Steel Times International March 2017

INNOVATIONS

CASTING

CONFERENCE REPORT

PERSPECTIVES

Two pages of the latest product innovations for steelmakers

Near Net Shape Casting explained

by WMG, University of Warwick

Cloudy days in Rio at Alacero’s 57th annual conference

Bloom Engineering’s David Boyce answers our questions

www.steeltimesint.com March 2017 - Vol.41 No2

STEEL TIMES INTERNATIONAL – March 2017 – Vol.41 No.2

ARCELORMITTAL’S ENVIRONMENT-FRIENDLY FURNACE STI Cover march.indd 1

07/03/2017 10:31:33

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CONTENTS - MARCH 2017

1

Picture courtesy of: Leybold

INNOVATIONS

CASTING

CONFERENCE REPORT

PERSPECTIVES

Two pages of the latest product innovations for steelmakers

Near Net Shape Casting explained

by WMG, University of Warwick

Cloudy days in Rio at Alacero’s 57th annual conference

Bloom Engineering’s David Boyce answers our questions

www.steeltimesint.com March 2017 - Vol.41 No2

STEEL TIMES INTERNATIONAL – March 2017 – Vol.41 No.2

ARCELORMITTAL’S ENVIRONMENT-FRIENDLY FURNACE STI Cover march.indd 1

07/03/2017 10:31:33

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com Consultant Editor Dr. Tim Smith PhD, CEng, MIM Production Editor Annie Baker Advertisement Production Martin Lawrence SALES International Sales Manager Paul Rossage paulrossage@quartzltd.com Tel: +44 (0) 1737 855116 Sales Director Ken Clark kenclark@quartzltd.com Tel: +44 (0) 1737 855117 Managing Director Steve Diprose stevediprose@quartzltd.com Tel: +44 (0) 1737 855164 Chief Executive Officer Paul Michael SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com Steel Times International is published eight times a year and is available on subscription. Annual subscription: UK £178.00 Other countries: £254.00 2 years subscription: UK £320.00 Other countries: £457.00 ) Single copy (inc postage): £40.00 Email: steel@quartzltd.com

2 Leader What is Industry 4.0?

Furnaces 17 An environment-friendly furnace.

25 Impact of cooling on blast furnaces.

4 News The latest steel industry news.

29 Conference report Cloudy days in Rio.

6 Innovations The latest new products.

Continuous casting 34 Enhancing mold flow control.

37 Near Net Shape Casting explained.

10 USA update Trump raises steel industry hopes.

42 Perspectives: Bloom Engineering Delivering value to customers.

14 Latin America update A strategic alliance - Nucor and JFE Steel Corporation.

44 History Pre-industrial revolution ironworkers.

Published by: Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, England.

Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034 www.steeltimesint.com Steel Times International (USPS No: 020-958) is published monthly except Feb, 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 2017

ISSN0143-7798

www.steeltimesint.com

Contents.indd 1

www.futuresteelforum.com March 2017

08/03/2017 09:11:18

2

LEADER

What is Industry 4.0? Visit Future Steel Forum...

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

There are so many different views and opinions about Industry 4.0 and with this in mind, I’m glad to say that Future Steel Forum, a conference devoted entirely to digital manufacturing and steel production, is taking place on 14-15 June at the Sheraton Hotel, Warsaw, Poland.

It is precisely because there are so many wide and varied perspectives on the subject of so-called ‘smart manufacturing’ that the conference exists and it will be interesting to see what delegates take away from the two-day event.

Russian steelmaker NLMK - like many steelmakers these days - is taking the subject of ‘smart factories’ very seriously and claims that while the topic is currently ‘more of a talk than a walk’ the company is well-positioned for new trends and has listed ‘digital technologies in operations’ as a key focus area in its Strategy 2022.

Having recently attended an NLMK media briefing in London where I broached the subject of Industry 4.0, I was slightly baffled when one of my fellow journalists asked, “What is Industry 4.0?”

Having worked on the development of Future Steel Forum’s conference programme for many months, I was

surprised that the question was asked, until I realised that, for anybody outside of the bubble, it probably is a mystery.

NLMK answered that it was ‘all about how to utilise data to your advantage’ prompting the subject of labour relations to raise its head. “Labour relations is less of a concern,” NLMK replied, adding that “it is our job to retrain people and develop new skills.”

And let’s not forget that NLMK has signed a memorandum of understanding with SAP with a view to creating a Coinnovation Lab - the first of its kind in the Russian steel sector, claims the company.

SAP is one of many distinguished companies presenting papers at Future Steel Forum in the summer. Delegates can look also forward to papers from Voestalpine, ArcelorMittal and Tata Steel as well as Primetals, SMS group and Danieli Automation, plus many others.

There are two discussion panels on new business models and general perspectives on digitalisation, not forgetting sessions on business organisation, IT Infrastructure, and plant safety and cyber security.

For details of the full programme, log on to www.futuresteelforum.com

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4 NEWS IN BRIEF

Tata ferro-chrome plant commences production Tata Steel’s recently commissioned ferro-chrome plant at the Gopalpur Industrial Park in the Ganjam district of Odisha, India, commenced production on 25 February 2017.

Chromite ore is being sourced from a chromite mine in Sukinda, Jaipur, Odisha, and chromite briquettes are produced by a briquetting plant within the ferrochrome plant (and commenced production on 23 January 2017).

ArcelorMittal and Votorantim join forces The world’s biggest steelmaker, ArcelorMittal and Votorantim SA have combined their long steel businesses in Brazil, according to a Nasdaq report.

Votorantim Siderurgia, which is the name of Votorantim’s long steel business in Brazil, will become a subsidiary of ArcelorMittal Brazil, and Votorantim will hold a minority interest in ArcelorMittal Brazil.

Primetals contracted to modernise Baosteel plant Baoshan Iron & Steel (Baosteel) has contracted Primetals Technologies to modernise its continuous slab caster number 3 at its 2.3Mt/yr Shanghai steelworks no.1.

The modernisation will increase the maximum slab thickness to 357mm and is scheduled to come on stream in Q1 2018.

In 2015 Baosteel produces around 35Mt of steel.

New president and COO for US Steel Mario Longhi has been replaced as president of US Steel by David B Burritt, who has been appointed president and chief operating officer. While taking on Longhi’s role, Burritt will retain his CFO roles until the company finds a suitable replacement.

Longhi remains as CEO and will continue on the board of directors.

POSCO upgrades Pohang facilities South Korean steelmaker POSCO is to upgrade its Pohang facilities to the tune of 1.05 trillion won (US$921.11 million).

The company plans to upgrade blast furnace number three and replace electric arc furnace number three in plant two. Work commenced on 27 February.

March 2017

Industry news.indd 1

INDUSTRY NEWS

ThyssenKrupp sells CSA to Ternium German industrial and technology group ThyssenKrupp has sold its CSA Siderúrgica do Atlântico (CSA) steel plant in Brazil for €1.5 billion.

“We now generate over 75% of our sales with our profitable capital goods and services businesses,” commented Dr. Heinrich Hiesinger, CEO of ThyssenKrupp AG. Hiesinger said that the sale of CSA meant that ThyssenKrupp was parting with Steel Americas. He claimed that the sale was ‘an important milestone’ in the company’s transformation into a strong industrial group. The sale brings to a close the German industrial giant’s loss-making venture in the Americas.

ThyssenKrupp’s original plan was to produce slabs at low cost in Brazil and process and sell them in the USA and Europe. It didn’t work. Significant increases in construction costs for facilities in Brazil and the USA, technical problems with plant ramp-ups and high start-up losses placed the entire project under review as soon as Hiesinger was appointed CEO. Hiesinger said that the economic parameters changed signifi-

cantly, leading to the sale of both plants.

Costs to date have reached €12 billion in capital expenditure and start-up losses, and even after deducting the proceeds from the divestment of the plants in the USA and Brazil – and Vale’s share in the financing – a net loss of around €8 billion remains.

ThyssenKrupp sold the processing plant in the USA in 2014 to a consortium of ArcelorMittal and Nippon Steel when it was not possible to divest CSA due to complex contractual ties with former co-shareholder Vale. Those ties ended in May last year, leaving ThyssenKrupp the sole owner.

ThyssenKrupp has recently optimised the CSA plant’s facilities and operational performance and succeeded in turning a profit.

“Step-by-step we created the conditions for a good solution in Brazil, making CSA attractive to a buyer. This is also reflected in the purchase price,” said CFO Guido Kerkhoff.

Ternium operates production facilities in Mexico, Argentina, Colombia, the southern United States

Dr Heinrich Hiesinger

and Guatemala and ships 9.8Mt/yr of finished steel products.

Last year Ternium purchased approximately 3.7Mt of steel slabs from third parties. With the purchase of CSA, it will acquire additional production capacity of up to 5Mt of slabs/yr. There is also a slab supply contract agreed up to 2019, involving the annual delivery of 2Mt to an ArcelorMittal/Nippon Steel plant in the USA.

Crude steel production up 7% World crude steel production for the 67 countries reporting to the World Steel Association (worldsteel) was 136.5 million tonnes (Mt) in January 2017, a 7.0% increase compared to January 2016.

China’s crude steel production for January 2017 was 67.2 Mt, up 7.4% compared to January 2016, according to figures released by worldsteel.

The apparently high percent-

age figure, claims worldsteel, is explained by the fact that January 2016 saw a marked dip in Chinese steel production. Japan produced 9 Mt of crude steel in January 2017, an increase of 2.7% when compared with January 2016.

German crude steel production was up 1.2% to 3.6 Mt, while Italy produced 1.8 Mt of crude steel, up 0.3% when compared with January 2016. In Spain 1.2 Mt of

crude steel was produced, down 4.2% when compared with January 2016.

Turkish crude steel production last month was up 12.8% at 2.9Mt. Russian crude steel production in January reached 6.2 Mt, an 11.6% increase over January 2016, while in the Ukraine 2.1 Mt of crude steel was produced, up 8.5% compared to January 2016.

The USA produced 6.9 Mt of crude steel last month, an increase of 6.5% compared to January 2016. Crude steel production for January 2017 in Brazil was 2.9 Mt, up 14.4% on last year.

Last month's crude steel capacity utilisation ratio of the 67 countries reporting to worldsteel was 68.5%. This is 3.4 percentage points higher than in January 2016. Compared to December 2016, it is 0.9 percentage points higher. www.steeltimesint.com

07/03/2017 10:40:52

INDUSTRY NEWS

Big River Steel plant up and running Big River Steel officially opened its new steelmaking plant in Osceola, Arkansas, USA, on 1 March. The site will produce steel grades for pipelines, silicon steels for electronic sheets and advanced high strength steels for the automotive industry in the USA. German steel production technology giant SMS group supplied all the equipment for the plant and provided process know-how as well as support during the commissioning phase.

Speaking at the opening ceremony, Big River’s CEO David Stickler said he was satisfied with progress. “Having SMS group by our side we are sure to achieve our ambitious project targets,” he said.

SMS group’s chairman of the

management board, Burkhard Dahmen, said that a strong and trusting partnership with Big River Steel had been crucial to the plant’s good production start. He said that because SMS group supplied the complete process chain, it was able to meet the challenge of providing all the required mechanical equipment and the electrical and automation systems.

“Harmonised process sequences and the use of cutting edge technology are basis and proof of the good ramp-up curve,” Burkhard said. “SMS group supplied the complete know-how needed to produce the latest steel grades.”

The mill’s phase one capacity is 1.6Mt/yr and there are several expansions planned to boost output to 4Mt/yr.

Twin-ladle furnace in operation at Big River Steel, Osceloa, Arkansas

Funding for green steel production The Swedish Energy Agency (SEA) is to finance a four-year research project initiated by SSAB, LKAB and Vattenfall and designed to create a carbon-dioxide-free steel industry.

The three main players – steelmaker SSAB, minerals company LKAB and Swedish electricity generator Vattenfall – have announced the formation of a corporate joint venture in the spring to spur on the initiative.

In total, funding of SEK102 million will be available for the project.

According to Jan Moström, CEO and group manager of LKAB, the decision by the Swedish Energy Agency to fund the project is a ‘real inspiration’ while Martin Lindqvist, CEO and group manager of SSAB, described it as ‘very exciting news’. Magnus Hall, CEO and group manager of power generator Vattenfall called it ‘extremely positive news’.

The SEA’s decision to provide additional funding on top of its initial SEK7.7 million (US$853,000) will open the door for new research projects by organisations such at KTH, Lulea University of

Martin Linqvist

Technology, SWEREA MEFOS, Lund University, Stockholm Environmental Institute and RISE, all of whom will work towards a carbon-dioxide-free steel industry.

Processes such as fossil fuel-free pellet manufacturing, hydrogen-based direct reduction, and the use of sponge iron in electric arc furnaces will all be scrutinised by the research project. Providing an electrical power supply source for hydrogen manufacturing and

storage will also be examined.

The funding is broken down into two chunks of money: SEK56 million (US$6.2 million) from the SEA; and the remaining SEK46 million (US$5 million) coming from SSAB, LKAB and Vattenfall.

