Element Bearings With Localised Faults. Journal of Vibration and Acoustics, 125(3):282, 2003.

2.

M. Cao and J. Xiao. A comprehensive

dynamic model of double-row spherical roller bearing. Model development and case studies on surface defects, preloads, and radial clearance. Mechanical Systems and Signal Processing, 22(2):467–489, February 2008.

3.

Feiyun Cong, Jin Chen, Guangming Dong, and Michael Pecht. Vibration model of rolling element bearings in a rotor-bearing system for fault diagnosis. Journal of Sound and Vibration, 332(8):2081–2097, April 2013.

4.

Hirotoshi Aramaki. Package BRAIN .

(3):15–24, 1997.

5.

Fucai Li, Lin Ye, Guicai Zhang, and Guang Meng. Bearing Fault Detection Using Higher-Order Statistics-Based ARMA Model. Key Engineering Materials, 347:271–276, 2007.

6.

Robert B. Randall and J´Jerome Antoni.

Rolling element bearing diagnostics – a tutorial.

Mechanical Systems and Signal Processing, 25(2):485–520, February 2011.

7.

M. Craig, T.J. Harvey, R.J.K. Wood, K. Masuda, M. Kawabata, and H.E.G. Powrie.

Advanced condition monitoring of tapered roller bearings, Part 1. Tribology International, 42(1112):1846–1856, December 2009.

8.

S Crep, I Bercea, and N Mitu. A dynamic analysis of tapered roller bearing under fully flooded conditions. Part 1: Theoretical formulation. Wear, 188, 1995.

9. Suri Ganeriwala. Rolling Element Bearing Faults. Rolling Element Bearing Faults. 2010.

10. Janetta Culita, Dan Stefanoiu, Florin Ionescu, and Computer Science. Simulation models of defect encoding vibrations. Control Engineering and Applied Informatics, 9(2):59–67, 2007.

11. D. Ho and R.B. Randall. Optimisation of Bearing Diagnostic Techniques Using Simulated and Actual Bearing Fault Signals. Mechanical Systems and Signal Processing, 14(5):763–788, September 2000.

12. I. Bercea, S. Cretu, and D. Nelias. Analysis of Double-Row Tapered Roller Bearings, Part I Model. Tribology Transaction, 46(2):11, 2003.

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FURNACES

Unique products for unique solutions INTECO is meeting evolving market demand for the continuous optimisation and design of smart and proven energy recovery solutions for electric arc furnaces, which recover off-gas energy effectively and work with scrap and other iron-bearing materials in variable proportions. Such a strategy offers many advantages for steel producers at a time when there is pressure on reducing costs and streamlining operational expenditure. By Luca Gemo* and Dipl.Ing Joachim Ehle** INTECO is a private engineering company founded in 1973 and highly specialised in the field of refining processes ESR, VIM, VAR, special metallurgy (LF, VD, VOD, RH), ingot casting, continuous casting (billets, blooms) and melting units with electric arc furnaces (EAFs).

The combined experience of professional steelmakers and engineering specialists was also driven by the acquisition of several companies possessing innovative technology and advanced design expertise, such as INTECO atec for complete automation systems with its Electrode Regulation System and INTECO PTI Process Technology Int., USA with continuous research and development work and its well-known integrated chemical energy and injection systems.

In March 2015 the INTECO Group acquired the electric arc furnace and ladle furnace technology patents and other intellectual property rights of FUCHS Technology AG, a full-line melt-shop equipment supplier including primary metallurgy with EAF-based melting.

EAF design concept principles The EAF is no longer just a basic melting unit, but it should be considered as one of the major areas of interest for steelmakers looking to reduce operational expenditure.

The dynamics of the market price of steel scrap and its substitutes have proved that substantial savings are possible when a melt shop uses different raw material mixes.

Reduced transformation costs can also be achieved through boosting melting process efficiency, reducing losses and recovering lost energy.

The objective of modern EAF design is to offer steelmakers flexibility in raw material selection. This needs to be done very carefully in order to discover the optimum solution with a provision that achieved results cannot reflect the best balance between absolute performance and transformation costs, hence some compromises should be accepted. The main advantage of EAF charge flexibility is to make it possible to move from one charge mix to another in line with market conditions or steel quality requirements and not encounter operational problems when using an EAF of the same design and configuration.

For different charge properties, there are various design parameters that influence overall EAF performance. These are to be considered geometric and ‘process-customised’ in nature and are the summary of experience gathered over many years of EAF usage as an optimised melting machine.

Energy recovery system A major part of EAF performance improvement and transformation costs can be obtained with the reduction of losses.