Erik Brandsma, director general of SEA said one of the biggest challenges faced with global warming is reducing industrial use of fossil fuels.

“Investigating how to replace coal and coke with hydrogen in the Swedish iron and steel industries is both an obligation and a unique global opportunity to improve our competitiveness in the future,” he said.

The project covers three phases with a pre-feasibility study running through to the end of 2017 followed by research and testing in a pilot plant through 2024, which involves carrying out testing in a full-scale demo plant through 2035.

According to SSAB, “Sweden is ideally suited for this type of initiative with its specialised, innovative steel industry, access to fossil fuel-free electrical power, and Europe’s highest quality iron ore.”

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

Industry news.indd 2

DIARY OF EVENTS

5

April 2017 20-22 India Steel 2017, Mumbai Exhibition Centre, India A joint initiative taken by the Ministry of Steel, Government of India and Federation of Indian Chambers of Commerce and Industry (FICCI).

For further information, log on to www.indiasteelexpo.in 20-22 India Steel 2017, Mumbai Exhibition Centre, India Organised by the Ministry of Steel, Government of India, this is an event for the steel and related industries. The organiser claims that the event offers ‘tremendous opportunities’ for participating companies to enhance their brand value.

For further information, log on to www.indiasteelexpo.in 26-27 5th World DRI and Pellet Congress, Park Hyatt, Dubai, UAE The streamlining of sustainable steelmaking, procurement and burdening – all subjects up for discussion at this Metal Bulletin event.

For further information, log on to www.metalbulletin.com/events/

May 2017 8-11 AISTech 2017, Nashville, USA The best way to describe this event is ‘a major global steel event with an American flavour’.

Not only is there are healthy and comprehensive conference programme, but also major forums attended by the great and the good of the American steel industry. Don’t miss it!

For further information, log on to www.aist.org

November 2017 14-17 Metal Expo, Hall 75, VDNkHa, Moscow, Russia This is one of those big, mustattend events. Last year the event attracted 530 companies from 32 countries, including steelmakers, tube and pipe manufacturers and distributors and engineers.

Expect a similar deal this year. In fact, there’s so much going on, you’d better check the website.

For further information, log on to www.metal-expo.ru

March 2017

07/03/2017 10:40:54

6

INNOVATIONS

Spray nozzles for continuous casting Lechler’s new air mist nozzle, the Billetcooler FLEX, is characterised by its constant spray angle over the entire turn-down ratio, says Lechler.

In addition, the liquid distribution can be set dynamically, according to the strand format, by controlling water and air pressures.

Lechler claims that these ‘innovative features’ offer greater process flexibility as local heat extraction can be increased or reduced. “This means an additional actuator for optimal cooling is now available,” claims the company.

Lechler has also developed water-only nozzles for secondary cooling. Its new full cone series 490 nozzles, which have large free cross-sections, provide the nozzles with ‘true non-clogging characteristics’.

Reduced nozzle clogging means higher operational safety and improved product quality due to more uniform cooling and reduced maintenance costs.

For further information, log on to www.lechler.de

A reproducible method of heating and testing Primetals Technologies’ automatic thermocouple checker is claimed to offer operators of continuous casting plants a standardised and reproducible method of heating and testing thermocouples in the copper plates of molds.

Unlike conventional test methods – such as those reliant upon gas torches – potential damage of the copper plates is eliminated.

Each thermocouple belonging to a mold is tested under identical conditions and almost fully automatically, Primetals explains. Uniform heating of the couples can identify defective elements and determine poor thermal contact caused by soiling or insufficient pressing force on the thermocouple. For quality management purposes, measured data gathered can be stored for later evaluation.

Temperature distribution in the mold is measured with the aid of thermocouples and must be as precise as possible to ensure

that any sticking in the mold is quickly detected. Sticking can lead to openings in the cast shell, resulting in damage averaging 100,000 euros.

Thermocouples have traditionally been tested by various manual methods including the use of gas torches. Individual thermocouples are heated up to different extents, making interpretation of the measured results difficult. Moreover, heating of thermocouples can damage the copper plates of the molds.

The use of blow heaters can result in a lower effective heating output on the copper plate and extend the time needed for measurement.

Primetals’ automatic thermocouple checker detects defective thermocouples and poor contact between the thermocouple and the copper plate. The computer-aided test process supports optimum installation of thermocouples, which reduces to a minimum the replacement

of molds and thus reduces maintenance.

Measured data gathered can be stored for later evaluation.

The system’s measurement arm is moved to a defined thermocouple column for testing and then automatically heats one thermocouple after the other; the temperature reached is measured. Once testing of the copper plate is completed, a report is generated to indicate correct or defective functioning of the thermocouples. Narrow and broad sides of molds can be tested equally and it can test one single mold plate or check the complete mold.

The automatic thermocouple checker is delivered as a transportable unit. The basic system consists of a heating arm that is mounted on a linear guide and a measuring and evaluation unit and is connected to the thermocouple connectors on the mold.

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

Castolin’s XuperCOAT for best-in-class mould wear resistance in continuous casting Mould coatings are a crucial part in continuously improving product quality and reducing operating cost in the continuous steel casting process.

Already 30 years ago, Monitor Coatings (UK), part of Castolin Eutectic, first developed a high performance ceramic composite coating technology XuperCOAT. It delivers best-in-class results in terms of mould life time, cast product quality and caster operating costs.

Continuous developments of the technology now enable the application of such coatings on all types of moulds including bloom and billet tubes.

Innovations.indd 1

XuperCOAT coatings, capable of functioning in extreme environments of high temperature, abrasion, fatigue and friction, show significant technical and commercial advantages compared to other thermal spraying systems.

XuperCOAT, it is claimed, demonstrates superior results such as higher thermal conductivity, hardness and ductility due to minimal phase transformations, thermal shock resistance and surface finish and lower friction due to thermochemical post treatment.

Stainless and carbon steel longs and flats producers reported yield increases in cast steel on the same mould in the range

07/03/2017 14:54:57

7

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of 2 to 8 fold compared to other solutions. With such low wear rates, there are marked improvements in the downstream surface quality of the billets and slabs, while the integrity of the original copper mould asset remains maintained.

Moreover, customers identified additional benefits of the application of XuperCOAT such as improved cast product quality due to less star and corner crack defects, less strand shape issues, stickers and sticker breakouts as well as reduced operating cost thanks to lower consumption of copper moulds and mould flux powder and fewer wear-related enforced stoppages.

Furthermore, XuperCOAT, being compliant with European Legislation (REACH), is claimed to be the most efficient and reliable alternative for steel makers moving away from electroplating, which will soon become obsolete under those regulations.

Castolin Eutectic will be present from 8 - 11 May 2017 at AISTECH in Nashville, USA, and from 26 - 29 June 2017 at the European Continuous Caster Conference in Vienna, Austria.

Non-contact Length and Speed Measurements Improve yield, reduce scrap, and increase profits. Polytec’s Laser Surface Velocimeters measure surface velocity and length from a safe distance without contact. Measure with Confidence!

Learn more: www.velocimeter.us

For further information, log on to www.castolin.com POLAZ-17004_LSV_engl_87x265mm.indd 1

Innovations.indd 2

March 2017

28.02.17 14:36

07/03/2017 14:55:02

REAL ENDLESS STRIP PRODUCTION - REAL SUCCESS • Save capital expenditures: first coil within 15 months of contract signing, FAC within 22 months • Lower your operating costs: only 124 kWh/t needed for the production of 2 mm thin and 1.500 mm wide strip • Target premium steel grades: outstanding geometrical, metallurgical, and surface quality for all thicknesses

WORLD RECORD in thin production

50

Production (%)

“WHY CHOOSE THE ORIGINAL THE SECOND-BEST ARVEDI ESP WHEN PRIMETALS TECHNOLOGIES OFFERS YOU REAL ENDLESS STRIP PRODUCTION.”

… can be achieved with the patented ARVEDI ESP technology.

40

36%

30 22%

21% 20

15%

10

6%

0 0.8 - 1.0

1.0 - 1.2

1.2 - 1.5

1.5 - 3.0

> 3.0

Strip thickness (mm) WORLD RECORD - 57% below 1.2 mm

THE NEW STANDARD IN HOT-STRIP PRODUCTION To meet the requirements of today’s steel industry, innovative technologies are called for.

At Primetals Technologies, we strive to be your partner in the manufacture of ultra-thin steel products and high-quality steel grades through the patented Arvedi Endless Strip Production (ESP) technology. Our know-how and experience will ensure a lower carbon footprint of your facilities, reduced operating costs, outstanding product quality, and overall success. Mr. Du, chairman of Rizhao Iron and Steel Co. is a satisfied customer with five original Arvedi ESP lines.

primetals.com

Mr. Du, Chairman Rizhao Iron and Steel Co., Ltd., China

Below 1.2 mm

Above 1.2 mm

REAL ENDLESS STRIP PRODUCTION - REAL SUCCESS • Save capital expenditures: first coil within 15 months of contract signing, FAC within 22 months • Lower your operating costs: only 124 kWh/t needed for the production of 2 mm thin and 1.500 mm wide strip • Target premium steel grades: outstanding geometrical, metallurgical, and surface quality for all thicknesses

WORLD RECORD in thin production

50

Production (%)

“WHY CHOOSE THE ORIGINAL THE SECOND-BEST ARVEDI ESP WHEN PRIMETALS TECHNOLOGIES OFFERS YOU REAL ENDLESS STRIP PRODUCTION.”

… can be achieved with the patented ARVEDI ESP technology.

40

36%

30 22%

21% 20

15%

10

6%

0 0.8 - 1.0

1.0 - 1.2

1.2 - 1.5

1.5 - 3.0

> 3.0

Strip thickness (mm) WORLD RECORD - 57% below 1.2 mm

THE NEW STANDARD IN HOT-STRIP PRODUCTION To meet the requirements of today’s steel industry, innovative technologies are called for.

At Primetals Technologies, we strive to be your partner in the manufacture of ultra-thin steel products and high-quality steel grades through the patented Arvedi Endless Strip Production (ESP) technology. Our know-how and experience will ensure a lower carbon footprint of your facilities, reduced operating costs, outstanding product quality, and overall success. Mr. Du, chairman of Rizhao Iron and Steel Co. is a satisfied customer with five original Arvedi ESP lines.

primetals.com

Mr. Du, Chairman Rizhao Iron and Steel Co., Ltd., China

Below 1.2 mm

Above 1.2 mm

10

USA UPDATE

Trump raises

steel hopes

Going by his election rhetoric on job creation for American workers and curbing foreign steel imports Donald Trump’s election victory may have raised the hopes of the US steel industry, but it is also causing trepidations among foreign suppliers. By Manik Mehta* CRITICS of Trump’s plans claim they present a threat of imposing punitive duties on imported steel and could easily unleash a trade war.

After axing the Trans-Pacific Partnership (TPP), Trump wants to renegotiate the existing North America Free Trade Agreement (NAFTA) with the two other trading partners, Canada and Mexico, both of whom have signalled their displeasure over such a prospect.

Trump said the decision was aimed at keeping jobs in the US, but Wood Mackenzie consultancy argued that the country has gained more from its steel exports than what it spent on imports.

Wood Mackenzie pointed out that in 2015, around 30%, or 11Mt, of all steel imported into the US came from the countries in the TPP at a value of approximately $11 billion. At the same time, 89%, or around 9Mt, of steel exported from the US was destined for these countries – at a value of approximately $12 billion.

This implies that while its volume may have been less, the US sold higher valueadded steel, the kind of steel that sustains high-cost US steelmaking.

But there is delicious irony in the fact that the US steel industry also relies on imports to keep costs to a minimum; if steel was sourced domestically, the high-priced domestic steel would put pressure on manufacturing costs, leading eventually to wiping out jobs.

Another disadvantage is that domestic steel would not be instantly available. Thus, renouncing foreign steel imports would not only pressurise manufacturers’ costs – the US consumer would have to bear the extra costs in the end – but also cause considerable supply delays.

In a recent meeting with small companies, Trump emphasised that steel pipe manufacturers should use US materials if they are involved in projects in the US, making it clear that he wanted pipeline companies to not only purchase US fabricated pipes but also use raw steel produced in the US. This call could not have come at a worse time, particularly because some manufacturers already face pressures of rising raw-steel costs resulting from efforts to stop imports of cheap steel supplied to the US market.

Trump issued a so-called presidential memo to the Commerce Secretary to draw a plan requiring any company that builds a pipeline within US borders to use Americanmade materials and equipment.

Later, at a retreat for Republicans, Trump said that if “people want to build pipelines on our land, we want the pipes … to be manufactured here”.

While the Cato Institute’s Herbert A. Stiefel Centre for Trade Policy Studies and other institutions have called this requirement a “very bad precedence”, the Association of Oil Pipelines said that US assembled pipes, pumps and valves typically contained both US and foreign parts,

adding that the association concentrated on ensuring that manufacturers used materials that conformed to quality and safety standards.

The President’s “America First” call has also fetched criticism from free market proponents who argue that such a move could provoke retaliation from trade partners and have an overall effect on the US economy. While voicing their misgivings against Trump’s views, they also felt that the President would not enforce the requirement, and was merely reassuring his voter base. Trump’s words, if translated into action, would be a violation of established global trade norms and deals, stipulating that a government should treat foreign companies at par with US companies.

Besides, no past US president has required private companies to use US manufactured materials or equipment, aside from wartime situations, according to Cato; also, this is a private sector investment over which the government did not exercise any legal authority to prescribe to companies where to source their materials, not to mention the surge in costs such a move would trigger.

One of the tricky issues that Trump will have to grapple with, assuming he is serious about the “America First” imposition, is that his move could violate the World Trade Organisation’s Government Procurement Agreement, which has restrictions on providing protection or special treatment to domestic suppliers or discriminating

* USA correspondent March 2017

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07/03/2017 14:48:46

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USA UPDATE

against foreign companies, goods and services. It remains to be seen if Trump’s memorandum provides room for manoeuvre.

But some experts privately told Steel Times International that the ‘Buy America’ principle has been in place, in some form or the other, for nearly four decades; consequently, one cannot pinpoint exactly if such provisions have had an impact on jobs or production in the nation’s steel sector.

Hard, accurate evidence substantiating the impact is mostly not available, partially because of the negligible impact on the overall economy and the overall growth in steel demand. Indeed, the data available so far indicated that the steel used under the ‘Buy America’ principle represented a mere fraction of overall domestic steel demand.

Support for Trump’s idea came from Thomas Gibson, president of the American Iron and Steel Institute, a national industry advocacy group, in a statement praising Trump for his focus on American steel.

“Taken together,” he said, “building these pipelines, ensuring key markets for domestic steel and pipe products, and lowering the burdens to manufacturing in the US, will help ensure that our industry remains highly

productive and internationally competitive.”

While the beneficiaries of the ‘America first’ rules would be US steel producers, critics find it troubling that the administration’s strong advocacy was tantamount to protectionism which could strain trade relations.

Besides doubts over the US steel industry’s capability to produce the huge volume of pipes needed for some of the larger projects in the works, there are questions about what the directive might mean for those projects, including at least one in Pennsylvania, already using, or already having ordered foreign-made steel.

The aforementioned Atlantic Sunrise pipeline, which is yet to be approved, will transport Marcellus Shale gas from Susquehanna County in northeastern Pennsylvania to as far south as Alabama and to the Cove Point export terminal on the Chesapeake Bay. The company constructing the pipeline, Tulsa-based Williams Partners, had already purchased foreign-made steel for the project because the huge volume of steel needed, according to company representatives, could not be met from local suppliers because of heavy demand for steel

pipes.

Pundits expect that President Donald Trump’s executive orders pushing construction of the Keystone XL and Dakota Access oil pipelines will boost demand for steel in the country. On another note, the recent acquisition by Dura-Bond Industries of the manufacturing facility of an idled US Steel Corp. plant in McKeesport, which is expected to go into operation this year, has generated some optimism in the industry.

Dura-Bond was hoping to hire about 100 workers to get the mill started in a matter of six to nine months.

For the McKeesport plant, this is a new lease on life; the plant was idled on 2 June, affecting some 260 jobs after US Steel said unfairly imported tubular steel products were hurting its business. Dura-Bond will be starting from scratch at McKeesport and building its team from the ground up. The company has previous acquisition experience: in 2003, it purchased an idled Bethlehem Steel pipe mill in Steelton and revived it. The oil and gas industry is a major part of Dura-Bond’s pipe business.

The 550-mile Atlantic Coast Pipeline in Virginia and North Carolina will be built with Dura-Bond pipes. �

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14

LATIN AMERICA UPDATE

A strategic alliance In June 2016, Nucor and JFE Steel Corporation announced an agreement to establish Nucor-JFE Steel Mexico, a 50:50 joint venture. This article discusses the motivations of the partnership. By Germano Mendes de Paula* NUCOR-JFE Steel Mexico (NJSM) will build a new 400kt/yr continuous hot-dip galvanising (HDG) line, in central Mexico, focusing on servicing the automobile market, at a cost of $270M. The plant is expected to start-up in the second half of 2019.

There are various steel finishing facilities (downstream plants without the production of crude steel) that belong to international joint ventures. In Latin America Nippon Steel & Sumitomo Metal Corporation (NSSMC) has minority stakes in Unigal (in association with Usiminas in Brazil) and Tenigal (in partnership with Ternium in Mexico).

Mexico is a very attractive market for HDG investment because of the high degree of dynamism observed by the country’s automotive industry over the last six years.

Fig.1 demonstrates that, based on statistics from the International Organisation of Motor Vehicle Manufacturers (OICA), Mexican automotive production (cars and commercial vehicles) diminished from 1.9 million in 2000 to 1.6 million over the 2003-2005 period. In 2010, it reached 2.3 million, which was only 21% higher than 2000 (or 1.9% CAGR). However, it skyrocketed to 3.6Mt in 2015 (or 8.8% CAGR). Additional 2% expansion was verified in 2016, according to the Mexican Association of the Automotive Industry (AMIA).

Fig.2 shows that Mexican participation in global automotive production contracted from 3.32% in 2000 to 2.45% in 2004.

This ratio was 3.02% in 2010 and 3.93% in 2015, stressing outstanding performance in the first half of this decade. Considering data related to the first semester of 2016, the country’s share diminished marginally

to 3.74%.

According to AMIA, in the period 20102015, $21bn were invested in the sector, resulting in the start-up of six new vehicle and motor assembly plants, the production capacity expansion of five plants already in operation, and the attraction of a bigger number of direct suppliers around the new developments.

Automakers have been attracted to Mexico’s low labour costs to produce small sedans, which offer slim profit margins compared to trucks, SUVs and luxury cars.

In 2015, Mexico was the seventh largest car producer globally and the second largest exporter to the USA. It is crucial to highlight that 80% of Mexico’s light vehicle production was exported in 2016, with 77% of exports going the USA and 9% to Canada.

Looking at the next five years, Fig.3 presents two forecasts. AMIA predicts that Mexican automotive production will reach 4.6 million in 2018 and even 5.3 million in 2020. For the consulting firm IHS Markit, the respective figures are 4.5 million and 4.9 million, and this illustrates quite remarkable market growth. However, it must be emphasised that both projections

were elaborated before the election of Donald Trump.

It is estimated that Mexican galvanised sheet demand expanded from roughly 1.4Mt in 2000 to 4.0Mt in 2016.

Meanwhile, the nation’s production rose from 1Mt to 2.3Mt and net imports enlarged from 0.4Mt to 1.7Mt. Therefore, even without any additional consumption, there is a considerable stimulus for investing in HDG in Mexico. According to market participants, local production will improve by 400kt up until 2018, which is insufficient to eliminate net imports.

The partnership A typical HDG joint venture consists of an established local steelmaker (responsible for the supply of substrate and commercialisation) and a foreign one (that detains high-value technologies and strong links to customers, particularly automakers).

In general, this kind of partnership has only two investors. However, there were some cases of tripartite associations, such as: a) Segal: originally belonged to CockerillSambre, Sidmar/Arbed and Hoogovens, in Belgium; b) Galmed: constructed by Ensidesa, Usinor and Thyssen, in Spain; c) Baosteel-NSC/Arcelor Automotive Steel Sheets (BNA): initially was controlled by Baosteel, Nippon Steel and Arcelor, in China; d) DNN Galvanising: a plant primarily detained by Dofasco, NKK and National Steel, in Canada.

One distinct characteristic of NJSM is that neither Nucor nor JFE Steel produce crude steel, hot rolled coils (HRC) or cold rolled coils (CRC) in Mexico. This is quite unusual where HDG international joint ventures are concerned, although someone can argue this dissimilarity is not so important because

* Professor in Economics, Federal University of Uberlândia, Brazil. E-mail: germano@ufu.br March 2017

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LATIN AMERICA UPDATE

Mexico is part of NAFTA. However, there are substantial trade barriers (anti-dumping measures) between Mexico and the USA for steel products. Because of lack of domestic CRC, the two investors aim to provide equal amounts of substrate for processing by the joint venture.

JFE’s investment in the Mexican HDG market is based on a finishing facility, which is often known as ‘follow-mycustomer strategy’. “JFE Steel has been seeking a manufacturing base in the region, the largest overseas market for Japanese automakers,” the company claims. Currently there are four Japanese automotive producers in Mexico: Nissan, Toyota, Honda, and Mazda. In 2016, Nissan had a 24.5% production share, 4,0

followed by Honda (7.3%), Mazda (4.3%) and Toyota (4.0%). As a consequence their joint participation in Mexican automotive production was equivalent to 40.1%.

JFE’s statement stated: “Nucor has an established business base in the NAFTA region and expertise in the efficient running of steel plants, while JFE Steel has the technology to produce high quality auto steel sheet”. Currently, Nucor has a presence in the Mexican sheet market via NuMit, which is also known as Steel Technologies. In 2010, Nucor purchased 50% of Mitsui’s assets in North America, comprising 23 sheet-processing facilities in the USA, Canada, and Mexico. Since then, it has grown its flat-rolled operations to include Celaya, Bajío and Monterrey. It

should be stressed that NuMit and NJSM are 50:50 joint ventures between Nucor and a Japanese company.

John Ferriola, CEO of Nucor, declared at last year’s Steel Success Strategies XXXI Conference in New York, that NJSM dispels the myth that mini-mills can’t produce toptier automotive steel. The partnership will allow Nucor to expand its business into the supply of high-grade steel for automobiles.

Last month Ferriola acknowledged that the plant could be constructed in a different location, due to threats from President Trump to impose high border tax on imports from Mexico. Nevertheless, the plant is currently planned to be erected in Mexico. The construction of the mill is scheduled to start in May or June this year.� 6 5

4,0 3,6

3,0

4

3,2

3

2,8

2

1,0

2,4

1

0,0

2,0 2000

2,0

2000

2002

2004

2006

2008

2010

2012

2014 2016e

0 2002

2004

2006

2008

2010

2012

2014 2016e

Source: International Organisation of Motor Vehicle Manufactur-

Fig 2. Mexico’s participation in world automotive production, 2000-2016 (%)

ers (OICA) and Mexican Association of the Automotive Industry

Source: OICA. Note: 2016 based on first half’s performance.

Fig 1. Mexico’s automotive production, 2000-2016 (M).

15

2016

2017 AMIA

2018

2019

2020

IHS Markit

Fig 3. Forecasts about Mexico’s automotive production, 2016-2020 (M). Source: AMIA, IHS Markit

(AMIA). Note: e = estimated

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07/03/2017 16:18:39

Innovative technologies for the metals industry

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FURNACES

17

An environment-friendly furnace ArcelorMittal Hamburg’s decision to choose an environmentally friendly, high performance/low emissions walking beam furnace for 16.5 m special steel billets could offer up the benchmark for quality and operational costs in long products heating systems. By A Biliotti* and D Garassino** A Danieli Centro Combustion (DCC) furnace equipped with a control system supplied

by Danieli Automation has been chosen by ArcelorMittal Hamburg.

The furnace has been designed for safe and reliable operation and offers a thermal profile that achieves optimum heating efficiency thanks to improved convective heat exchange in the furnace’s unfired zone. Proprietary flameless burners, supplied by DCC, reduce the environmental impact of the equipment.

The ‘state-of-the-art’ equipment, coupled with Danieli Automation’s fully automatic control logic, will allow the most flexible reheating practices to match production mix requirements at the plant for low and medium carbon, bearing, spring and cold heading steel.

During the next shutdown period, the existing mill will be connected to the new furnace and this will allow the steelmaker to increase the weight of coil to 2 tonnes and

Fig 1. Discharging of a billet

improve productivity and efficiency at the special steel wire rod mill on-site.

A walking beam furnace for billets The walking beam furnace supplied by DCC guarantees a production rate of 175 tonnes/hr at a discharging temperature of 1,250°C. The furnace can achieve a 235 tonnes/hr production capacity meaning that ArcelorMittal Hamburg can increase production going forward by acting on the installed thermal power.

The furnace can process a wide range of products including 140x140 mm billets with lengths ranging from 9m to 16.5 m.

Products are charged into the furnace in a single row with processed steel grades ranging from low carbon to more valuable metals such as 100Cr6, 34CrMo4, 42CrMoS4, 30NiCrMo3.

The furnace has six combustion control zones which include two types of burners (frontal for the walls and radiant

for the roof designed using Ultra Low NOx technology) with different heating capacities according to zone requirements.

This configuration ensures the best heating quality and the fastest response time when a change in production is required.

Frontal MAB burners (Multi Air Burners) are designed to operate with PHL (Proportional High Low) control logic to create optimal conditions at all operating levels. This is achieved by cyclically turning the burners on and off to reduce thermal flow according to requirements. This results in higher process heating quality and easier furnace management.

MAB and radiant burners rely upon flameless technology to reduce NOx emissions, while offering a more uniform heating in all burner areas.