It is well known that energy losses in the melting process are mainly related to off-gas, cooling water and slag. The first two items are the ones that are more technologically explored so far.

The recovery of the fumes’ enthalpy has been rigorously analysed and several practical applications have been developed.

The real benefit of energy recovery is seen when it is possible to transfer the heat of the fumes directly to scrap.

The remarkable technological efforts involved in converting off-gas heat into pure electrical energy are not thermodynamically sustainable.

The passage from “low quality energy” (heat) to “high quality energy” (electricity) needs to pay the price of low thermodynamic yield, which is dramatically decreasing the real benefit of energy recovery.

Charge pre-heating is a much more efficient process when it is just applied as a transfer of heat from the gas to the scrap. The expected flexibility of charge pre-heating requires the handling of not only medium or light scrap, but also some quantities of DRI/HBI or pig iron.

Furthermore, the pre-heating system must be designed to allow for disconnection from the EAF in case of maintenance or a charge strategy change. With these conditions, a combination of continuous feeding and batch pre-heating seems to be the most advantageous.

*Senior metallurgist, **Consultant Digital Edition - February 2016

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FURNACES

Fig 1. INTECO Fuchs COSS furnace in operation

Telescope furnace INTECO Fuchs’ answers the challenges above with its Telescope EAF, a new furnace solution with telescopic roof closure allowing a single bucket charge operation even with a low charge density.

The system enables a gradual shell volume decrease in terms of the progress of the melting process, leading to reduced energy losses to water-cooled panels. A movable electrode lifting system and roof reduces the length of the electrode under a clamping device and this leads to substantial savings.

Energy consumption is reduced by 30 – 40 kWh/t thanks to: • Increased EAF upper shell height with a reference H/D ratio of about 0.6 for direct energy recovery. Such efficient in-shell scrap pre-heating is achieved through the heat generated by the hot heel of the previous charge, burners and oxygen injection and a higher degree of CO post-combustion thanks to an extreme high charge pile within the enlarged shell volume. Thanks to the utilisation of high voltage and a serial reactor even throughout the first boring the scrap caving is minimised.

• Single bucket charge and associated reduction of energy losses due to roof opening plus a reduced dust load in the meltshop building.

• Better cost balance between chemical and electrical energy is possible.

• Efficient operation at the highest chemical and electrical input.

The solution is made with simple, reliable design features for high plant www.steeltimesint.com

Inteco furnaces.indd 2

availability and easy component exchangeability (i.e. cylinders, bearings etc). Due to proven design and nonusage of exotic solutions, maintenance is reduced to a minimum.

• Reduction of power-off times, as less buckets are charged, less scrap levelling is necessary, a better scrap partition within the single bucket is possible and a better self-compacting of light scrap within the same bucket is achieved.

• Reduction of electrode consumption (yearly average below 1,0 kg/t have been achieved).

• Less electrode breakages compared to other single bucket technologies.

Excellent potential to reduce the price of the metal charge input: • It is possible to charge lighter and/or cheaper scrap due to bigger EAF volume.

• Flexible input of raw materials and compatible with light, heavy scrap.

Safety improved: • Simplified processes and mode of operation lead to less failures.

• Higher plant availability with reduced

47

maintenance.

• Minimised inherent risk of explosion when charging the second bucket (very sensitive during icy winter times).

• Operation with closed door thanks to the INTECO PTI Swing Door® system.

Emissions are reduced: • Reduced dust load, linked to reduced number of charged buckets.

• Less levelling.

• Comparable to a classical EAF, preheating without VOC off-gas treatment • Tighter EAF with lower emissions Best performance figures: • Electric Energy: 340 Nm3/t • Oxygen Consumption: 27.5 Nm3/t • Tap-to-Tap: 41.4 min • Average Power: 112.6 MW • Productivity: 225.1 t/h (good billets) • Productivity: 155.1 t/heat

(good billets) Evolution of scrap pre-heating One of INTECO Fuchs’ patents is COSS (Continuous Optimised Shaft System) scrap pre-heating. COSS is composed of a shaft that receives the scrap to be preheated by the off-gas before feeding the furnace.

The shaft is installed adjacent to the EAF shell to take advantage of the highest off-gas temperature and the remaining post combustion of CO. Scrap is introduced into the EAF shell by means of a pusher activated by hydraulic cylinders with simple and accurate speed regulation so that it is not necessary to interrupt the power in order to charge scrap into the EAF shell.

The main improved features are: • Shaft not water-cooled (less thermal losses and maintenance).

• No fingers (less thermal losses and maintenance).

• Flat bath operation leads to lower Fig 2. INTECO Fuchs telescope furnace in operation

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FURNACES

noise and lower flicker level.