DCC will supply ArcelorMittal Hamburg with all the necessary handling equipment upstream and downstream of the furnace from billet charging on the stock yard to

Fig 2. General Overview of a walking beam furnace

* Danieli Centro Combustion, process engineer ** Danieli Automation, design engineer – process Control Systems www.steeltimesint.com

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07/03/2017 14:17:41

18

FURNACES

Fig 3. Staged combustion; semi-visible flame

Fig 4. Flameless combustion; invisible flame

the first stand of the rolling mill, including pawl tables, transfer devices, weighing and measuring systems, reject devices, diverter and pinch roll.

To minimise material and energy loss, DCC’s and DA’s combined technology ensures that no billet is rejected in the case of mill cobles: along the 90-metre long rollerway between furnace and pinch roll, machines and logics have been designed to have constant control of billet temperature, and in case of mill stoppage, up to two billets can be charged back in the furnace.

temperature. Unfortunately, combustion temperature amplifies NOx emissions.

For this reason, over the past few years innovative combustion technologies have been developed, with the aim of maintaining high burner efficiency and reducing polluting emissions into the environment. Two of these technologies are “staged combustion” and “flameless combustion”.

DCC’s R&D department has been particularly active in this field, with theoretical simulations and experimental campaigns (research furnace exclusively dedicated to burner testing), which have enabled a complete range of highperformance burners to be developed.

The main advantages of flameless combustion are: • Significant reduction of polluting emissions • Uniformity of flame temperature, therefore higher product quality • Increased furnace efficiency • Reduction of combustion noise.

Flameless burners New burner design has been greatly influenced by national and international norms and regulations concerning environmental protection: a modern burner guarantees optimal efficiency while complying with ever-decreasing limits on pollutant concentrations in waste gas exhausts.

Furnace efficiency is generally increased by pre-heating combustion, a technique that recovers part of the heat from the exhaust fumes, while increasing flame

DCC has developed a new generation

burner that guarantees extremely low NOx emissions and uniformity over the entire operational range and for any temperature of the furnace chamber. This is achieved by using two different combustion techniques: staged combustion (below self-ignition temperature) and flameless combustion (above self-ignition temperature).

The fundamental concept, which is common to both techniques, is to minimise temperature peaks and oxygen presence in the combustion reaction by diluting the reacting gases with those that have already been combusted.

Staged combustion is performed by injecting combustion air in different steps, thereby obtaining a primary combustion zone which is rich in fuel (reducing zone), and a secondary combustion zone rich in air (oxidising zone), however highly diluted by fume recirculation; this allows a gradual and complete combustion, avoiding the coincidence of high oxygen content and high reaction temperature. The system is based on the specific geometry of the air diffuser inside the burner, which leads the primary and secondary air flows to the different combustion zones, with the appropriate speed and angle. This type of staged combustion permits a substantial reduction in NOx emissions and the high recirculation factor reduces the temperature gradient along the flame length (Fig. 3).

Once the furnace temperature is above the self-ignition temperature, the flameless combustion mode can be activated, by switching gas entry to a separate gas lance while keeping the same air feeding. The special fluid-dynamic design and the high gas and air speeds further increase flue gas recirculation and cause an expansion of the

120 NOx [ppm]

Models Semivisible flame

Communications

Double air staging combustion

- Product - Chamber - Metallurgical

- Other automation systems

- Static - Dynamic

60

Visible flame Flameless combustion 0 800 Standard 1% O2

9800 Standard 2% O2

1000 Standard 3% O2

1100 Flameless 1% O2

1200 Flameless 2% O2

Fig 5. NOx emissions (ppm), measured with natural gas firing

March 2017

furnaces arcelormittal.indd 2

User interfaces

Tracking - Entry area - Exit area - Furnace area

Control loops

Level 2

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1300 Flameless 3% O2

Fig 6.Level 2 architecture

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07/03/2017 14:17:43

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FURNACES

Fig 8. Continuous emission monitoring system.

Fumes

Trends & monitoring (PC/server)

Probes

Fig 7. Typical online overview page of Level 2 client application.

Analyser

Acquisition (PLC)

Carbon steel

Fig 9. An example of furnace consumptions in the long run

Specific consumption [Sm3/t]

30 25 20 15

T-disch T-target

10 5

Fe 55

0 0/100 101/200 101/200 201/300 301/400 401/500 501/600 601/700

Fe 41 Fe 37 Fe 34 >701

Charging temperature [°C]

reaction process to a larger volume; the low oxygen content in the reaction ensures a diluted combustion that makes the flame invisible (Fig. 4).

Burner performances Fig. 5 shows experimental measurements of NOx emissions as a function of furnace temperature and air excess (evaluated in terms of O2 content in the fumes); the three curves in the upper left refer to the staged combustion mode, while the three curves in the lower right refer to the flameless mode. The best NOx performance is obtained by operating the burner in the green areas: staged combustion is used for heating up the furnace, and in pre-heating zones working at low temperature; at higher temperatures the burner is switched to flameless combustion, which cuts emissions by 50%.

Another advantage of the DCC flameless burner is increased uniformity of furnace March 2017

furnaces arcelormittal.indd 3

RM lastpass

Steel grade

Fe 50 Fe 45 Fe 41st

Fig 10. An example of correlation between furnace target, model temperature and measured temperature at rolling mill

temperature. This implies an improved temperature uniformity in the furnace charge, and higher quality final products.

The burner has proven to be extremely flexible and can be used either with high calorific value fuels (such as natural gas) or with low calorific value fuels; combustion air can be pre-heated to temperatures in excess of 500°C, in order to increase combustion efficiency and overall furnace performance.

Optimisation model Danieli Automation (DA) Furnace Level 2 is a software package consisting of several modules that work in real time in order to optimise the reheating process. They can be grouped into the following tasks: • Material tracking and communication with other systems • Process Models • Process Control • User interface

The use of instruments to measure billet temperature in a furnace has always been debated. As the noisy environment makes a direct measurement very difficult, a mathematical model of the heating process is used as a virtual sensor and, in the same time, it is applied in the set-up of the control strategy as explained below. It is based on a finite difference model in order to evaluate material bulk temperature and uniformity. All the relevant thermo-physical characteristics of steels and interactions within the furnace chamber and among billets are considered for the calculation of temperatures when the mathematical model is used as virtual sensor.

The furnace model is used for the control strategy based on a Model Predictive Control (MPC) technique. It uses a feedforward algorithm to estimate furnace behaviour from its actual condition and evaluates the proper actions needed to get the desired product output, while fulfilling constraints and optimising furnace performances. In fact the heating process is slow and requires the right amount of energy and time to be given to the products. In addition the state of the furnace is not observable until the end of the process, when it is too late to get any correcting action. www.steeltimesint.com

07/03/2017 14:17:45

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30 20 10

Intelligence: utilise information and knowledge to improve the process

0

11 minutes 51 seconds

Knowledge: is a combination of information, experience and insight Information: is data endowed with relevance and purpose Data: raw data is not information

Fig 12. Q3 intelligence concept Last hot billet

13:30

First cold billet

13:35

The first aim of MPC is to automatically calculate furnace set points in order to minimise the difference between the mean product temperature and their heating practice.

Heating practices describe the heating rules for each product and are open to process engineers, who can manage them in order to achieve the desired results, like fuel consumption saving or following special heating strategies (low decarburisation, alloyed steels, …).

Continuous emissions monitoring A dedicated system for combustion monitoring installed in the chimney provides online fumes Typical monitored emissions are nitrogen oxides (NOx), carbon monoxide (CO), carbon dioxide (CO2) and sulfure oxides (SOx). These values can be stored by a trending system (Danieli Automation HMI server and/or Danieli Automation Fast Data Analyser) and can be used for certification according to the regulation in force.

Quantity, quality and quickness DA’s design concept is based on the Q3 formula: • Quantity • Quality • Quickness Such an approach, fully in line with the Industry 4.0 paradigm, introduces the data-driven philosophy exploiting the hidden value of the usual parameters for process control. In fact, even if obtaining a quantitative estimation of consumption savings is immediate, additional constraints can be addressed by applying online and real time multi-objective techniques. In March 2017

furnaces arcelormittal.indd 4

Fig 11. An example of hot/cold job transitions within a furnace and result at rolling mill

this context, DA’s online control system maximises furnace efficiency and directly acts on environmental impact and other aspects. Proper combustion ensures that emission limits are met and production yield is increased as a consequence of reduced weight loss due to scale formation.

Quality is commonly considered a competitive factor. Danieli Automataion Level 2 focuses on achieving the temperature and uniformity required by a rolling mill. This is the first step that is necessary to obtain the desired mechanical properties at the end of the overall process.

Quality assurance is made possible by a reporting system that provides all the necessary data for periodical evaluation of the furnace, such as fuel-specific consumption, temperatures, ratios, and analysis.

The combination of adaptive mathematical models and the feed-forward strategy allows the MPC to maintain consistent behaviour during stationary conditions and a quick reaction to transitory productions.

In the first instance it allows the steel maker to balance furnace loads according to installed heating power. In the latter case, it anticipates furnace behaviour according to the incoming production, optimising transitions of productivity (full to slow production and back), product geometry, charging temperature and steel quality.

Getting value from data From the 1960s automation systems and equipment gained in popularity in the steel industry. Today all steel plants are equipped with a series of complex systems that monitor relevant data and control processes

automatically.

Danieli Automation Q3 Intelligence, a business intelligence platform dedicated to the metallurgical production process, can improve things further by merging, storing, processing and evaluating data from, say, Danieli Automation Furnace Level 2, and transforming it into knowledge.

In a scenario where smart systems are applied more and more to industry, Q3 Intelligence Analytics allows exploration and investigation of past process performances to gain insight and drive process design and planning, via advanced statistical methods and predictive modeling. Q3 Intelligence Analytics can help answer questions such as “why is this happening?”, “what if these trends continue?”, “what will happen in the future?” (predictions), “what is the best that can happen?” (optimisation).

Conclusions DCC has proposed a new generation of furnaces that integrate the sharp edge of combustion technology with the integrated design of both the process and environmental aspects. In this context, the staged/flameless burner is yet another example of DCC’s focus on innovation.

The company’s chief objective is to provide leading-edge technology, allowing high product quality, lower operating costs, trouble-free operation and ever-increasing environmental friendliness.

Danieli Automation Level 2 is a robust control system which allows users of the DCC furnace to achieve uniform operation, process cost savings and product quality. A careful analysis of its performance indicators can also lead to product flow optimisation and improved performance of the entire plant. � www.steeltimesint.com

07/03/2017 14:17:45

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Untitled-2 1

21/02/2017 10:57:39

FURNACES

25

Impact of cooling on blast furnaces The life of the refractory lining, and the type of cooling system employed, in a blast furnace has a major influence on campaign life. By improving the method of cooling the lining life can be prolonged which leads to increases in campaign life and so a reduction of down-time for furnace repair, so improving productivity and, therefore, decreasing the unit cost of the hot metal. By S Sudhir, RR Kumar, RK Singh, VK Jha, BK Das and A Arora* LINING life, cooling system and operating practice all have a major influence on the campaign life of a blast furnace. By improving the method of cooling, lining life can be prolonged, which will lead to an increase in the campaign life of the furnace.

This facilitates a reduction of down-time of the furnace leading to a decrease in hot metal cost.

The improved process efficiency in blast furnace operations combined with ever larger furnaces has increased the heat flux with a consequent requirement for greater levels of cooling to ensure a long shelf life.

The heat flux has a major influence on blast furnace operation, optimum heat flux being required for smooth furnace operation.

Heat flux is thus used as a tool to set the burden distribution to optimise the use of the furnace gas.

The traditional function of the cooling elements and water cooling circuits is the protection of the shell. To achieve this goal the cooling system must remove sufficient heat from the refractory lining.

The cooling water circuit must also keep the wall temperature of the cooling elements, plates or staves, within prescribed limits to optimise campaign life.

By recording the thermal status when the furnace is running in an optimum condition, heat loss may be minimised by optimising the quality of water, its thermal conductivity and that of its cooling materials. A small rise in water temperature is preferred which may be achieved by adjusting water flow and selecting materials of desired thermal conductivity.

Any reduction of the heat load/loss will

Fig 1. Installed cooling plate

Fig 2. Uneven wear of plates

influence production costs.

water ‘once through’ to sophisticated soft/ demineralised water closed loop circuits.

Evolution of cooling Blast furnace cooling systems have been developing since 1884. Until the late 1920s, cooling was applied to the hearth and bosh areas only. Cooling for the stack region was developed between 1930 and1940.

External cooling methods such as shower and jacket cooling of the furnace shell were tried. This method relied on extracting the heat through the furnace shell to the cooling medium which generated high thermal stresses and hence reduced the life and integrity of the shell. This problem was later eliminated by the use of plate coolers and stave coolers in which heat is extracted from the furnace before it reaches the furnace shell. The development of various generations of cast iron stave coolers continued until the late 1980s.

Further development of stave coolers in the 80s and 90s gave birth to copper stave coolers. To support the advancements in cooling elements, the cooling water system has likewise seen an evolution from raw

Types of cooling Cooling systems are often compared based on their maximum heat flux capability.

Selection of cooler type must be made on the basis of equilibrium heat flux (load) in the specific region of the furnace. External spray cooling was the earliest development and is still extensively used to protect the hearth shell and in some cases bosh. Spray or shower cooling is simply the addition of a water spray or curtain down the outer shell of the furnace. The advantages include low cost, easy repair, minimal refractory consumption and no chance of water leakage inside the furnace. High wear areas such as the slag zone can be cooled using spray or shower cooling at very low investment. The main disadvantages are high thermal stresses on the furnace shell along with lower rates of heat removal.

An additional drawback is that the heat transfer decreases with time due to scaling and deposition of dust and microbiological

*The authors are with RDCIS, SAIL, Ranchi-834002, India www.steeltimesint.com

FURNACES SAIL.indd 1

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26

FURNACES

and additional zig-zag pipe arrangement provide better cooling; • Generation IV – These have edge cooling at top and bottom, ledge cooling and serpentine pipe behind the primary vertical part. The front face of the stave is provided with slots for fixing refractory blocks.

1st generation stave

2nd generation stave

3rd generation stave

4th generation stave

Fig 3. Generations of staves with enhanced cooling

impurities on the surface of the furnace shell. External spray cooling also has problems counteracting hot spot formation over large areas, since boiling of the film of water may occur away from the zones of impingement.

Plate cooling Plate coolers are located inside the furnace shell in the refractory (Fig. 1) and are normally made of copper or cast iron, thus providing intensive cooling while withstanding high heat fluxes inside the furnace. Furnace cooling intensity can be increased in regions of high heat load, such as the bosh, belly and lower stack by varying the spacing between the coolers.

It is also observed that relatively few plate coolers use copper resulting in lower costs when compared to other coolers, such as copper staves. The limitations are that the plates take a greater width on the refractory which reduces the working volume of the furnace and installation requires large openings in the furnace shell. Also, cooling can be non-uniform (Fig. 2) which leads to uneven refractory wear and disruption of the flow of the process gases in the furnace. Moreover, it is also often difficult to mount or replace coolers in the tuyere zone of the furnace.

March 2017

FURNACES SAIL.indd 2

Stave cooling Stave coolers are generally used in the bosh and stack region of the furnace. These are large water-cooled blocks of metals, usually with refractory inserts between them and the hot face. Initially they were constructed of cast iron with steel pipes cast inside for water to circulate through. Copper is now generally used to improve the cooling performance and to allow the formation of a freeze layer to provide extra protection.

The advantages of stave coolers are uniform cooling, the possibility of directly inspect the furnace shell for hot spots, long life, and the copper from end-of-life stave coolers can be recovered. The limitations are: Difficult to replace during furnace operation and expensive as a large amount of copper is required in the designs. Hence some stave coolers are still made of grey cast iron or SG cast iron. Four generations of staves have now evolved (Fig. 3): • Generation I – Staves are deficient in corner cooling; • Generation II – Staves have improved corner cooling; • Generation III – Staves are better developed to provide refractory support by providing a nose above the straight stave face. Serpentine pipes for nose

Cooling medium and circuit There are four main types of water circuits for furnace cooling systems in use around the globe: a. Once through cooling water: Requires a very large volume of water usually pumped from a natural source. The disadvantages include difficulty to control of chemical composition of discharge water, which is environmentally hazardous and a large volume of water is also discharged. b. Open re-circulating with cooling tower: Here water is heated as it cools the shell of the furnace and then passes to a hot sump. Pumps are installed to transfer the hot water to the cooling tower and cooled water is then held in a cold sump from where it is recirculated. c. Open re-circulating with indirect cooling: In the case of an open recirculating system with indirect cooling, the heat is removed from the water by means of heat exchangers, either to air or to water. There is no direct contact between the circuit water and secondary cooling. d. Closed loop cooling water (Fig. 4): In this system there is no chance of atmospheric contamination of the cooling water. This will prevent scaling/corrosion of these coolers, in the long run, leading to lower thermal conductivity or water leaking into the furnace - major reason for damage to the refractory.

Heat loss in blast furnace The heat load is given by the formula: Heat Flux = V d S ∆t where V = flow rate of water, S = specific heat of the cooling medium, d = density of cooling medium and ∆t = temperature difference between outlet and inlet.

In general, the heat losses in a blast furnace are 3-6% through the cooling circuit and 2-5% through the top gas.

Therefore, the total heat loss is 5-10%.

Within this total, around 50-60% of the heat loss takes place in the stave/plate coolers, around 25-30% from the tuyeres, www.steeltimesint.com

08/03/2017 09:23:57

27

FURNACES

about 10-12% in the hot blast valve and about 5-7 % from the hearth area.

Fig 4. Close loop cooling water circuit

Results An effective cooling system keeps the hot face temperature of the refractory linings at a sufficiently low temperature to form a skull on the inside lining. The lower the hot face temperature, the greater tendency to form a stable skull. The temperature of the hot face depends on the rate of heat extraction from the lining refractory.

This skull formation acts as a thermal barrier and protects the refractory lining from some of the attack mechanism such as alkali and chemical attack, oxidation by CO2, H2O and O2 and abrasion / erosion.

The cooling system counters some of the attack mechanisms on the refractory face, for example, heat load and temperature fluctuations.

A rough estimate indicates that reducing cooling loss through the tuyere by 5% would result in saving of 0.7-1kg coke/tHM. In conclusion, an efficient cooling system contributes significantly to a longer campaign life, higher productivity and safe operation of a blast furnace.

Quantification of the thermal load is necessary to design the cooling system and requires calculation of water flow rates for different zones to optimise water flow in each cooler thereby ensuring increased life and minimising the use of excessive water.�

Expansion tank with pressure Secondary cooling water

and level control

N2 Table 1. Blast furnaces operating in SAIL plants

BF

Working

Prod.

Carbon

Specific

HBT

Energy

Type

Cooling

volume

(t/d/M3)

rate

wind

(°C )

input

of cooling

circuit

(kg/tHM)

(Nm3/tHM)

(Gcal)/tHM

member

(M3) BSP #1

886

1.91

474

1290

924

4.19

CI Staves

Open

BSP #2

886

1.37

485

1641

896

4.37

CI Staves

Open

BSP #3

886

1.45

485

1484

905

4.33

CI Staves

Open

BSP #4

1491

1.14

489

1543

655

4.25

C Staves

Open

BSP#5

1491

1.70

462

1391

943

4.14

CI Staves

Open

BSP#6

1491

1.81

468

1271

941

4.14

C Staves

Open

BSP#7

2105

1.71

471

1384

904

4.19

CI Staves

Close

BSL#2

2250

1.64

491

1392

974

4.38

CI Staves

Close

BSL#3

1758

1.55

486

1534

781

4.28

CI Staves

Open

BSL#4

1758

1.45

501

1629

834

4.46

CI Staves

Open

BSL#5

1758

1.81

473

1270

936

4.18

CI Staves

Open

RSP#3

996

1.28

501

1487

929

4.47

Cu plate

Open

RSP#4

1448

1.48

498

1390

939

4.42

CI Staves

Open

RSP#5

3470

1.90

458

906

1149

4.01

ISP#5

3551

0.98

452

1405

1205

4.18

CU & CI Staves

Close

DSP#2

1204

1.62

460

1381

978

4.13

CI Staves

Open

DSP#3

1204

1.84

457

1235

999

4.07

CI Staves

Open

DSP#4

1539

1.68

466

1225

894

4.09

CI Staves

Open

and Erection of Large Blast Furnace’ Steel Tech

Programme ,28-31 August 2007

proceedings September 2010 p42

7.

3

Cooling System using CFD’ Rand Afrikaans University

http://ispatguru.com/blast-furnace-cooling-

Hugo Joubert ‘Analysis of blast furnace lining /

system/

November 1997

4.

8.

Lecture 6/page 26-36, 22nd McMaster

www.paulwurth.com/Our-Activities/.../Furnace-

Bibliography

University Blast Furnace Iron Making Course-2012

Lining-Cooling

1.

5.

9.

PCH Zonneveld , RJ van Laar , Danieli Corus

Cu Plate & CI Staves Close

L Vroman, SIDMAR ‘Longer campaign life

Karel Verscheure, Andrew K Kyllo, Andreas

BV, The NETHERLANDS ‘21st Century Blast Furnace

through lining and cooling system at SIDMAR Blast

Filzwieser, Bart Blanpain, Patrick Wollants ‘Furnace

Design in India’ ,Steel Tech proceedings September

Furnace’, McMaster Symposium No. 10, May, 1982

Cooling Technology in Pyrometallurgical Processes’

2010 (p 4)

‘Optimization of Furnace Lining Life’

10. M P Smith, J Fletcher, R W Harvey, R Horwood,

2.

6.

Primetals Technologies, Stockton-on-Tees, TS17 6ER,

Martin Smith, Mike Eden and Alex Hancock,

Siemens VAI, Stockton-on-Tees, UK ‘Design

RK Verma, RDCIS,SAIL ‘Blast Furnace Cooling

System & Campaign Life’, Technology Awareness

UK ‘Blast Furnace Cooling Stave Design’

HigH TemperaTure BarCode Tags and LaBeLs

Westmoreland, nH 03431 usa / www.polyonics.com / +1.603.352.1415 / info@polyonics.com www.steeltimesint.com

FURNACES SAIL.indd 3

March 2017

08/03/2017 09:23:58

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29

CONFERENCE REPORT

Cloudy days in Rio

Alacero (the Latin American Steel Association) organised its 57th conference in late-October 2016 in Rio de Janeiro, Brazil. Rio is traditionally associated with the samba, sunny days and beautiful beaches, but last year it also hosted the Olympic Games, which generated important improvements for its transportation systems. Despite the pleasure of visiting the so-called ‘wonderful city’, the mood generated at the conference can be summarised as cloudy days, due to external threats and domestic hurdles. By Germano Mendes de Paula* SARA JOHNSON, senior research director of IHS Markit Economics, delivered an interesting presentation on global economic outlook. According to her, in the shortterm, world economic growth remains subdued: the globe’s GDP will expand below 3% in 2017, because slowdowns in Europe and China will offset accelerations in the USA and emerging markets.

Johnson declared that US economic growth will pick up from 1.4% in 2016 to 2.2% in 2017, led by improvement in consumer spending and business fixed investment. Eurozone growth is projected to slow from 1.6% in 2016 to 1.3% in 2017, reflecting increased political instability and banking problems. Economic and political uncertainty will hurt the UK’s investment, consumer spending, and capital inflows in 2017. IHS Markit Economics forecasts that advanced countries’ GDP growth will be relatively stable around the 2% plateau until 2020.

The macroeconomic perspective is more optimistic for emerging nations. The consultancy company predicts that they will achieve a GDP growth equivalent to 4% in 2016. Moreover, this figure will exceed 5.5% as of 2020. This outcome is quite positive, mainly when it is taken into consideration that Chinese economic growth will slow further because of imbalances in credit, housing, and industrial markets.

IHS Markit Economics provided a disaggregated GDP forecast by regions and told delegates that the NAFTA region (excluding Mexico) would enlarge roughly 2% per annum until 2023, while Western Europe will amplify below 2% and Japan will increase around 1%. It is worth noting that for these nations the expected trajectory is very stable. Nevertheless, there will be considerable differences regarding economic performance among Western European nations: Ireland, Spain, and

Sweden will maintain relatively healthy economic growth, whereas the UK, Italy, and France will struggle.

Asia-Pacific (excluding Japan) will achieve the fastest growth in real GDP, almost 6% per year until 2023. More importantly, they will experience a dynamic and stable growth. Good performance will be delivered by India (nearly 8% per annum), followed by China, Vietnam, and the Philippines (~6%), Indonesia and Malaysia (~5%). Other emerging countries tend to experience enhancements, in particular from 2018 and beyond.

Johnson also highlighted that an era of rapid growth in global trade has ended and that, for most of the period 1980-2015 real world exports expanded at higher rates comparatively to global economic growth.

However, the two variables will be in line for the years 2016-2025. She explained that this new pattern is a consequence of both cyclical (slow growth in aggregate world

* Professor in Economics, Federal University of Uberlândia, Brazil. E-mail: germano@ufu.br www.steeltimesint.com

Conference report Germano.indd 1

March 2017

08/03/2017 09:27:59

30

CONFERENCE REPORT

“...there will be

Spain, and Sweden will maintain

considerable differences

relatively healthy economic

regarding economic

growth, whereas the UK, Italy,

performance among Western

and France will struggle.

European nations: Ireland, demand; weak capital spending; collapse in commodity markets) and structural forces (limited progress on trade liberalisation; a shift from manufacturing to services; rising trade in data and information; shortening of global supply chains). Therefore, the global economy will face various challenges, which will obviously affect Latin America.

Latin American economy IHS Markit Economics forecasts that Latin America GDP will dip in 2016-2017, in contrast to what will occur worldwide.

There will be substantial regional variations.

Brazil is expected to end its recession in 2017, achieving a 0.5% GDP improvement, with better outcomes from 2019 onwards.