• Independence of bucket charging. from melting process – charging causes no power-off time, no reactions or explosions caused by charging .

• Scrap optimisation.

• Smell elimination.

Fig 3. Inteco PTI Swingdoor in operation

The furnace is operated during the entire melting process in flat bath conditions with foamy slag, leading to flicker reduction and better yield process.

The COSS is installed on a weighing frame that gives the exact scrap weight in the shaft in real time and allows the operator to calculate the charged scrap weight. In this way the shaft remains loaded with scrap at all times for extending the pre-heating effect.

Best performance figures: • Electric Energy consumption: 300 kWh/t.

• Oxygen Consumption: 27 Nm3/t.

• Tap-to-tap time: 53 min.

• Average Power: 50 MW. • Productivity: 128.2 t/h (liquid steel).

• Productivity: 113.2 t/heat (liquid steel).

Process tools INTECO PTI, the US-based company leader in the field of injection technology, offers a wide range of EAF injection systems and process tools. The leading idea of each one of the INTECO PTI systems is to combine high reliability with high efficiency.

The injection tools are installed a short distance from the liquid bath level and this increases the injection efficiency and heat transfer of the burner flame energy to the metal.

Among the available injectors, one of the latest developments – the Annulus Burner – is quite interesting because of its role in the operational flexibility of an EAF. The Annulus Burner integrates three burner functions in a single tool: supersonic oxygen lance as well as solid material injector designed for high flow rates at high speed of materials such as lime, carbon, dolomite, FeSi or DRI fines.

In case of any change of raw material mix, for example, an increased percentage of DRI in the charge, it is then very easy to adjust the required oxygen, carbon, lime and gas flow rates at each injection point for the new mix.

Foaming slag management plays an important role in the melting process.

Another INTECO PTI process tool is an automatic slag door (Swingdoor) which enables proper slag quantity in the furnace to be maintained, resulting in a 100% covered arc at any moment during the melting process. Swingdoor acts as a

“proportional valve” for controlling slag quantity and for de-slagging operations.

Its application improves safety on the furnace floor since the presence of an operator in front of the slag door is no longer required.

Operation with a proper slag quantity at all times has a positive effect on an overall increase of electric arc stability and heat transfer as well as oxygen and carbon injection efficiency.

INTECO Group is now a full-line melt-shop equipment supplier including primary metallurgy for EAF-based furnaces. It develops and designs all components and auxiliary units with several special and unique design solutions to fulfill all market and customer needs.

There is a wide variation in the availability and price of iron bearing materials. Steelmakers are forced to change their raw material mix in order to reduce production costs.

At the top of the process route, the EAF no longer performs the simple role of a basic melting unit. It should be considered as a major instrument of opex reduction. Modern EAF design should assess innovative mechanical solutions and future add-on packages that are focused directly on further optimisation of the melting process in relation to the charge material mix.

Further information, www.inteco.at References: [1] A. Partyka, L. Gemo, R. Gottardi, S. Miani “The Energy Recovery And the Raw Material Flexibility Are the Keys for the Design of a New EAF”, Proceedings of the ICS Conference, Beijing 2015.

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PERSPECTIVES: REDWAVE

Sorting steel from scrap The metals industry keeps Redwave XRF busy. The company is very active in the USA and Europe at present, claims global sales manager Martin Weiss.

1. How are things going at REDWAVE? Is the steel industry keeping you busy?

The metal industry in general keeps us very busy. Our newly developed REDWAVE XRF is an innovative sorting machine that brings more value than any other sorting equipment when it comes to sorting metal scrap and steel.

2. What is your view on the current state of the global steel industry?

Everyone knows that revenues are going down and have been going down for a while now. I hope it will be going up again soon.

rather stay in the background and use the benefit this new technology brings as long as possible.

6. “Aluminium will always outperform steel on a weight basis; and on the stiffness issue alone it will carry the day,” said Alcoa’s chief technology officer, Ray Kilmer, speaking about aluminium usage within the global automotive industry. Where do you stand on the aluminium versus steel argument?

We as REDWAVE provide solutions to sort and separate both aluminium and steel, so in that matter we hope that both step each other up.

3. In which sector of the steel industry does REDWAVE mostly conduct its business?

By providing sorting machines that are, among others, used to sort and separate steel based on alloying elements. The principle of XRF makes it possible to sort metals based on a chemical analysis. This principle is known in handheld or benchtop devices, but is new in so-called sensorbased sorting machines. We are market leader in the XRF-area with our REDWAVE XRF sorting machines.

8. “Within the next 15 years or so there could be a nearly even split between steel, aluminium and carbon fibre content in the average North American-produced light vehicle.” So said Jay Baron, president of the Centre for Automotive Research. Who is closer to the truth – Dick or Jay? If production costs of carbon fibre can be reduced, it will substitute various metals and have a bright future. On the other hand, it is difficult to recycle.