Mexico will benefit from sustained growth in the US economy and rising foreign investments in the automotive and energy industries. Argentina’s government has lifted currency and capital controls, cut trade barriers and subsidies, and returned to the international bond market.

Reducing inflation and fiscal deficits will prove more difficult. Colombia, Chile and Peru will benefit from sound fiscal and monetary policies, trade alliances, and rising commodity exports. Venezuela’s oil-dependent economy is in a downward spiral, with huge deficits, hyperinflation, good shortages, and plummeting investment.

Juan Carlos Rodado, head of Latin America Research at French investment bank Natixis, scrutinised the short-term prospects (2016 and 2017) for the USA, Eurozone, China and eight Latin American nations. He forecasts that the US economy March 2017

Conference report Germano.indd 2

“

Sarah Johnson. will rise 1.5% in 2016 and 2.2% in 2017.

For the Eurozone, the respective figures are 1.5% and 1.2%, and for China, 6.8% and 6.7%.

Natixis expects Brazilian GDP to decline 3.4% in 2016 plus an additional contraction of 0.5% in 2017, contrary to forecasts from IHS Markit Economics (0.5% enlargement) and the country’s market consensus collected weekly by the Central Bank (1.2% expansion, at the time of the conference). The Natixis’ estimation seems fairly pessimistic, because its presentation acknowledges that there will be relative political and economic stability until the next Presidential election in 2018. Moreover, inflation is gradually decelerating, allowing the Central Bank to cut interest rates. There are additional signs of cyclical improvement related to retail sales, industrial production and confidence indicators. Brazil’s budget deficit, the nation’s prime economic hurdle, is predicted to stay around the 10% level in 2017.

In Mexico, Natixis’ base scenario (grounded on the assumption that Hillary Clinton would win the US Presidential election) considers a 2.3% GDP growth in 2016 and 2.6% in 2017. However, Mexico will be affected negatively by having Donald Trump in the White House, due to his intention to renegotiate NAFTA and deport illegal immigrants. The first shock will be observed in the currency market as the Mexican Peso will be significantly devalued and the country’s GDP will dip by 2.1% in 2017.

Natixis forecasts that Argentina’s GDP

will drop by 1.5% in 2016, followed by a partial recovery of 1.0% in 2017. Rodado mentioned that the new government has adopted various good measures, such as the lifting of capital controls, interruption of political influence on statistics, resolution of conflict with foreign bond owners, and the implementation of a tax amnesty.

Nonetheless, there is likely to be some noise from the Supreme Court on the utilities

price hikes. In addition, inflation is going to increase from 26.5% in 2015 to 39% in 2016, reverting moderately to 30% in 2017.

Natixis predicts that Colombia’s GDP will increase by 2.0% in 2016 and by 1.5% in 2017. Rodado comments that citizens narrowly voted against the peace deal with the Revolutionary Armed Forces of Colombia (FARC), as it was too lenient on the rebels, in a referendum. The two sides vowed to maintain a ceasefire and keep www.steeltimesint.com

08/03/2017 09:28:08

CONFERENCE REPORT

31

“The US economy will rise 1.5% in 2016 and 2.2% in 2017. For the Eurozone, the respective figures are 1.5% and 1.2%, and for China, 6.8%

“

and 6.7%.

Juan Carlos Rodado.

working together. On fiscal issues, a fiscal reform was adopted late last year, implying a two-percentage point increase for Valueadded Tax (VAT).

It is important to remember that the budget deficit in Colombia last year was equivalent to 3.9% of GDP, against the regional level of 2.8%.

Where Chile is concerned, GDP growth decelerated from 2.1% in 2015 to 1.4%

in 2016 and will remain modest at around 1.6% in 2017. The economy continues to weaken because of the labour market adjustment and weak confidence.

Moreover, political discontent is rife, demonstrated by the low approval rate (15%) for President Bachelet. Natixis’ director also discussed that there will be a heavy political calendar in 2017.

Even considering that the copper mining boom is fading away, Peru is expected to www.steeltimesint.com

Conference report Germano.indd 3

achieve the best economic performance in the region, boosting GDP by 3.8% in 2016 and 3.6% in 2017. However, excluding mining activities, the rest is somewhat weak. The outlook for metal prices will be constrained by higher interest rates in the US (affecting gold) and lower Chinese demand (notably for copper). Natixis stressed that a good investment climate followed the presidential election of Pedro Pablo Kuczynski. On the negative side, the lack of liquidity can put constraints on economic growth.

Natixis described the Ecuadorian case as “Rafael Correa is definitely not Nicolás Maduro”, despite the ideological closeness between the two Presidents. Ecuador has been negatively affected by the reduction in oil prices, as the share of oil-related revenues has declined from 41% in 2011 to only 14.8% in Q2 2016. Nonetheless, the relationship with China is strong, a fiscal adjustment is underway and Correa will not run for President in 2017. Even tougher, GDP will diminish 3.0% in 2016 and there will be an additional 3.5% drop in 2017.

Venezuela has the worst economic performance in Latin America. The nation’s GDP decreased 15% in 2016 and will be down 17% in 2017. The respective figures for inflation are 800% and 1,600% (in fact, a hyperinflation), and for budget deficits 25% and 30%. According to Natixis, while the short-term is manageable, there are concerns that the government and the State-owned oil company PDVSA will not pay its bonds in April 2017 (respectively $4.3bn and $3.4bn). Not surprisingly, this chaotic situation led to a social implosion.

Latin American infrastructure Arlindo Eira Filho, a partner at the consultancy company McKinsey, analysed the perspectives of the infrastructure sector in Latin America, which can foster steel consumption. In reality, there is strong evidence that Latin American invested less than is deemed appropriate in infrastructure. Along the period 19922013, China spent 8.6% of its GDP on infrastructure. It was followed by India (4.9%); developed Asia and Oceania (Australia, Hong Kong, Japan, New Zealand, and Singapore; 4.6%); Middle East (4.3%); Eastern Europe (4.1%); other emerging Asia (Bangladesh, Indonesia, Malaysia, Pakistan, the Philippines, Sri Lanka, Taiwan, Thailand, and Vietnam; 3.6%); Africa (3.1%); USA and Canada (2.5%); Western Europe (2.5%); and Latin America (2.4%). Meanwhile, the global average was equivalent to 3.5%. Therefore, Latin America invested 31% less than the global average in infrastructure (as a proportion of GDP) and 72% less than China. The lag of Latin America is even more notable due to the region consisting of emerging nations.

As a result of low investment, most Latin American countries are classified as lagging behind on infrastructure development – certainly more so than expected. The World Economic Forum’s (WEF) infrastructure quality is plotted related to a vertical axis, varying from 2 to 7, while GDP per capita (in 2012 $ purchasing power parity) is related to a horizontal axis. The trend line ratifies that richer countries usually have better infrastructure quality. The nations situated below this line have worse-thanMarch 2017

08/03/2017 09:28:16

32

CONFERENCE REPORT

“... According to

that, in order to close

McKinsey, infrastructure

its infrastructure deficit

investments can offer

by 2030, Latin American

returns as high as three

countries would have

to five times the invested

to increase their historic

capital. The consultancy

investment by 40%.

company estimates

Arlindo Eira Filho

expected infrastructure, including Brazil, Colombia, Venezuela, and Peru, for instance. Few Latin American countries are located above the line.

Need for investment According to McKinsey, infrastructure investments can offer returns as high as three to five times the invested capital.

The consultancy company estimates that, in order to close its infrastructure deficit by 2030, Latin American countries would have to increase their historic investment by 40%. Indeed, regional investment totalled $5trillion in the period 2000-2015 (at constant 2015 prices), but will reach $7trillon for the period 2016-2030.

McKinsey’s Eira Filho affirmed that the pipeline of investment projects in Latin America is equivalent to $706bn over the next few years, which are insufficient to eliminate the regional infrastructure gap.

Brazil is expected to lead the infrastructure investments. The Brazilian government has announced plans to invest $277bn, with the following composition: transport improvements ($116bn); oil, gas and renewable energy ($78bn); other energy infrastructure ($58bn); water supply and sewage ($14bn); and real estate and housing ($4bn). The current pipeline of projects represents a ~25% amplification from estimated investments in 2014.

Mexico has announced a pipeline of infrastructure projects worth $95bn in the next five years, of which $30bn will be on oil and gas industry development, $15bn on power, $14bn on airports, $10bn on roads and $26bn on other activities (mainly March 2017

Conference report Germano.indd 4

“

in renewable energy and housing). If Mexico implements this pipeline, it would increase average annual investment from $17bn to $20bn per year.

Argentina plans to spend $78bn over the next five years on infrastructure, including $25bn on roads, $20bn on water and sewage, $15bn on railroads, $11bn on real estate and housing, $5bn on mobile phone networks and $2bn on airports and ports. If the country goes ahead with this pipeline, it would amplify average annual investment from $12bn to $15bn per year.

McKinsey estimates that Peru plans to invest $45bn in infrastructure in the coming years, while the amount for Chile reaches $42bn and for remaining nations (specifically Colombia, Nicaragua and Panama), $171bn. Most of these national programmes will require private sector involvement and financing. Investment conditions in Latin America still need to be enhanced.

World and Latin American steel consumption Dr Edwin Basson, director general of worldsteel, explained that global steel consumption, having declined 3.0% in 2015, is expected to jump by 0.2% in 2016 and by 0.5% in 2017. Looking at the period 2014-2017, world steel demand is going to face a -0.3% compound annual growth rate (CAGR). In this context, it seems that industry has started a new phase characterised by low growth and even stagnation. This diagnosis is underpinned by weak economic growth, derived from the following issues: a) modest recovery

in the developed economies; b) emerging economies struggling to grasp momentum; c) low oil prices reshuffled oil-exporter budgets; d) global trade remains anaemic hitting growth in the developing world; e) global economic outlook continues to be revised down.

Diminishing regional demand Martín Berardi, general director of Ternium Siderar, presented worldsteel’s forecast concerning Latin American steel apparent consumption for 2016 and 2017. Regional demand is predicted to diminish 6.2% in 2016, followed by a partial recovery of 3.8% in 2017.

Brazil is experiencing a sharp decline in steel consumption, down 8.6% in 2014, 16.9% in 2015 and expected to drop 14.4% in 2016, with a partial retrieval of 3.8% in 2017. The Mexican situation is much better, because it has been obtaining only positive outcomes: 13.7% in 2013, 5.8% in 2015, 1.6% in 2016 and 3.2% in 2017. Argentina’s performance oscillates positive and negative results.

It is predicted to contract by 18% in 2016, as a consequence of economic adjustments put in place by the new government. Colombia has a similar pattern to Mexico. Other Latin American countries have indicated a stop-and-go performance, almost offsetting positive and negative outcomes.

Summing up, Latin American countries have reacted quite differently to the fierce global macroeconomic conditions and this fact has generated remarkable disparities regarding steel demand evolution. � www.steeltimesint.com

08/03/2017 09:28:20

ECCC

9 European Continuous Casting Conference th

®

2017

VIENNA, AUSTRIA

26 – 29 JUNE 2017

© IAKW AG, Marius Hoefinger

3 ESTAD rd

EUROPEAN STEEL TECHNOLOGY AND APPLICATION DAYS

Contact: ASMET Franz-Josef-Str. 18 8700 Leoben, Austria Tel. +43 (0) 3842 402 2290 Fax : +43 (0) 3842 402 2202 E-mail : estad2017@asmet.at Website: www.estad2017.org

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Enhancing mold flow control Tata Steel Europe (Ijmuiden) has installed an OptiMold monitoring system, co-developed by ABB and Proximion. The system was developed to measure flow conditions online, in real-time, and adjust the flow control device accordingly. By Martin Sedén1, Jan-Erik Eriksson1, Arnoud Kamperman2, Edward Dekker2, Johan Pejnefors3 and Krister Fröjdh3

ELECTROMAGNETIC flow control is a well-proven technology for improving quality in continuous slab casting[1]-[4].

Electromagnetic stirrers, based on the principles of travelling magnetic fields, have been shown as particularly efficient for flow acceleration, temperature homogenisation and inclusion washing in surface/subsurface regions of the strand. Different configurations of static magnetic fields have also been utilised to brake and stabilise high speed processes. For varying casting conditions such as throughput, slab format, slag type, steel grade, argon flow injection, SEN type and immersion depth mold level and so on, different electromagnetic settings are needed to create the best possible flow conditions. Appropriate settings can be found through trials where an experience database can slowly be built up, or by numerically simulating the process with modern computer technology and software. Both methods, however, are very time-consuming. The OptiMold Monitor has been developed to measure flow conditions online, in real-time and adjust the flow control device accordingly. This technology provides superior thermal monitoring

OptiMold monitor Transport cable

Harsh environment collector cable

Harsh environment connection box Interrogator unit

OptiMold control

Mold EM device

Fig 1. Schematic setup of OptiMold monitor

Mold temperatures [°C]

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Fig 2. Time averaged OptiMold monitor 2D heat maps for different FC Mold magnetic field configurations (Bbottom/Btop)

1ABB AB, Terminalvägen 24, SE-721 59 Västerås, Sweden, 2 Tata Steel Europe, P.O. Box 10000, 1970CA IJmuiden, Netherlands, 3 Proximion AB, Skalholtsgatan 10, SE-164 40 Kista, Sweden March 2017

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CONTINUOUS CASTING

60

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resolution and has been co-developed by ABB and Proximion. It is installed at Tata Steel Europe (Ijmuiden).

Measurement system and test set-up The core of the installed OptiMold Monitor (Fig. 1) is a set of 38 measuring optical fibres. One end is mounted into evenly spaced vertical holes in the top half of a new copper broad face plate, 15mm from the hot face, and the other end is spliced into a multi-strand harsh environment collector cable in a connection box mounted on the side of the mold plate.

At the mold end of each fibre, 70 Fibre Bragg Gratings (FBGs) have been accurately positioned every 5mm,[5] starting 30mm from the top of the copper plate and covering the upper broad face down to 375mm from the top of the copper. Each FBG acts as a single temperature sensor, equipping the broad face plate with a total of 2,660 sensors. See[10] for system set-up details.

Using robust, expanded beam connectors, four 15m long collector cables www.steeltimesint.com

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hL, [mm] hR, [mm] mtundish[ton]]

20

0.2 0.1

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Fig 3. Meniscus shape along the width of the mold for different FC mold settings.

Estimated from measured temperature

Avg. meniscus flow speed [m/s]

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-10 16:30:00

16:45:00 17:00:00 17:15:00

0 17:30:00 17:45:00 17:45:00 18:00:00 18:30:00

Fig 6. Monitored left and right hand side estimated meniscus wave heights (hL and hR) for last 2 heats before tundish and SEN change

are plugged in to an intermediate box positioned close to the caster. From the intermediate box, the optical transmission is carried by a 125m transport cable, which connects all the caster fibres to interrogators in a climate-controlled room.

The light source in the interrogator sends a broadband light pulse into the fibres.

Reflections caused by the FBGs are picked up by the interrogator unit and translated by software to temperature data for all sensor points. Temperature data is scanned and treated online for the entire mold plate twice every second.

High resolution temperature mappings The slab caster at Tata Steel Europe (IJmuiden), where the OptiMold Monitor has been installed, is also equipped with an ABB FC Mold, a two-level electromagnetic brake controlling the flow of molten steel in the mold. During a trial, the FC Mold’s magnetic fields were varied, as the OptiMold Monitor scanned the thermal status of the mold.

The time-averaged temperature

mappings (Fig. 2) show that a strong magnetic field (2a) results in a relatively homogeneous temperature distribution.

For a vanishing top magnetic field (2c), temperature distribution becomes inhomogeneous with accentuated hotspots close to the narrow faces.

Meniscus shape has been estimated based on measured temperature distributions. Fig. 3 illustrates the resulting time average calculated meniscus shape for the FC Mold configurations described above for the 1100mm width, 190 mm SEN immersion depth and 1.9 m/min casting speed.

The estimated meniscus shape results indicate that the stronger top magnetic fields ensure a lower wave peak close to the narrow faces, whereas the meniscus wave height is much more pronounced for the un-braked top domain. In Fig.4, an estimate of dynamic meniscus fluctuations is shown. It also indicates a stabilisation over the entire width of the mold with the application of magnetic fields.

A set of numerical simulations of molten March 2017

07/03/2017 14:31:49

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steel flow in the mold was produced to illustrate the causes of the observed meniscus shapes and flow speeds. The CFD-simulated meniscus shapes are very similar to the OptiMold Monitor’s estimated meniscus shapes shown in Fig. 3. As the top magnetic field is missing, the flow pattern shows a strong upward directed flow along the upper part of the narrow faces. This vertical momentum pushes the meniscus wave upward and creates a high crest of potential energy close to the narrow face; energy that is converted into kinetic energy in the form of meniscus flow speed towards the SEN. For the stronger top magnetic field, the upper recirculation loop is restricted in speed and hence has a flatter meniscus with lower flow speeds. A strong bottom field restricts downward-directed flow momentum, reducing the penetration depth of the lower recirculation loop.

Meniscus flow speed can be calculated based on the meniscus shape. In Fig. 5 the variation of meniscus flow speed is given over the two-minute trial period. The connection between the top magnetic field and meniscus general flow speed level is apparent. It is also clear that the unbraked high flow speeds undergo large fluctuations as well as left/right-asymmetry over time. A stable meniscus flow level around 0.3 m/s is in this 237x1100 mm, 1.9 m/min casting sequence found for an FC Mold field setting of 57%/100% (top/bottom).

Meniscus speed control Implementing the algorithms for meniscus profile and meniscus flow speed in the OptiMold system analysis unit, the deduced in-mold flow speeds can be monitored over time. In Fig. 6 the meniscus wave height has been monitored over the last two heats of a casting sequence before tundish and SEN change.

Before the ladle change at 17:14, temperature distribution and meniscus wave are relatively symmetric. In the last part of the sequence, asymmetry becomes more pronounced, biasing the meniscus wave on the left side. It can be concluded that clogging affects flow pattern symmetry in the last stages of casting.

These results reveal the OptiMold Monitor’s potential in conjunction with a flow control device for counteracting and controlling in-mold flow asymmetries as soon as they are detected by the temperature measurements. A modern generation FC Mold has the ability to

2017-3550-015_LEC_Anzeige_Billetcooler_FLEX_EN_70x285.indd 1 03.03.17 11:49

March 2017

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control left and right side magnetic fields independently and consequently apply different electro-magnetic forces to the mold flow on the left and right sides, and is a perfect fit for OptiMold Control to regulate symmetry as well as the appropriate flow speed levels in real time.

Conclusions By means of high-resolution temperature measurements the OptiMold Monitor can allow for powerful analysis of casting conditions and detection of mold flow pattern characteristics such as meniscus shape, flow velocity and flow asymmetry.

This opens up new possibilities for enhancing mold flow control where it can, in a closed-loop connection to an electromagnetic actuator, dampen or accelerate flow speeds as well as control flow asymmetry. What’s more, the OptiMold Monitor can extend functionality and performance of conventional thermocouple systems and detect local thermal phenomena. Fibre-optics measure undisturbed in the presence of magnetic fields.

To read the white paper that this article is based on or for more information on our offerings visit www.abb.com/metals �

References [1] S. Kenichiro et al., “Flow field control of liquid steel in the mold of a continuous slab caster by an electromagnetic brake”, Tetsu-toHagane (1983), Vol. 69, No.12, pp. 912 [2] H. Okuda et al., “Effects of electro-magnetic brake on surface quality of medium carbon strand cast slabs”, Tetsu-to-Hagane (1986), Vol. 72, No.4, pp. 196 [3] H. Yamamura, T. Toh et al., “Optimum magnetic flux density in quality control of casts with level DC magnetic field in continuous casting mold”, ISIJ International (2001), Vol.41, No. 10, pp.1229-1235 [4] Y. Miki, S. Takeuchi, “Internal defects of continuous casting slabs caused by asymmetric unbalanced steel flow in mold”, ISIJ International (2003), Vol. 43, No. 10, pp. 1548-1555 [5] A. Asseh et al.,”A writing technique for long fibre Bragg gratings with complex reflectivity profiles”, Lightwave Technology, Volume 15, 1997, Issue 8, pp. 1419-1423.

[6] G. Hedin, A. Kamperman, M. Sedén, K. Fröjdh, J. Pejnefors, “Exploring Opportunities in Mold Temperature Monitoring Utilising Fibre Bragg Gratings”, Presented at SCANMET V, (Luleå, 2016). www.steeltimesint.com

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Near net shape casting explained As part of a 3.5-year EPSRC project, research has begun at the University of Warwick in the UK on the metallurgical implications of moving towards near net shape casting, with a particular focus on belt casting technology. Near net shape casting has the potential to dramatically reduce energy costs associated with steelmaking while broadening the range of alloys that are currently unable to be produced by conventional means. By Dr. Carl Slater,* Dr. Claire Davis,* Dr. Mihaiela Isac,** and Professor Roderick Guthrie** STEEL remains the most used material in the world by value, and plays a critical role in industries such as oil and gas, construction and transportation. In a 2016 report by the World Steel Association, it was highlighted that although energy consumption per tonne has been reduced by nearly 60% in the last 50 years, energy costs still comprise up to 40% of steel production in some countries. This has led to research in alternative casting methods, and in particular, near net shape casting (NNSC). One promising method of NNSC is horizontal single belt casting (HSBC).

Commercialisation of the belt casting process for steel is starting to take place with the first horizontal single belt caster (HSBC) for steel production being implemented at Salzgitter’s plant in Peine, Germany. The benefits of such a system are immediately obvious when comparing belt casting to conventional continuous casting.

They include: • Casting speeds up to 60 times faster.

• Reduction of overall mill length by up to eight times.

• Reduction of > 3 GJ/tonne in energy of production due to reduced rolling/ reheating of the near net shape cast.

While many engineering challenges have been overcome to reach this point, in order to encourage the move to NNSC, then in addition to the energy savings made, strong evidence is needed that grades can be produced to the same quality (or greater) than conventional means. ASSURE 2 (Advanced Steel Shaping Using Energy Reduction) is a 3.5 year EPSRC-funded project that commenced at the beginning of 2017, following a short feasibility study (ASSURE). The project aims to assess the metallurgical implications of NNSC, while considering new compositions and

b

microstructures made possible by the new capabilities/opportunities this method offers.

Scientific challenges In order to exploit the possibilities of NNSC, several fundamentals of thermophysical steel processing need to be more comprehensively understood. One of the key differences between conventional continuous casting and NNSC is the solidification rate. Solidification during belt casting can reach > 50 °C/s (around 50-80x faster than continuous casting) while twin roll casting of steels by CASTRIP, is much faster (> 150x faster). This difference can be both beneficial and harmful; it has been well documented that an increased cooling rate can lead to a reduction in grain size (and this will be fully explored within the project, particularly for alloys that are currently limited in use due to their large

c

Fig 1. As-cast grain size of three low density steels with different alloying additions produced under identical conditions with a cooling rate applicable to belt casting

* WMG, University of Warwick, UK, **McGill University, USA. www.steeltimesint.com

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steels much more readily.

Another branch of steels that belt casting would benefit are low density steels, which have particular relevance to the automotive industry, where light-weighting is essential.

These steels are prone to hot tearing due to their inherently large grains. Finally, HSBC is also a mould powder-free process, which aids in the production of these steels, since they can be particularly reactive with the oxide rich fluxes used in conventional casting. In ASSURE 2, the processing of low density steels will be investigated in terms of grain size development during solidification and deformation.

Fig 2. Image of the new Advanced Steel Research Centre at WMG, University of Warwick

grain sizes). The cooling rate also affects micro-segregation levels, which can result in non-homogenous structures and properties.

The solute rich regions that form can give premature nucleation of precipitates, resulting in larger, less beneficial (lower strengthening / limited grain pinning) precipitates. This was observed in the ASSURE feasibility study where precipitation of large Nb(C,N) occurred in the liquid phase when the steel was cooled at rates of around 50 °C/s, while only small Nb(C,N) occured during post solidification in slow cooling rate tests Conventional casting requires subsequent hot rolling to both reduce the product thickness while simultaneously breaking down the microstructure into a finer grain size. NNSC does not require the same reduction in thickness. As such, the ability to refine the grain size via hot rolling is somewhat reduced for HSBC product, but this is compensated by a much finer initial as-cast microstructure, complemented by a 90% reduction in cast thickness for HSBC products, versus only a 50% possible reduction for TRC products.

Within the ASSURE 2 project, consideration of the optimum strains – temperatures for recrystallisation during hot rolling for the NNSC grades will build upon work already carried out at the University of Warwick on recrystallisation in conventional steels. With the reduced amount of deformation, the final microstructure is heavily dependent on the cast structure.

Therefore, the influence of composition, cooling rate and belt surface morphology on the as-cast grain structure will be March 2017

Con casting WMG.indd 2

evaluated, since producing as fine a grain size as possible during casting will mitigate the loss of refinement normally achieved during the hot rolling stage. Fig. 1 shows results from the ASSURE feasibility project for the effect of composition on grain size: it can be seen how three grades of low density steels, cast at a similar cooling rate of 70 °C/s, can vary in grain size.

Other areas that ASSURE 2 will investigate are the interaction of the steel with both reactive and non-reactive gases, differential cooling and solidification under the effects of electromagnetic fields.

Alloy development A key difference between conventional casting and HSBC is the orientation of the cast. Most conventional steel casting machines cast vertically and then use a series of rolls to curve the strip into being horizontal.

This bending results in surface stresses, which can lead to hot tearing in susceptible grades. Horizontal Single Belt Casting, on the other hand, casts directly onto a horizontal cooling substrate. As such, minimal stresses are imposed onto the solidifying steel; this should allow for a wider range of steel grades to be cast.