9. It is always claimed that aluminium is the ‘greener’ metal when compared to steel. What’s your view?

Our technology is used to recycle aluminium and may change the way aluminium is recycled. Recycled aluminium as well as recycled steel have a great potential and environmental footprint.

As for aluminium, of course more energy can be saved due to the massive energy conservation when it is recycled.

4. Where in the world are you busiest at present?

We are active worldwide. At the moment Europe and the USA keep us busy.

5. Can you discuss any major steel contracts you are currently working on?

As our REDWAVE XRF sorting machine is a new development our customers would

We will continue to see steel in cars for quite some time. I assume, however, that aluminium will be used more and more and substitute steel at least in some areas.

7. “While there will be increased aluminium penetration, vehicles will continue to be predominantly steel,” said Ducker Worldwide’s Dick Schultz. Is he right or wrong?

10. “…any hint of doubt when it comes to predictions of climate doom is evidence of greed, stupidity, moral turpitude or psychological derangement.” This is a quote from Bret Stephens writing in The Wall Street Journal. Do you sympathise with his view?

Every human being in a civilised world is, to some point, responsible for climate

* Mining correspondent Digital Edition - February 2016

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PERSPECTIVES: REDWAVE

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change and all other anthropogenic-caused pollution. Of course some greedy or stupid human beings are more responsible than others.

11. In fact, talking of ‘green issues’ and emissions control, how is the steel industry performing in this respect?

During production of steel a lot of emissions are generated and stricter regulation is needed, especially in some countries such as China and India. Those countries should learn from the mistakes of Europe and USA rather than repeating them.

12. In your dealings with steel producers, are you finding that they are looking to companies like REDWAVE to offer them solutions in terms of energy efficiency and sustainability? If so, what can you offer them?

This is exactly what we do. By sorting metal scrap and steel, we create secondary resources and, therefore, reduce the amount of steel produced primarily. This saves a lot of energy and dramatically reduces pollution and emissions.

13. How quickly has the steel industry responded to ‘green politics’ in terms of making the production process more environmentally friendly, and are they succeeding or fighting a losing battle?

This depends on the local requirements in terms of regulations. Again in countries such as China and India there is an urgent need for stricter regulations.

14. Where does REDWAVE lead the field in terms of steel production technology?

Our sorting machines can help to improve the quality of segregated steel scrap. This secondary resource can then be used to produce steel, which reduces the need of primary produced steel.

15. How do you view REDWAVE´s development over the short-tomedium term in relation to the global steel industry?

We follow the CIP principle and try to be on-top of our competitors. The ones who www.steeltimesint.com

perspectives.indd 2

contribute a lot in this matter are the ones using our sorting machines – our customers.

16. China dominates global crude steel production and is accountable for almost half of total production.

How should the industry react to this situation?

No one should dominate production, not for steel nor for anything else. The western world needs to be innovative in order to stay competitive. China can still produce much cheaper steel, not only because of lower labour costs, but also because of looser environmental regulations.

17. The Chinese still rely heavily upon Western steel production technology. What is REDWAVE´s experience of the Chinese steel industry?

We do not have any competitors in China.

18. Where do you see most innovation in terms of production technologies – primary, secondary or further downstream?

In secondary, new innovative products will be developed that change the existing way of recycling steel – our REDWAVE XRF is just an example for such a product.

Also, downstream has a high potential for production technologies in my opinion.

There are so many companies working in the material science area.

19. How optimistic are you for the global steel industry going forward

and what challenges face global producers in the short-to-medium term?

Europe and the US may just become suppliers of niche products or high quality products if nothing changes.

20. What exhibitions and conferences will REDWAVE be attending in 2016?

REDWAVE will be attending every important exhibition and conference in the recycling area in 2016.

21. You’re based in Austria, but what’s happening steel-wise in the country?

Austria is home of voestalpine, but also many other steel producers in Europe are close to our headquarters.

22. Apart from strong coffee, what keeps you awake at night?

Jet lag when coming home from a business trip in the USA and my eight-month old son. I enjoy my last coffee at 3 pm to avoid such a problem.

23. If you possessed a superpower, how would you use it to improve the global steel industry?

If I possessed a superpower I´d reduce the emissions in all production facilities worldwide. Nothing is worse than being in a city full of smog where one is not able to see the sun or the building at the next block. t Further information, www.redwave.at Digital Edition - February 2016

2/22/16 11:43 AM

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Two powerful companies in the metals industry have forged together. Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies have united to become the new global force in metals technologies.

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