HSBC has been suggested as a possible route for the production of next generation advanced high strength steels (AHSS), including TWIP and TRIP steels, which have been shown to have twice the strength and three times the ductility of conventional steels. TWIP grades inherently work harden rapidly, and thus become hard to hot roll.

As such, NNSC allows processing of these

Investment in technology In June 2016, the Advanced Steel Research Centre was opened in at the University of Warwick, Fig 2. The building has been kitted out with state-of-the-art equipment for the development of steel processing and characterisation. Part of this capability includes equipment integral to the ASSURE 2 programme: • A Gleeble HDS-V40, Fig. 3 – The first of its kind in the UK. This machine is capable of casting and directly deforming steel and simulating full deformation cycles during rolling from roughing down to finishing. Currently, high temperature deformation testing involves reheating cast samples to the deformation temperature with the limitation that the microstructures are generally no longer representative of a cast structure, due to phase transformations occurring on cooling/heating. The HDS simulates casting – direct rolling through insitu solidification and deformation and thus gives a much better representation of the final microstructure that can be expected from full-scale production during NNSC processing.

• Vacuum Induction Melting Furnace (VIM). A new 10 kg VIM has been commissioned with an auxiliary charging chamber that allows for the rapid systematic production of alloys. The VIM offers the capability to fully instrument the casting process, using infrared thermography of the molten steel and mould, giving feedback on the kinetics of transformation. Steels with different compositions will be produced for the ASSURE 2 programme as feedstock material for HDS casting-direct deformation studies.

Scale-up trials The research in ASSURE 2 is based around www.steeltimesint.com

16/03/2017 16:29:58

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CONTINUOUS CASTING

Fig 3. Image of the Gleeble HDS-V40 showing the melting-casting capability as well as plane strain loading

understanding how the microstructure and properties of steel change when moving to near net shape processing from conventional casting. To provide confidence to the steel producers that the knowledge gained from the laboratory studies is relevant to full-scale production WMG at the University of Warwick has teamed up with Prof Roderick Guthrie and Dr Mihaiela Isac and their group at McGill University.

Among the capabilities they have (at their MetSim high temperature melting and casting facility) are a pilot-scale HSBC, a high temperature laser confocal microscope for in-situ solidification studies, and a 388 core high performance computer cluster for CFD modelling. Experimental trials will be carried out on compositions selected from the initial laboratory experiments using process parameters developed at McGill from its extensive modelling and casting experience.

The HSBC system includes an in-line pinch roll/mini-mill, plus an advanced control system. A wide variety of alloy strips can be processed using the HSBC machine,

Limit switch Gear box

Tachometer

Fig 4. A schematic of the horizontal single belt casting system, located at MetSim Laboratory

Screw

Motor

Piston Air gas purging

Gasket

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Tundish Side dam

Coiler

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Rolling table Back up roll

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Caster

ranging from lower melting temperature alloy systems, such as aluminium, and magnesium to copper alloys, and high melting temperature alloys, such as low carbon steel, TRIP, or TWIP or high strength high ductility steels. A high temperature laser confocal microscope is used for in-situ phase transformations analyses, during melting and solidification of alloys

Hot rolling process

cast using the HSBC process. The effect of specific metal delivery systems, belt substrate coatings, casting speeds, and melt superheat, on heat fluxes, microstructures, and surface quality of metal /alloy strips and sheet product characteristics, together with in-line thermo-mechanical treatments, can all be studied at MetSim Inc., and perfected for full scale HSBC casters. ďż˝

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PERSPECTIVES: BLOOM ENGINEERING

Delivering value to customers While cautiously optimistic, Bloom Engineering has enjoyed a busy year and is preparing to ship ‘many orders’ over the next few months. The company claims to be involved in nearly every combustion application in steelmaking operations and, says David Boyce*, is very busy in China and North America 1. How are things going at BLOOM ENGINEERING? We’ve had a very busy year, with many orders to ship in the next few months.

While Bloom serves a number of industries, it was founded more than 80 years ago to serve the needs of steel producers, and they’re not disappointing us now.

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

We are cautiously optimistic. It seems that demand is moving in the right direction, in particular with recent discussions about expanding infrastructure spending in the USA.

6. Where do you stand on the aluminium versus steel argument?

It is clear that steel will always have a significant role in filling global demand for transportation, infrastructure, and energy production and transmission. While aluminium has increased its presence in traditional steel applications, the continuing advancements in ultra- and advanced high strength metallurgy is a clear indication of the critical role steel maintains and the innovations that result from a competitive market.

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

Bloom is involved in nearly every combustion application in steelmaking operations, including in upstream applications for raw material processing.

Additionally, we are developing advanced generations of many of our burners for cold rolling mill continuous processing line furnaces and heat treating furnaces.

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

Our activity has recently increased dramatically in China and North America.

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

We are finishing up manufacturing the burners for a large reheat furnace in China. This project combines Bloom’s broad experience applying regenerative combustion systems to the heating process with the customer’s need for fuel flexibility.

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

We have had millennia to study and perfect iron and steel production. It has only been in the past few hundred years that we have produced aluminium on an industrial scale. That means that we have had many hundreds of years more to optimise our steel production processes. I feel that up and down the line in steel production, we

have done a pretty good job of that, and the exciting aspect to me is the role that combustion plays now and in the future.

8. “…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?

First, I must clarify that this was not Mr. Stephens’ view. Rather, his 2014 article identified the challenging political positions that emerge in this discussion. Our position is much simpler. The global economy and individual communities benefit when the most fuel efficient, lowest emissions combustion solutions are used in heavy industries like steel and aluminium. We will continue to support those endeavours.

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

Steel is a wonderful metal that can be recycled many times over. In a macroview, this recycling continually reduces the environmental footprint of each kilogram of steel produced. There are two ways to address emissions from combustion: within the combustion process itself, and through downstream pollution control technologies.

Bloom’s intense focus is to help steel producers decrease emissions at the source, utilising nearly any fuel.

10. Are steel producers relying upon companies like BLOOM ENGINEERING to offer them solutions in terms of energy efficiency and sustainability? If

* President, Bloom Engineering March 2017

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PERSPECTIVES: BLOOM ENGINEERING

so, what can you offer them?

We develop solutions that target specific needs – whether it’s reducing scale loss, installing ultra-low NOx burners, or improving the energy consumption of the overall process, the people of Bloom have built a reputation upon which customers depend.

11. Where does BLOOM ENGINEERING lead the field in terms of steel production technology?

Bloom’s reason for existence is transferring energy from a fuel source to a steel heating application. Our low NOx combustion technologies generate high efficiency heat transfer in conventional, recuperative, regenerative, and radiant tube combustion system applications.

12. What is your view on digital manufacturing?

Efficient conversion of data into information and algorithms is at the heart of Industry 4.0 for the steel industry. Linking the operating parameters of the combustion process to the output of the heating application is essential to improvement. It also enables even further expansion of automation in the steel making process. Bloom has already been engaged in projects advancing this concept over the last few years.

13. How do you view BLOOM ENGINEERING’s development over the short-to-medium term in relation to the global steel industry?

Over the next few years, the steel industry will face challenges to close outdated facilities, reduce energy consumption and emissions, and produce advanced-grade materials to meet market demands. In each of these areas, Bloom will continue to be a solution-provider to global steel producers.

14. How should the industry react to China?

The challenge to the overall industry is to continue developing higher grades of steel, improve plant efficiencies, reduce emissions, and keep workers safe.

15. What is BLOOM ENGINEERING’s experience of the Chinese steel industry?

We have over a decade of experience with a local presence in China and will continue to expand our products and services there. www.steeltimesint.com

Perspectives.indd 2

16. Where do you see most innovation in terms of production technologies?

One of the most exciting developments is in ultra- and advanced high strength steels.

Achievement of many of the material properties occurs during heat treatment phases. Bloom continues to develop products for continuous processing line furnaces for increasing heating uniformity, improving fuel consumption, and decreasing emissions.

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

I am fairly optimistic, but that is my nature.

The calculus is clear, however – outdated plants have to close, existing plants must be improved to meet the demands of their end-markets, and innovation is the name of the game.

43

I think we are already seeing positive directional signals in the form of revisiting energy transmission (Keystone Pipeline) and broad infrastructure investment. Politics in the USA are not that different to many other countries. The President is not a king, and together with Congress must satisfy the needs of a broad constituency that has local and special interests in play. It is certainly a challenging environment.

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

Constantly thinking of what is next. My over-arching concern is to drive Bloom to deliver value to our customers. If we do not anticipate what our customers will need tomorrow, and in five years down the road, our relevance will cease.

21. If you possessed a superpower,

18. BLOOM ENGINEERING is based in the USA, but how is the steel industry performing on both sides of the pond?

While we are based in the USA, our customers depend on our strong local presence in Europe, China, and India. Each region has its own ‘periodicity’ and that is generally a good thing for our business. Our global presence has a positive impact on our innovation process. We are challenged to meet the needs of a diverse global market and we seek to apply those lessons learned to our product development.

19. Will President Donald Trump be good for the US steel industry?

how would you use it to improve the global steel industry?

Only one! I think it is insightful to think of the question differently. What magical ‘thing’ does the global steel industry need to improve? My answer? Insatiable demand that never stops. My superpower, then, is a complex one. It must solve the developing world’s many challenges that keep it from reaching first-world infrastructure status.

It would develop and produce materials that prevent natural disasters from causing existential threats. It would align politicians around the world to collaborate and inspire ways to stimulate demand. I think I need another cup of strong coffee … � March 2017

08/03/2017 09:52:02

44

HISTORY

Pre-industrial revolution ironworkers Most historians refer to the dates 1760-1780 as the start of the Industrial Revolution – but it may well have been several decades earlier. By Harry Hodson* THEY are, of course, attributing this period to the development of the steam engine invented by James Watt in 1765, but how did he acquire the necessary materials to construct his engine? These early engines were known as ‘atmospheric’ and were developed by Denis Papin (France), and Cornish engineers Savory and Newcomen.

In 1700 Britain’s iron industry was concentrated in Sussex and Surrey in an area known as The Weald. These early ironworkers used charcoal to smelt iron in their blast furnaces, but this was becoming a problem with the great number of trees being felled to make the charcoal. The government acted to put limits on charcoal production in these counties. Because of this, many of the ironworkers re-located to the West Midlands and parts of Wales where there were abundant supplies of forestry and the River Severn, a 220mile long spate river, which would be an excellent source of power. Most of these ironworkers earned their living by making domestic products such as fire grates, ovens and cooking pots. Others engaged in whatever was within their melting capacity.

but a number of brass founders in Britain were keen to get in on the act. Early in the century Abraham Darby (1678-1717) was a partner in the Cheese Lane Brass Foundry in Bristol. He was aware of the lucrative market for cooking pots and sold his shares in the company in order to set up in business elsewhere. He found a derelict furnace at Coalbrookdale in Shropshire where coal and water were in abundance – vital ingredients for his intended business. On visiting the site, apart from seeing that much needed work would have to be done to restore the furnace, he also found a woman and six children in dire circumstances. According to records the furnace had previously been operated

by Shadrach Fox, when one night two drunken workmen fell asleep and allowed water to seep into the hot furnace, causing an explosion which rendered the furnace useless. Nevertheless, Abraham Darby decided there was potential at this site and started to make repairs. Shadrach Fox boarded a ship for Russia where he took up employment making cannons for Peter the

A derelict furnace Most early ironworkers did not own their furnaces, which were usually built by the landowner or a tenant farmer to whom they paid a fee for setting up an ironworks close to the furnace. Among the previously mentioned products cooking pots were the most prized possessions of ordinary families. These came in the form of a ‘witches cauldron’ ranging from a few pints to several gallons capacity.

They were expensive because they were made of brass, and were handed down through generations of the family. Many brass cooking pots were made in Holland,

Great. He found suitable accommodation and employment for the family as he set about his business of manufacturing cast iron cooking pots. After several years of experiments aided by a young employee called John Thomas, he perfected a moulding box of several parts from which a cooking pot could be made using a minimum of materials. Queen Anne granted Darby a patent in 1708.

Coke After many years free from restrictions on charcoal burning in the midlands the government once became concerned about tree-felling and applied restrictions to the area. An alternative fuel was needed.

Dud Dudley (1599-1685) was one of the previously mentioned landowners who probably owned blast furnaces. He had spent most of his life trying to smelt iron using different types of coal, with limited success.

In 1708 Abraham Darby was established in business at Coalbrookdale in Shropshire.

His father had been employed in the brewing trade at Bristol where coke was used as a boiler fuel. Abraham had borne this in mind as a possible alternative to charcoal. After experimenting coking several different grades of coal he decided on a trial run to smelt iron with coke. Over Christmas 1708 the Coalbrookdale blast furnace was blown out while modifications to the bellows and melting zone took place. On 10 January 1709 the furnace was re-started with coke and a heavier charge of ore than was previously used.

The results were satisfactory with the usual products being cast close to the furnace hearth, requiring temperatures of 1500c.

It is arguable that this date kick-started the Industrial Revolution. �

* The author is a former employee of John Grundy Ltd March 2017

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07/03/2017 14:35:37

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